南海石化工艺管线施工技术方案

工艺管线施工技术方案CONSTRUCTIONTECHNIQUESCHEMEFORPROCESSPIPELINES1工程概况我公司承建的中海壳牌石油化工有限公司南海石化项目苯乙烯、环氧丙烷及丙烯乙二醇装置位于广东省惠州市大亚湾区海畔该项目由德悉尼布天辰化学工程（天津）有限公司设计，所处地区环境干燥温度最高385，最低23，湿润温度281，空气湿度大，雨期较长。2编制依据21德悉尼布天辰化学工程（天津）有限公司提供的工艺管道施工图；22工艺管道设计技术交底（会议纪要）；24石油化工剧毒、可燃介质管道工程施工及验收规范（SH35011997）；25工业金属管道工程施工及验收规范（GB5023597）；26现场设备、工业管道焊接工程施工及验收规范（GB5023698）；27埋地钢质管道环氧煤沥青防腐技术标准（SY/T044796）；28石油化工钢制通用阀门选用、检验及验收规范（SH306494）；29石油化工设备和管道隔热技术规范（SH30102000）；210工业设备、管道防腐蚀工程施工及验收规范（HGJ22991）；211工业设备及管道绝热工程施工及验收规范（GBJ12689）；212石油化工工程铬钼耐热钢管道焊接技术规程（SHJ52091）；213电力建设施工及验收技术规范管道篇DL503194214电力建设施工及验收技术规范（火力发电厂焊接篇）DL500792215石油化工企业设备管道表面色和标志SH30431991216石油化工异种钢焊接规程SH35261992217石油化工铬镍奥氏体钢、铁镍合金和镍合金管道焊接规程SH35231999218压力容器无损检测（JB473094）；219石油化工施工安全技术规程（SH350599）；220工程建设交工技术文件规定（SH350393）；22150万吨/年延迟装置施工组织设计；222压力管道安装质量保证手册（QG/M444150001999）；223压力管道安装质量程序文件QG/P444350001999；224压力管道安装工艺标准（QG/444152001999）；225压力管道安装竣工技术文件规定（QG/M444153001999）。3工艺配管的特点THECHARACTEROFPIPEERECTION31PTA装置中易燃，易爆及腐蚀性介质的管道较多，且物料大多为浆料和粉料，有强烈腐蚀性，故配管材料选用要求严格。本装置中大量使用超低碳不锈钢，包括304L、316L、317L等，并有少量钛管、海氏合金管及塑料管。INPTAINSTALLATION,THEREAREMANYPIPESWITHINFLAMMABLE,EXPLOSIVEANDCORROSIVEMEDIUM,MOSTOFWHICHARESLURRYANDPOWDERWITHSTRONGCORROSIONTHEREFORETHEREQUIREDMATERIALOFPIPEERECTIONISVERYSTRICTINTHISINSTALLATION,WENOTONLYUSEALOTOFLOWCARBONSTAINLESSSTEELWITHSPECIFICATIONOF304L,316LAND317LBUTALSOSOMETITANIUMPIPE,ALLOYPIPEANDPLASTICPIPE32本装置动设备较多，必须保证无应力配管，不得对设备施加外力。配管应从设备开始向设备外配管，配管过程中应及时设置管道支吊架，不得让设备承受管道系统的重力。THEREAREMANYMOVABLEEQUIPMENTSINTHEINSTALLATION,WENEEDENSUREPIPEERECTIONWITHOUTSTRESSING,ANDCANNOTIMPOSEEXTERNALFORCEONTHEEQUIPMENTS,INTHEPIPEERECTION,WENEEDSTARTFROMTHEEQUIPMENTINSIDE,ANDTHENTHEOUTSIDEOFTHEEQUIPMENTSWENEEDSETUPTHEPIPERACKINTIMETOAVOIDTHEGRAVITYFROMTHEPIPESYSTEM33本工程管道焊接量大，需要投入大批量的优秀焊工。我公司目前有压力管道持证焊工685名，能够保证焊接要求。如我公司中标本项目，将派出具有行业及国家级先进水平的优秀焊工来承担本工程的焊接任务，能够确保装置的长期有效地运行。