巴斯夫工艺管道施工方案

目录Contents

一、工程概况General....................................................................................................2

二、编制依据Reference................................................................................................3

三、施工准备ConstructionPreparation.........................................................................3

四、施工管理ConstructionManagement........................................................................4

五、管道安装Pipeinstallation.......................................................................................10

六、材料管理Materialmanagement..............................................................................39

七、施工进度控制与管理ControlandManagementofConstructionProgress............41

八、人力计划ManpowerPlan........................................................................................42

九、机具动员计戈IMobilizationplanofequipmentsandtools......................................43

十、安全文明施工Safetyandhousekeeping................................................................44

H—、安全分析Safetyanalysis.....................................................................................47

一、工程概况General

本工程位于马来西亚关丹吉本工业园的柠檬香精项目。业主方为巴斯夫马来西亚国油化学公

司(简称BPC),管理公司由FLOUR负责，综合专业工程C420区域由中国化学工程马来西亚公司

(以下简称“CCEM")承建。

TheprojectisBPCLemongrassProjectwhichislocatedinGebengIndustrialParkof

KuantanMalaysia.TheOwneristheBASFPETRONASChemicalsSDNBHD(BPC).Owner

representativeisFLUOR.Multi-disciplinework(AreaC420Citralplant)iscontractedand

constructedbyChinaChemicalEngineering(M)SDNBHD.(HereinafterreferredtoasCCEM)

㈠、工程简介Projectdescription

1、本项目地上工艺管道主要由管廊管道和装置区域管道工程组成。管道总长约42.5KM,约

22.0万DB,主要材质有碳钢A材6-B、A53・B、A312-TP316/316L,A312-TP304/304L、合金钢

及非金属管道HDPE等。

TheA/Gprocesspipesoftheprojectaremainlyforthepiperackandtheplantarea.The

totallengthofthepipesisabout42.5km,whichconsistsofabout120,000DBintotal.Andthe

majorspecificationsarecarbonsteelA106-B,A53-B,A312-TP316/316L,A312-TP304/304L,

Alloyandnon-metalpipe,suchasHDPE,etc.

2、管道的主要连接形式有焊接、法兰连接以及螺纹连接和卡套连接等。

Themainconnectionwaysforthepipeincludewelding,flangeconnectingandthread

connectingandjacketconnecting.

3、从管道输送的介质及操作温度、压力等级划分为常压及压力管道。

Thepipesaredividedintoatmosphericpressurepipeandpressurepipebyservicemedia,

operationtemperatureandpressurerating.

㈡、工程特点Projectfeaturesandchallenges

1、本管道工程材质多样，管径跨度范围大，温度、压力范围广，这给施工方面带来较大难度。

Therearevarioustypesofpipematerials,whichhavewiderangeofpipediameters,

temperaturesandpressures,bringingmuchdifficultytoconstruction.

2、本工程有易燃、有毒介质管线，施工质量要求高，特别对焊接质量更为严格。

Theprojecthaspipesservicinginflammableandtoxicmedia,whichdemandshigh

standardonconstructionquality,especiallyonweldingquality.

3、该工程的设备较多，增加配管难度；阀组、仪表调节元件多且要求配管质量高，增加管道

施工的复杂性及难度。

Theprojecthaslargeamountofmechanicalequipment,whichmakestubingmoredifficult.

Valvesetsandinstrumentshavemanyregulatingelements,whichdemandshighstandardson

pipeworkquality,andmeanwhilemakesitmorecomplicatedanddifficult.

4、管道的总DB量较大，走向复杂，管线密集，加大施工工作量；工作任务重，施工人员多，

加大管道施工管理工作难度。

ThepiperoutesarecomplicatedandconcentratedwithlargeDiameterBorequantity,which

makesworkquantitymorewhileheavyworkloadandlargeamountofconstructors,andmakes

pipeconstruction&managementworkmoredifficult.

