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1、船名标记 数量修改单号签字日期编制打字校对工程编号审核总面积0.69 M2共 10 页第 1 页标检审定日期内底板换新工艺 INNER BOTTOM RENEW PROCEDURE 船厂内底板换新工艺 INNER BOTTOM RENEW PROCEDURE船名 工程编号共 10 页第 2 页一、一、修理范围修理范围 Repair Scope：根据船方提供资料，货舱 NO.1-NO.7 内底板大面积换新。具体范围见船上标记。 Renewed parts marked on site.二、二、使用材料使用材料 Material：内底板板厚及材料级别参见船供图纸。该轮入美国船级社.Material
2、 of inner bottom plate and material refers to the drawing supplied by owner. ABS certificate should be supplied. 三、三、动工前准备工作动工前准备工作 Before Cropping：1.油舱及其他相关舱室需测爆合格；Gas free oil tank/ Finished desilting for ballast tank.2.应有合适的脚手、照明、通风、安全设施及足够的消防设备以保证工程的顺利进行；Suitable staging, enough illumination, ve
3、ntilation and fire fighting equipment will be arranged for steel work and inspection.3. 施工区域应有安全员时刻监督；Firemen will be arranged at hot work area.4. 施工中生活的垃圾排放应符合环保要求。Deal with the rubbish should be complying with law of environmental conservation.5.施工人员应配带合格的劳保用品Workmen should wear valid labor protec
4、tion appliance.四、四、修理要求修理要求 Repair Requirement：1.为防止船体变形，内底板拆旧换新过程中，若有外板，主甲板，内纵壁，横舱壁等的大面积换新，不可同时进行。To control the deformation, after renew inner bottom， other bigger renewal area will be permitted to do.2. 内底板应在车间内场进行预拼板，内底板拼板采用 2 拼 4000X8000 和 3 拼板6000X8000 两种，内底板最大拼板重约 7 吨.New inner bottom plate i
5、s fabricated in accordance with the existing vessels plans. Each D.B panels size is 4000X6000 or 6000X8000, and the max weight is to be about 7.0 ton.内底板换新工艺 INNER BOTTOM RENEW PROCEDURE船名 工程编号共 10 页第 3 页3.全船内底板拆旧换新应分批进行，沿船长方向，左右交错施工，具体工艺顺序参见（附图 1） ，以每个舱为单元，任何一个舱，要求在前一批装配板材单面焊结束、角焊缝单面焊结束后方可进行下一批的拆旧换
6、新； Renew inner bottom plate, the whole vessel should be renewed step by step (see FIG.1). Before cutting the next part, former part should be finished assembling and single side welding should be finished. 4.对一个批次内的内底板拆旧的同时对相应区域范围内的底边舱斜坡板进行拆旧换新,斜坡板换新范围宽约 300mm。Sloping plate of hopper tank（about300mm
7、） cut also should be divided two parts. Sequence of its renewal is same to inner bottoms.5.折旧时划线进行，保证割缝平直。对于原有老焊缝，切割线应在焊缝中间，且老焊缝要延长割开不小于 100mm；若不在老焊缝上，要求折角处开 R=10t 且不小于 100 mm 的圆弧过渡，两条平行对接缝间距应大于 300mm;角接焊缝（下墩座与内底板的角接缝）与内底板端接缝的间距不小于 100mm。Cut in line .Cutting line should be in the center of original
8、welding. Cutting exist seams should be extend at least 100mm.If cutting line not located at exist seam, the transition of arc (R=10t then fillet weld to inner bottom and longitudinal. Welding is to proceed systematically with each welded joint being completed in correct sequence without undue interr