THEPIPEWELDINGQUANTITIESISVERYHEAVYINTHEPROJECTITNEEDSPROVIDEALARGENUMBEROFQUALIFIEDWELDERSNOWOURCOMPANYHAS685WELDERSWITHCERTIFICATES,WHICHCANCOMPLYWITHTHEWELDINGREQUIREMENTSONCETENDERED,WEWILLSENDQUALIFIEDWELDERSTOBEARTHEWELDINGTASKOFTHEPROJECT,ALLTHEWELDERSHAVEMUCHEXPERIENCEANDADVANCETECHNIQUE,WHICHCANENSURETHEERECTIONINGOODQUALITYINALONGTIME34本装置工艺配管工程量大，共有各类管道132KM。为提高劳动效率，加快施工进度，我们将大力推进管道自动焊，实行管道预制工厂化、产品化。我公司有各种型号的自动化焊机多台，在管道预制过程中，配以高纯度氩气（9999）的气体保护管道自动焊，可以极大地提高劳动效率，有效地抑制焊接接头部位的氧化，保证接头内部平整、外型美观。6314THEQUANTITIESOFPROCESSPIPEERECTIONISHEAVY,ITINCLUDESALLKINDSOFPIPEOF132KMINORDERTOENHANCETHEWORKEFFICIENCYANDSPEEDTHECONSTRUCTIONPROGRESS,WEWILLTRYOURBESTTOPUSHPIPEAUTOMATICWELDINGANDPERFORMPIPEPREFABRICATIONINMARKETTHEREAREMANYAUTOMATICWELDINGMACHINESWITHMODELSINOURCOMPANYINTHEPROCESSOFPIPEERECTION,THEAPPLICATIONOFARCPROTECTIONAUTOMATICWELDINGMACHINEWITHHIGHPURITYOFARGONCANIMPROVETHEWORKEFFICIENCY,HOLDBACKTHEOXIDIZATIONOFTHELOCATIONOFWELDINGJOINT,ANDENSURETHEINSIDEOFJOINTFLATANDONGOODLOOKOUTSIDE4管道安装工程量THEQUANTITIESOFPIPEERECTION类别TYPE材质MATERIAL规格（MM）SPECIFICATION质量（T）QUALITY数量（M）QUANTITYCS1/2548780462813SS1/280315138850钛材TITANIUM3/4803853650合金钢ALLOYSTEEL3/4361353630铜管COPPERPIPE1/23/4172728403管材PIPINGMATERIAL塑料管PLASTICPIPE3/456149706法兰FLANGE11492配件FITTINGS2553阀门VALVE27321弹簧支撑SPRINGSUPPORTING1188其它支撑OTHERSUPPORTING15745、管道材料检验PIPEMATERIALINSPECTION管道施工材料的质量保证是施工质量的基础。我公司具有一套成熟可行的原材料检验管理制度，我们将按照具体工程特点建立健全切实可行的材料检验管理体系以提供质量保证。THEQUALITYASSURANCEOFPIPECONSTRUCTIONMATERIALISTHEBASISOFTHECONSTRUCTIONQUALITYOURCOMPANYOWNSAAVAILABLEANDMATUREMANAGEMENTSYSTEMOFMATERIALINSPECTIONANDWEWILLADJUSTITACCORDINGTOTHEACTUALPROJECTCHARACTERFORQUALITYENSURE51成立专门的检验小组实施统一的管材管件检验，并按照相应标准组织检验。SETTINGUPAINSPECTIONGROUPFORPIPEMATERIALANDFITTINGSCHECK,ANDINSPECTINGWITHRELATIVESTANDARD52材料检验设有独立的检验场地，并划分出待检区、检验区、合格品区和不合格品区。SETTINGUPAINDEPENDENTINSPECTIONAREAFORMATERIALEXAMINATION,ANDDIVIDEITINTOWAITINGINSPECTIONAREA,INSPECTIONAREA,QUALIFIEDPRODUCTIONAREAANDUNQUALIFIEDPRODUCTIONAREA53训练有素的检验人员将严格按照以下检验工艺进行检验THETRAINEDPERSONWILLSTRICTLYINSPECTMATERIALCOMPLYINGWITHTHEFOLLOWINGPROCEDURE管材、管件接收PIPEMATERIAL,FITTINGSACCEPTANCE品种、规格、数量检查BRAND,SPECIFICATIONANDQUANTITIESINSPECTION外观质量检查CONFIGURATIONQUALITYINSPECTION材质检查MATERIALQUALITYINSPECTION质量验证ERECTIONQUALITYINSPECTION产品标识和检验状态标识PRODUCTIONIDENTIFICATIONANDINSPECTIONINSITUATIONIDENTIFICATION54管道组成件的检验PIPINGFITTINGINSPECTION541不锈钢管子、管件（包括螺栓、螺母），应用光谱分析仪对材质的主要化学成份进行复查，并作好检验状态标识。