二、编制依据Reference

1、施工设计图纸及技术要求；

Constructiondesigndrawingandspecifications&code;

2、本项目的施工合同；

ProjectConstructionContract

3、国际通用标准：

InternationalStandards

a.ASMEb.ASTMc.ANSI

4、马来西亚香精项目管道工程相关标准和技术文件：

RelatedpipingspecificationsofLemongrassProject

9355-C400-EPSP-ACC-001REV.O-PipingmaterialspecificationLineClass-processof

liftingpiping

9355-C400-EMSP-ACC-0022REV.1-Generalmaterialrequirement

9355-C400-EMSP-ACC-0004REV.O-pipesupport

9355-C400-EMSP-ACC-0009REV.1Specificationforpositivematerialidentification

9355-C400-EMSD-ACC-0001REV.O-jackedpipingdetail

9355-C400-EMSP-ACC-0014REV.O-shopandfieldfabrication/installationand

Handingprocess/utilizingpiping

9355-C400-EMSP-ACC-0017REV.O-PipePressureTesting

9355-C400-EMSP-ACC-0006REV.1-SpecificationforweldingandNDEfor

equipment/fieldfabricatedpiping

JB-9-O17-Rev.O-Fieldmaterialmanagementcontrolprocedure

JB-15-003-Rev.0-LemongrasssiteNonDestructiveTestExecutionPlan

JB-15-004LemongrasswelderTestcenterPlan

5、我公司企业标准

CompanyStandards

a.压力管道安装《质量手册》(QG/CC・7.PP.0501・00)

QualityHandbookforPressurePipeInstallation

b.压力管道安装《质量体系文件》(QG/CC・7.PP.0502・00)

QualitySystemDocumentforPressurePipeInstallation

c.压力管道安装《作业指导书》(QG/CC・7.PP.0503・00)

WorkGuidebookforPressurePipeInstallation

三、施工准备ConstructionPreparation

3.1.标准、规范准备PreparationofStandardandSpecification

3.1.1,收集管道施工要求的规范、标准。Topreparestandardandspecificationofpipe

construction

3.12收集施工记录和交工资料表格。Toprepareconstructionrecordandhandoverdocument.

3.1.3.熟悉业主关于管道施工的特殊要求。Toknowthespecialrequirementofpipeconstruction

32技术准备TechnicalPreparation

3.2.1.图纸会审Drawingjointreview；

322管道预制、安装方案的编制与审批

MethodstatementcompilationandApprovedforpipefabricationandinstallation；

3.2.3根据管道单线图、平面图、流程图组织技术交底.Technicaldisclosureworkshallbedoneas

perpipeisometricdrawing,elevationplanandworkflowchart.

3.3.其他Others

3.3.1.施工计划编制ConstructionMethodStatementPreparation

根据工程实际及工期要求，编制施工计划°Theplanshallbecompiledaspersitecondition

andrequiredconstructionduration.

3.32施工人员准备ManpowerPreparation

根据现场施工条件，合理组织管道安装人员(人力计划详见附表)；Thepersonnelforpipe

installationshallbemobilizedsuitablyaccordingtositecondition,(seeattachmentofmanpower

plan)

3.3.3.施工机具准备EquipmentandToolsPreparation

根据现场施工条件，合理组织管道安装的施工机具(施工机具详见附表)。Theequipmentand

toolsforpipeinstallationshallbemobilizedsuitablyaccordingtositecondition.(Seeattachment

ofequipmentandtools)

四、施工管理ConstructionManagement

4.1.建立健全质量保证体系Toestablishqualityassurancesystem

4.1.1.建立以项目经理为第一质量责任人，各专业质量工程师、质检人员为主导的质量控制体系。

质量文件的建立和管理要细化到每个环节，分工明确、责任分明。

TheprojectmanagerisfirstresponsibilitypersonandeachdisciplineengineerandQA/QC

inspectorsareleadingrolesforQA/QCcontrolsystem.