9、uption. Where practicable, welding is to commence at the center of a joint and proceed outwards or at the center of an assembly and progress outwards towards the perimeter so that each part has freedom to move in one or more directions. 9.手工焊：新板装配后要求开坡口，反面碳刨出白。CO2 陶瓷衬垫焊：如反面焊缝成形较差，碳刨补焊。采用埋弧自动焊时，在焊接接头
10、的两端应装焊工艺板（引弧、收弧） ，工艺板的尺寸不小于 100X100，其板厚与工件同。在焊接方式的选择时，优先使用高效焊（坡口形式附图） SMAW: edge preparation, back gougingFCAW: If necessary, back gouging and repair welding。SAW： The welding should be started and finished at run-off tab pieces, that is at least 100mmx100mm. (Groove as follow figure)10.当坡口间隙过大超差时，不允
11、许在坡口内镶嵌填充物后再进行焊接施工。对于对接焊逢，焊缝的增宽（相对于装配时的坡口宽度）不应超过较薄板厚度的 0.5 倍，最多为12.5mm,此时应加衬垫，沿两边坡口堆焊，然后反面碳刨补焊。如果间隙超过 25mm,则需要进行挖补（视其位置而定） 。所有这些都应符合船东和船检的要求。When the groove gap of butt joint is more than 0.5t or 12.5mm，build up edge preparation on one or both sides, grind edge preparation, weld with backing strip ,
12、remove backing ,back gouge and back weld. If gap is more than 25mm ,insert plate to be fitted (depending on location)内底板换新工艺 INNER BOTTOM RENEW PROCEDURE船名 工程编号共 10 页第 5 页11.焊材的选用 Welding consumables：焊材的选用请参照下表. The Welding consumables used in this project is listed below.No .Welding ProcessWelding
13、ConsumableTradeSize (mm)AWS GradeGrade序序焊接方法焊接方法焊接材料焊接材料牌号牌号尺寸尺寸AWS 级别级别级别级别1CJ5073.2,4.0E70152Manual Metal Arc Welding 手工电弧焊Electrode 焊条NJ5073.2,4.0E70153Y3Flux-Cored Wire 药芯焊丝TWE-7111.2E71T-14Flux Cored Arc Welding CO2气保护焊Ceramic Backing 陶质衬垫JN-401-3Y5Wire 焊丝JW-1 (H10Mn2)4.0,4.86Submerged Arc Weld
14、ing 埋弧自动焊Flux 焊剂JF-B (SJ101)F7A0-EH143YTM说明 Note：1）上述焊接材料适用于普通强度钢和高强度钢.The welding consumables listed above are all applicable to Normal strength steel and higher strength steel.2）低氢型碱性焊条须在350 450烘焙，置于保温桶中随用随取。Electrode will be baked for 1 2 hours under 350 450 and kept in heat containers before usi
15、ng.3) 对于普通强度的结构的角接缝的焊接，J422（E4303）酸性焊条也可以使用The electrode of E4303 (AWS A5.1 E6013) is permitted for fillet of mild steel.内底板换新工艺 INNER BOTTOM RENEW PROCEDURE船名 工程编号共 10 页第 6 页手工电弧焊坡口形状和公差范围手工电弧焊坡口形状和公差范围 SMAW Groove preparation and tolerance limits板厚 (mm)6t20t 20PA; PF 平、立 对接PC横对接CO2 气体保护焊坡口形状和公差范围气
16、体保护焊坡口形状和公差范围 FCAW Groove preparation and tolerance limits焊接位置坡口形状、尺寸焊缝PA; PF平、立PC横内底板换新工艺 INNER BOTTOM RENEW PROCEDURE船名 工程编号共 10 页第 7 页埋弧自动焊坡口形状和公差范围埋弧自动焊坡口形状和公差范围 SAW Groove preparation and tolerance limits板厚 (mm)坡口形状、尺寸备注t18f=81说明：1）上述装配坡口如存在板厚差大于 4mm 时，应进行必要的削斜过渡。Note: 1) Grind corner to smooth taper over a minimum distance l=4(t1-t).12. 各焊缝间相对距离应符合 “IACS 修造船质量标准 ”的要求.Distance between welds accord with “IACS”.内底板换新工艺 INNER BOTT