STAINLESSPIPINGANDFITTINGSINCLUDINGBOLTSANDSCREWNUTSSHALLBERECHECKEDCHEMICALCOMBINATIONSBYSPECTRUMANALYZER,ANDLOCATEDININSPECTIONSITUATION542螺栓、螺母的螺纹应完整、无划痕、毛刺等缺陷，并应配合良好，无松动或卡刺现象。THESCREWTHREADSHALLBEFREEFROMDEFECTSSUCHASDEFORMITIES,SCRATCHESANDIRREGULAROFDISTANCEBETWEENTHREADTOTHREAD,ANDSHALLBEINGOODQUALITYWITHOUTLOOSENINGANDJAMMING543法兰密封面、缠绕垫不得有径向划痕、松散、翘曲等缺陷，石棉垫表面应平整光滑，不得有气泡、分层、折皱等缺陷。THEAREABETWEENFLANGETOFLANGEANDCIRCLEPADSHALLBEPROTECTEDFROMSCRATCHESLOOSENING,TWISTINGANDSOONTHESURFACEOFASBESTOSSHALLBEFLATANDSMOOTH,ANDBEFREEFROMBUBBLES,MULTILAYERS,CREASEANDSOON544阀门检验VALVEINSPECTION5441阀门试验、检验前，专门成立阀门检验、试验小组，其成员应由施工班组、相关技术人员和质量检查人员组成。同时必须进行专门的技术交底，并配置相应的工装设备。WEWILLSETUPAVALVECHECKANDTESTGROUPBEFOREVALVEINSPECTION,WHICHINCLUDECONSTRUCTIONTEAM,RELATIVETECHNIQUEPERSONNEL,QUALITYINSPECTORMEANWHILEWEWILLTRANSFERNECESSARYTECHNIQUEINFORMATIONANDASSEMBLEPROPERWORKEQUIPMENT5442阀门检验、试验程序见图31。THEVALVEINSPECTIONANDTESTPROCEDURESEEDRAWING315443阀门试验应从每批中抽查10，且不少于1个，进行壳体压力试验和密封性试验。当不合格时，应再抽查20抽查，仍然不合格时，该批阀门不得使用。10OFVALVESSHALLBETAKEFORINSPECTIONFROMEACHBATCHOFITANDNOLESSTHAN1PIECETOSHELLPRESSUREANDDENSIFICATIONTESTINCASEITISNOTQUALIFIED,ANOTHER20OFITSHALLBERECHECKEDIFUNQUALIFIEDAGAIN,THEVALVESCANNOTBEUSED5444阀门的壳体压力性试验和密封性试验必须用洁净水进行。不锈钢阀门试验用水的氯离子含量不得超过25PPMCLEANWATERSHOULDBEUSEDINTHEVALVESHELLPRESSUREANDDENSIFICATIONTESTTHECONTENTOFCHLORINEUSEDINSTAINLESSSTEELVALVESHOULDNOTOVERPASS25PPM5445阀门的壳体试验压力应为公称压力的15倍；试验时间不得少于5MIN，以壳体、填料无渗漏为合格。