4.1.2.建立明确的质量责任制度，质量责任分解到各个岗位、各个环节、各个工种。从制度上落实

谁管生产谁管质量，谁施工谁负责质量，谁操作谁保证质量。

Toestablishqualitysystemdefined,whichshallbeappliedtoeachposition,eachstepand

eachdisciplinetoensurequalitycontrolduringconstruction.

4.1.3.积极主动配合业主、管理机构的工作，认真和严格地执行其发出的指令、意见和建议。

Toassistandexecutetheinstruction,suggestionandcommentbyOwnerand

managementagency.

4.1.4.对有特殊资格要求的管理人员和操作人员须经资格审查和确认，持证上岗。

Formanagementpersonandoperatorwithspecialrequirement,thequalification

certificatesshallbeexaminedandconfirmed.

42压力管道施工质量保证体系QA/QCSystemofPressurePipe

压驶朝量艇卢4

项目质保工程师

各

专

业

质

检

员

图（1）

QASystemofPressurePipe

ProjectQAEngineer

PW

rle

cod

eni

sg

prp

iri

ncn

ici

plp

ele

Sketch1

4.2.1.压力管道安装时，为确保其安装质量其处于受控状态，应建立如图(1)的压力管道安装质量保

证体系。

Wheninstallingthepressurepipe,QA/QCsystem(seesketch1)ofpressurepipe

installationshallbesettedforcontrollinginstallationquality.

4.2.建立健全安全管理体系Tosetintegralsafetymanagementsystem

421,建立以项目经理为第安全责任人，专、业安全工程师、安全人员为主导的安全控制体系。

BuiltaHSEcontrolsystem,whichshallincludeprojectmanagerasafirstresponsibility

personandHSEengineerandsupervisoraskeypersons.

422.落实安全责任到施工班组、到施工责任人。

Safetyresponsibilityshallbeputintoworkteam/groupandpersonal.

4.2.3.现场施工人员必须遵守现场的安全规定，定期进行安全学习与培训。

Constructionstuffshallcomplywiththesafetyrequirement,andcarryoutsafetytraining

regularly.

4.2.4严格执行各安全制度与操作规程，做到安全、文明、环保施工。

Safetysystemandoperationspecificationshallbecarriedoutstrictlyforsafety,healthand

environmentalprotectionconstruction.

4.3工艺管道检验与试验计划Inspectionandtestplanofprocesspipe

在工艺管道的施工过程，全方位的质量监督。并极力配合业主、管理公司、监理、质检站对

各检查点的监督检查工作；严格执行停检点、必检点的监督检查。在管道施工过程中，应切实重

点做好质量监督检查控制工作，以便更好地控制管道施工的质量，执行相关ITP计划。During

processpipeconstruction,WellcooperatedwithBPC/FLOUR,supervisionandrelative

governmentbureauforsupervisionofeachinspectionpoint.Strictlycomplywithsupervisionand

inspectionrequirementsonholdpointandwitnesspoint.Duringpipeconstruction,thefollowing

issuesshallbefocusedonforbetterfabricationquality.

4.4.工序交接Workprocedurehandover

4.4.1.做好各道工序之间的交接工作，确保上道工序不合格的产品严禁进入下道工序。

Handoverbetweeneachprocessshallbewellperformedtoensurenounqualifiedproduct

beingusedinthenextprocess.

441.1•管件、阀门、管材等工程材料经检验不合格者，禁止用于本工程施工；同时临时管道，

管件和阀门材料需要合格。

Itisforbiddentousenon-conformingconstructionmaterial,suchaspipefitting,valveand

pipematerial,inthisproject；Thetemporarymaterialsshouldbequalifiedtoo.

4.4.12管道除锈、防腐检查及管件组对不合格，不得进行焊接工作。

Poorfit-uppipefittingscannotbewelded.

4.4.1.3预制产品安装前，必须经相关的质量检查人员或专业工程师检查，确认合格后，方可

用于安装施工。Beforeinstalling,fabricatedproductsmustbeinspectedandapprovedbyrelated

qualityinspectorordisciplineengineer.

4.4.1.4预制管段安装前需对管段内部垃圾进行清理，并组织检查，检查合格后才能继续安装。

Theinternalwasteofpre-fabricatedspoolsshouldberemovedbeforeinstallationof

pre-fabricatedspools,theinspectionwillbeperformed,thepre-fabricatedspoolscanbe

installedafterpassingtheinspection.

4.4.1.5预制管段安装前需对有法兰面的管道进行保护，法兰面安装时需安装临时橡胶垫，避

免对法兰水线照成机械损坏。

Thepipewithflangefaceshouldbeprotectedbeforeinstallationofpre-fabricatedspools,

thetemporaryrubbergasketneedtobeinstalledwhileflangefaceisbeinginstalled,toavoidthe

mechanicaldamageforflangesealsurface.

4.42施工过程必须加强施工班组的自检工作，严格“三检”制度（自检、互检、交接检），确保每道

工序产品合格。

Duringconstruction,internalinspectionofconstructionteamshallbeimproved."Three

Inspections"Regulation(internal-inspection,mutual-inspectionandjointinspection)shallbe

strictlycompliedtoensureproductsusedineachprocessarequalified.

4.5.工艺管道焊接质量保证体系QA/QCsystemforProcesspipewelding

4.5.1.现场施焊人员资格审查；Qualificationexaminationforsitewelder

4.52焊接工人上岗前,现场实际操作考试;Weldershallpassweldingtestinsitebeforeanywork.

4.53焊接过程合格率考核与控制；Testandcontrolofweldingqualificationrate

4.5.4.焊接工程师及焊接质量检查人员现场指导、检查；Siteguidanceandinspectionactedby

weldingengineerandweldingqualityinspector.

4.6施工技术及资料管理Constructiontechniqueanddocumentcontrol

4.6.1,施工过程中必须严格执行相关的规范、标准、要求等。

Relatedspecification,standardandrequirementshallbeperformedstrictlyduring

construction.

4.6.2.严格按照我公司质量体系文件运行程序进行施工和管理。

Relatedspecifications,standardsandrequirements,etc.shallbestrictlycompliedinthe

processofconstruction.

4.63施工图纸管理Managementofconstructiondrawing(IFCdrawing)

4.6.3.1.施工前，施工图纸必须经专业工程师审查，并进行图纸会审。IFCdrawingmustbe

reviewedandjointreviewedbydisciplineengineerbeforeconstruction.

4.6.32图纸收发必须进行登记，以便核查。图纸版次更替应做到及时，确保施工图纸一直处

于最新版次。对于旧版次应即刻回收，并做好登记保管，做到无遗漏。Drawingissuancestatus

shallberecordedforeasycheck.Drawingversionshallbeupdatedtimelytomakesurealways

usingthelatestversion.Oldversionshallbereturnedbacktimely,recordshallbemadeaswell

toavoidmissingitems

4.6.3.3•施工图纸发放前，必须对施工队进行技术交底及图纸答疑。

Technicaldisclosureanddrawingclarificationshallbedonetoconstructionteamsbefore

issuingIFCdrawing.

4.6.3.4.图纸设计变更应及时传达到施工队，并及时对图纸进行修改，并及时执行设计变更。

Designchangeshallbeinformedtoconstructionteam,drawingshallberevisedtimelyand

designchangeshallbecompliedtimelyaswell.

4.6.4.施工过程记录应做到及时、准确，并签字保存妥当。

Constructionprocessrecordsshallbemadetimely,accuratelyandwell-kept.

4.6.5为加强质量管理，保证为业主提供合格的工程项目产品，在施工过程管理工作中，使用公司

开发的管道施工管理系统软件，跟踪、记录管道的主要施工信息、质量II检信息、无损检验信息

等，以便施工人员及时了解相应的质量进度信息，便于质量管理和控制，同时辅助生成主要的交

工资料•，提高交工的质量。

lbimprovequalitymanagementandprovidequalifiedproducttotheOwner,company

developedpipeconstructionmanagementsoftwarewillbeusedintheconstructiontotraceand

recordmajorconstructioninformation,dailyqualityinspectioninformation,NDEinformation,etc,

whichmakeconstructorknowrelatedqualityprogressinformationwellandeasytomanagement

andcontrolquality.Mainhandoverdocumentwillbegeneratedasauxiliaryfunction,which

improveshandoverqualityaswell.