VALVESSHELLTESTEDPRESSURESHOULDBE15TIMESOFNOMINALPRESSURE,ANDTHETESTSHOULDLAST5MINUTES,ITWILLBEQUALIFIEDINTHECASEOFSHELLANDPACKINGBEFREEFROMLEAKAGE图31阀门检验、试验工艺流程图DRAWING31VALVEINSPECTIONANDTESTFLOWPLAN5446除止回阀、节流阀外，阀门的密封试验宜以公称压力进行，以阀瓣密封面不泄漏为合合格不合格UNQUALIFIED合格工装设计制作检验场地准备PROCESSASSEMBLYDESIGNANDFABRICATIONINSPECTIONYARDPREPARATIONYARD编制技术措施并进行技术交底PREPAREDTECHNIQUEANDTRANSFERIT成立阀门检验、试验小组SETTINGUPVALVEINSPECTIONANDTESTGROUP质量证明文件核查、确认REVIEWANDCONFIRMATIONOFQUALIFICATIONDOCUMENTQIQUUQQ阀门外观质量检查VALVECONFIGURATIONQUALITYINSPECTION强度试验INTENSITYTEST严密性试验PRESSURETEST检验、试验状态标识INSPECTION,TESTSITUATIONIDENTIFICATION交付安装ERECTIONAVAILABLE不合格品处置NONQUALIFIEDPRODUCTIONDISPOSAL格。EXCEPTBACKANDTHROTTLINGVALVES,VALVEQUALIFIEDINSPECTIONSHALLBEDETERMINEDBYNOMINALPRESSUREANDNOLEAKAGEINTHEDENSIFICATIONAREAOFVALVEPETAL5447公称压力小于1MPA，且公称直径大于等于600的闸阀，壳体压力试验宜在系统试验时，按系统的试验压力进行试验，闸板密封试验可采用色印等方法进行检验，接合面上色印应连续。ASFORTHEGATEVALVEWITHNOMINALDIAMETERMORETHAN600ANDNOMINALPRESSURELESSTHAN1MPA,WHENDOINGTHESHELLPRESSURETEST,ITISBETTERTOEXAMINEACCORDINGTOTHESYSTEMTESTINGPRESSURESLIDEPLATEMAYUSETHECOLORPAPERSFORTESTINGANDTHECONTINUATIONAREASHOULDBECONTINUED5448合金钢阀门的壳体材质必须逐件进行快速光谱分析，不合格时该批阀门不得使用。THESHELLMATERIALOFALLOYSTEELVALVESHOULDBEANALYZEDONEBYONEBYHIGHSPEEDSPECTRAIFUNQUALIFIEDVALVESINIT,THISBATCHOFVALVESAREFORBIDDENTOUSING5449试验合格的阀门，应及时排净内部积水、吹干密封面上应涂防锈油，关闭阀门，封闭出入口。INTERNALWATERINTHEVALVEACCEPTABLESHOULDBEDRAINEDINTIMEANDDENSITYAREASHOULDBEDRIEDANDCOATEDWITHRUSTPREVENTIVEOILTHEVALVESHOULDBECLOSEDTHEEGRESSANDINGRESSSHOULDBECLOSED54410安全阀按设计文件规定的定压值进行调试，允许偏差为3。调试介质管道内介质为气体时，优先酇用氮气调试；管道内介质为液体时，应使用液体调试。调压时的压力应稳定，每个安全阀启闭次数为3次。要求起跳压力明显，无前漏、后漏现象。由于安全阀进出口压差较大，不进行壳体压力试验，密封试验时，压力小于定压值，不得泄漏，可在安全阀出口贴纸进行目测。CONSTANTPRESSUREOFSAFETYVALVESSHOULDBEADJUSTEDACCORDINGTOTHEDOCUMENTREGULATIONSAND/3DEVIATIONISPERMITTEDWEWILLUSEDIFFERENTMEDIUMSASFOLLOWSACCORDINGTOTHESPECIFIEDCONDITIONSUSINGNITROGENFIRSTINCASEOFAIRINTHEPIPINGUSINGLIQUIDINCASEOFLIQUIDINTHEPIPINGTHEPRESSURESHOULDBESTABLEWHENADJUSTINGANDEVERYSAFETYVALVESHOULDBEOPENEDANDCLOSEDTHREETIMESTHEUPANDDOWNPRESSURESHOULDBECLEARWITHOUTINTERNALANDEXTERNALLEAKAGEBECAUSETHEPRESSUREDEVIATIONBETWEENSAFETYVALVESINGRESSANDEGRESSISRELATIVEFAR,THEPRESSUREISLESSTHANITSCONSTANTPRESSUREINDENSITYTESTINTHISCONDITION,THELEAKAGEISNOTPERMITTEDANDTHELABELSCANBEMADEONSAFETYVALVEINGRESSANDEGRESSFORVISUALCHECK55质量检验人员均对检验过程做出详实的检验记录，以备随时查证。