4.7.现场安装管道的标识Pipeidentificationforsiteinstallation

4.7.1.管材、管件的追溯检查Traceabilityofpipematerialandpipefitting

4.7.1.1材料到预制区域后按管道预制过程标识和出厂标识的要求严格执行，以实现管材鉴定

到管道安装的全过程可追溯性。

Arrivedatfabricationarea,materialsshallbemarkedasperrequirementsonpipe

installationprocessandmanufacturetomaketraceabilityofwholeprocessfrompipematerial

identificationtopipeinstallationpossible.

4.7.12材料使用前，应先确认材质色标是否符合规定。Ensurethematerialcolorsystem

appliestotherequirementpriortouse.

4.7.1.3.材料分离、分割而使原标识不全时，要进行原标识的移植；

Originalidentificationshallberelocatedifmaterialisincompletebyseparatingorcutting.

4.72安装管段的标识Pipespoolidentificationforsiteinstallation

4.7.2.1,管段及焊口的编号和标识工作贯彻管段安装全过程。采用在单线图上标明焊口检验状

态，在实物上用记号笔做标识方法进行标注。Serialnumberandidentificationofpipespooland

weldjointshallbemadeduringwholepipespoolinstallationprocess.Markinspectionstatusof

weldjointintheISOdrawing.Markidentificationonspoolbymarkerpen.

472.2,管端上的焊工号、焊口号及安装管段号不得用打钢印，而采用记号笔(不得含锌、氯

离子等对母材有危害的成分)在距焊缝边缘50mm处标注，字迹清晰工整。WeldersIDnumber,

No.ofweldjointandNo.ofinstallationspool,whichareinthepipeend,shallnotbesteel

stampedbutbemarkedat50mmawayfromweldjointedgebymarkerpen(freeofzinc,and

choirion,whichisharmfultobasemetal)inavisibleandneatlyway.

4.7.2.3.管段及焊口的标识方法如下：管道标识的责任：焊工代号由焊工填写，质检员代号山

质检员检验后填写，其余标识(预制管段号、管段长度或炉批号)均由管工填写。管工和焊工自

检合格，且所填内容齐全后，山管工班长或焊工统一向质检员报检，经质检员外观检查合格后报

FLOUR检查，由FLOUR点口确定需检测的焊口并在焊缝上用记号笔按照要求作为无损检测的标

识(RT、PT等)标识内容见图(2)：Identificationmethodofpipespoolandweldjointasfollows:

Responsibilityofpipeidentification:welder*sIDnumberwillbefilledbywelder,quality

inspector'sIDnumberwillbefilledbyqualityinspectorafterinspection,otheridentifications(No.

offabricatedpipespool,lengthofpipespoolorheatNo.)willbefilledbypipefitter.Pipefitter

andweldershallinspectfabricatedpipeandcompleteidentificationsfirstly,thenpipefitterleader

orwelderleadershallreporttoqualityinspectorforinspection.Qualityinspectorwillreportitto

FLOURifvisualinspectionisaccepted.Weldjunctionshouldbedeterminedaccordingto

FLOURspotweldjunction,andmarkedNDE(RT,PT,etc.)ontheweldjointbymarkingpenas

perrequirements.RefertoSketch(2)fordetailedmark.

SpoolfabricationWeldseam

五、管道安装Pipeinstallation

5.1.施工准备Preparation

5.1.3.3.施工人员准备Manpowermobilization

根据现场施工条件，合理组织管道安装人员（人力计划详见附表）；Pipeinstallationpersonshall

bemobilizedaccordingtositeconstructioncondition.（detailedmanpowerplanisattachedas

bellow）

5.1.3.4.施工机具准备Equipmentandtoolspreparation

根据现场施工条件，合理组织管道安装的施工机具（施工机具详见附表）。Equipmentandtools

shallbemobilizedaccordingtositeconstructioncondition.（detailedequipmentandtoolsplanis

attachedasbellow）

52管道安装Pipeinstallation

521.安装流程Workingprocedure

管道施工安装流程如图（图）Pipeinstallationprocedureisshownassketch1.

5.2.2安装位置核查Inspectionoflocationforpipeinstallation

管道安装前，检查土建基础、结构、设备管口的尺寸、标高、位置等是否与管道图纸相符。Before

pipeinstallation,inspectdimension,elevation,positionofcivilfoundation,structureand

equipmentnozzleaccordingtopipedrawing.

523.预制管段安装前内部清理检查Checkinginteriorcleaningstatusbeforeinstallingfabricated

spool.

安装前，通过预制记录及预制管线标识找查安装的管线，检查预制管段的管内部清洁度。Before

installation,findthepipelineaccordingtofabricationrecordandpipeidentification,andcheck

theinternalclearnessofpipespoolfabricated.

524.管道安装的允许偏差AllowableDeviationofpipeinstallation

架空及地沟平面坐标：室内允许偏差15mm,室外允许偏差25mm。Coordinateofoverhead

layerandtrench:indoorshallbe15mm,outdoorshallbe25mm.

架空及地沟标高：室内允许偏差±15mm,室外允许偏差±20mm。Elevationofoverheadlayer

andtrench:indoorshallbe±15mm,outdoorshallbe±20mm.

水平管道平直度：DN<100,允许偏差为2L%。，最大50mm。DN>100,允许偏差为3L%。，

最大80mm。Straightnessofhorizontalpipeline:ifDN<100,allowabledeviationshallbe2L%o,

maximumdeviationshallbe50mm.ifDN<100,allowabledeviationshallbe3L%o,maximum

deviationshallbe50mm.

立管铅垂度：允许偏差为5L%o,最大30mmoTheverticalityofriserpipeline:allowable

deviationshallbe5L%o,maximumallowabledeviationshallbe30mm.

成排管道的间距：允许偏差15mmoTheintervalofpipeinarow:theallowabledeviationshall

be15mm.

交叉管或绝热层间距：允许偏差20mm。Theintervalofcrosspipelineorthermalinsulation

layer:theallowabledeviationshallbe20mm.

525.管道各类焊缝间距要求intervalspacerequirementofvariousweldjoint

管道各类焊缝间距要求详见(图3)及表二

Pleasereferto(sketch3)andform2forintervalspacerequirementofvariousweldjoint

管道焊缝间距要求示意图(图3)

Sketchforintervalspace

requirementofpipeweldjoint

(sketch3)

表二(forrr)2)

焊缝最小间距(选最大者)Minimum

焊缝类型DescriptionofWeldTypeDistanceBetweenWeldToes(whichever

isgreater)

A120°or7CDr)or5t<1>

B120°oi■小而or5t⑵

C100mmor2t⑶

D50mmor2t

Dimensionaltolerancesforfabricatedpiping

5.2.6管线铺设Pipelinelaying

526.1管廊管道铺设Rackpipelaying

A.管廊穿管Pipelaying

对于管廊及管吊架上管线，其为分层排列，给管道铺设工作造成极大麻烦，因而必须合理地

安排施工方法。管道敷设时;从管廊端头穿入管廊各层，并计算好各层用料。穿管时，通过吊车

直接将管道放置于窜管器上。Forthepiperackandpipelineonthebracket,whichshallbe

arrangedreasonablybylayers,topreventpipelayingfrombeingintrouble.DuringPipelaying,

pipeshallbeputonpipeconnector,andpassthroughintoeachlayerofpiperackbylifting.The

amountofpipematerialshallbecalculatedinadvance.

B.管廊传管Pipedelivery

管道穿入管廊各层后，应即刻组织人力将管道传输到安装位置，调整好各管线间间距，并临时固

定好。管廊传管必须使用窜管器（如图4）进行。窜管器应牢固地安装在管廊横梁上，窜管器滚筒必

须采用橡胶皮等缠好，以保护管线油漆及不锈钢管避免污染。窜管器宜每3米间隔距离安装1件,

这样管子窜起来就容易得多。Pipeshallbedeliveredtothepositionofinstallation,adjustedthe

intervalofeachpipe,andfixedforthepresent.Thepipeconnectorshallbefixedfirmlyonthe

beam.Wrappedtherollerwithrubberskintoprotectpaintingandstainlesssteelpipeis

preventedfrompollution.Pipeconnectorshallbeinstalledatintervalsof3M,itiseasytopipe

connectio

C.管道牵引Pipetrailing

管廊在窜管器匕牵引一般采取人工形式或采用倒链牵弓I。对于同层管道数量大且直径相对较

大时，可采用卷扬机牵引，如图（5）。Piperackshallbetrailedbymanualorchainblock.Fora

largequantityanddiameterofpipeinthesame,itshallbetrailedbywindlass.Seesketch（5）

5.2.62设备间管线铺设与安装Pipelinelayingandinstallationbetweenequipments

安装时，首先测量好现场已安装完成的管线连接设备间距离、标高等参数，预制管段。将连

接设备两端法兰固定在设备口，螺栓拧紧，数量不得低于4颗。Pipespoolshallbefabricated

accordingtothedistance,elevationetc.betweenpipeinstalledandequipment.Fixtheflangeon

theendofequipment,tighteningthebolt,andshouldbenotlessthan4.

然后采用吊车将预制管段吊装就位，组对，点焊好。LiftPipespoolfabricatedtothecorrect

positionbyhoist,fitupandspotweldo

点焊好后，应采用临时措施加固避免变形（防变形的临时加固件，应在焊接工作彻底完成后

才能拆卸）。待焊口根部焊缝完成后，拆卸组对管线，在地面完成剩余的焊接、探伤、试压、清洗

等工作，然后复位安装。Afterspotwelding,pipespoolshallbestrengthenedbytemporary

measurestopreventdeforming（Thetemporarymeasurescan*tberemoveduntilwelding

completefinish）.Afterfinishrootweldingofweldjoint,removethepipespoolfittedup,which

shallbetreatedbywelding,crackdetection,cleaningontheground,andberepositedand

installedatlast.

527.管道对口Pipefittingup

527.1.管道对口连接时，不得用强力进行组对，亦不得通过松或强紧连接螺栓或添加法兰连

接垫片来调整组对间隙及管口平直度。Duringfittingupwork,pipecannotbejointedbytheaction

ofastrongforce,alsonotbeadjustedtheintervalandstraightnessbyflangegasket.

5272管口组对时，应符合图(6)要求.

当管子公称直径小于100mm时，允许偏差值。为1mm；当管子公称直径大于或等于100mm时,

允许偏差值a为2mm；但全长的偏差值不得超过10mm。管道坡口加工时，壁厚V3mm采用I

型坡口，壁厚N3mm采用V型坡口；组对间隙应控制在2~4mm；允许最大错边量为壁厚的10%

且不大于2mm。Pipefittingupshallmeettherequirementofsketch(6).Whenthenominal

diameterofpipe<100mm,allowabledeviationvalueashallbe1mm.Whenthenominal

diameterofpipe>100mm,allowabledeviationvalueashallbe2mm,butthewholedeviation

shouldnotexceeds10mm.Forthepipefit-up,adoptItypegrooveforthethicknesslessthan

3mm,andadoptVtypegrooveforthethickness>3mm;thespaceofthefit-upshouldbe

controlledwithin2~4mm;permittedmaximumunfitnessvalueis10timesofthewallthickness

butnotexceed2mm.

5.2.73作为封闭管段组对时，其首先应根据现场实测的安装长度进行下料加工，其偏差

不得超过1.5mm,确保焊口间隙，保障焊接质量。Sealpipespoolshallbefabricatedasper

surveyedinstallationlengthwithallowancenomorethan1.5mm,tokeepaintervalbetween

weldjointswithahighqualityofwelding.

5.2.8.法兰安装Flangeinstallation

528.1.法兰连接应与管道同心，并确保螺栓自由穿过螺栓孔；Connectedflangeshallbea

samecenterwithpipe.

5282垂直或倾斜法兰面螺栓孔应垂直跨中安装，其连线水平度不得大于1.5mm；水平法兰

面螺栓孔安装应跨装置南北或东西方向；Allboltholesofflangeshallstraddleverticaland

horizontalcentrelinesofthepipe.Levelnessshallbenomorethan1.5mm.Flangeboltholeson

horizontalpipeshallstraddlethesitesystemlines,i.e.sitePlantNorth/SouthorPlantEast/West.

528.3.水平法兰水平度及垂直法兰的铅锤度不得大于法兰外径的1%。,且不得大于2mmcThe

verticalityofhorizontalandverticalflangeshallbenomorethanouterdiameter1%o(2mm).

528.4.当法兰采取螺纹连接时，管端应低于法兰密封面1.5mm.Iftreadedconnectionisused

toflanges,theendofpipeshallbelowerthanthesealingface1.5mm.

528.5.不得用强紧螺栓的方法或松螺栓方法来消除歪斜。同时、不得加偏垫或多层垫等方法

来消除法兰接口端面的间隙、偏斜、错口或不同心等缺陷。Itisnotallowedtotightenorloosebolt

foradjusttiltedsurfaceofbolt,meanwhilenotallowedtoaddpartialpadorcushionstoeliminate

defectsofclearance,deviations,mismatchanddisalignment.

5286动设备法兰口最终连接时，必须在联轴器上架设百分表监视动设备的位移。

当动设备额定转速大于6000r/min时，其位移值应小于0.02mm；当额定转速小于或等于

6000r/min时，其位移值应小于0.05mm。Flangeconnectionofrotaryequipmentmustbetested

withdialgauge.installingthedialindicatoroncouplertomonitorequipment'sdislocation.When

ratedspeedismorethan6000r/min,thedislocationvalueshouldbelessthan0.02mm,when

ratedspeedisnotmorethan6000r/min,it'sdislocationvalueshouldbelessthan0.05mm.

529.垫片安装Gasketinstallation

529.1.垫片安装前，应按图确认其型号规格是否满足设计要求。法兰安装前，应检查法兰密

封面及密封垫片，不得有影响密封性能的径向划痕、斑点、破损、皱折等缺陷。同时:配对法兰

环槽密封面与金属环垫还应作接触线检查，当金属环垫在密封面上转动45。检查接触线不得有间断

现象。Beforegasketinstallation,thetypeandspecificationshallbeconfirmedtomeetthe

requirementofdesign.Beforeflangeinstallation,checkthesealingfaceandsealinggasket

whichfreeofscratch,stain,damagedandwrinkledetc..Contactinglinecheckbetweenflange

ringsealfaceandmetalringgasketshallbedoneinthemannerthatnodiscontinuousline

existingwhenrotatemetalringgasketfor45°.

5.2.92安装时，必须确保垫片安装位置应在法兰密封面中心，1个密封面只安装1块垫片，

禁止安装多层垫。Duringgasketinstallation,gasketmustbeplacedinthecenterofflange

surface,only1piecegasketcanbeusedforflangesurfaceinsteadofmulti-piece.

5210阀门安装Valveinstallation

5210.1,阀门安装前应检查阀门的规格型号是否与设计一致，并检查填料其压盖螺栓应留有

调节余量。Thetypeandspecificationofvalveshallbecheckedformeetingtherequirementof

design,asuitablespaceshallberemainedbetweenglandboltandfillingmaterial.

5210.2,当阀门与管道以法兰或螺纹方