QUALITYINSPECTORSHALLMAKEDETAILEDINSPECTIONRECORDFORVERIFYINGANYTIME56装置区工艺管道材料经检查合格后，均将做出不同色标加以标识。防止施工过程用错材料，并方便检查人员监查确认。各种管道配件在易于辨认处做出两处标识，各种管材、型材均做出通长标识。AFTERCHECKEDQUALIFIED,THEPIPINGMATERIALSHALLBEIDENTIFIEDWITHDIFFERENTCOLORTAGS,WHICHCANAVOIDMISTAKEOFMATERIALUTILIZATIONANDMAKEACONVENIENCEFORSUPERVISORCHECKINGANDASSURANCETWOTAGSSHALLBEMADEONTHECLEARAREAOFEVERYKINDOFPIPINGFITTINGSANDGENERALTAGSSHALLBEMADEONEVERYKINDOFTUBEMATERIALANDSHAPESTEEL6管道的预制加工PIPINGPREFABRICATIONANDPROCESSING61为了减少现场预制带来的技术管理、材料管理、设备管理的工作负担，搞好文明施工，开辟第二现场，设置管道预制场地，进行管道的工厂化、产品化的预制加工，而后再在现场进行安装。管道预制加工厂设有轨道式天车、车床、摇臂钻床、剪板机、坡口加工机、自动焊机等施工机具。WEHAVETRACKCROWNBLOCKS,LATHES,BEAMDRILLS,PLATESHEARS,GROOVEPROCESSINGMACHINEANDAUTOMATICWELDINGMACHINESINTHEPIPINGPREFABRICATIONYARDTOAVOIDFIELDWORKBEARINGSUCHASTECHNIQUEMANAGEMENT,MATERIALMANAGEMENTANDEQUIPMENTMANAGEMENT,MAKEHOUSEKEEPING,DEVELOPTHESECONDSITE,SETUPPIPINGPREFABRICATIONYARD,MAKEPIPINGPREFABRICATIONPROCESSINTHEMARKETANDTHENERECTINTHEJOBSITE62预制前仔细核对单线图与平面图，核对基础、设备、管架、预埋件、预留孔是否正确，对于最后封闭的管段应考虑组焊位置和调节裕量。BEFOREPREFABRICATION,WEWILLCHECKTHEISOLATEDDRAWINGSANDPLANSCAREFULLY,ALIGNTHEFOUNDATIONS,EQUIPMENTS,PIPEFRAMES,EMBEDDEDPARTSANDPREFORMEDHOLESINCORRECT,ANDCONSIDERTHEWELDINGPOSITIONANDADJUSTTHESIZEUNDERTHEACTUALCONSTRUCTIONCONDITIONTOTHEPIPINGSECTIONSCLOSEDLAST63管道预制应按单线图规定的数量、规格、材质选配管道组成件，预制过程中的每一道工序均应核对管子的标记，并做好标记的移植，做到用料正确、尺寸准确、标识明显。INPIPINGPREFABRICATIONPROGRESS,WEWILLPURCHASEPIPINGFITTINGSACCORDINGTOTHESPECIFICATION,QUANTITIESANDMATERIALQUALITYFORMEDINISOLATEDDRAWINGSWEWILLCHECKTHEPIPINGTAGSINEVERYSTEPSANDMAKECHANGEDTAGSINGOODCONSEQUENCEFORUSINGCORRECTMATERIALANDSIZEANDMAKINGCLEARTAGS64钢材的切割及管道坡口的加工应采用以下方法镀锌钢管和公称直径50的碳钢管，采用机械切割，公称直径大于DN50的碳钢管采用氧乙炔焰法切割；不锈钢管应用机械或等离子的方法切割，304L、316L和317L材质的钢管用砂轮切割或修磨时，应有专用砂轮片。管子切口表面应平整、无裂纹、重皮、毛刺、凸凹、缩口、熔渣、氧化物、铁屑等。STEELMATERIALCUTTINGANDPIPINGGROOVEPROCESSSHOULDUSEMETHODSASFOLLOWSFORGALVANIZEDSTEELTUBESANDCARBONSTEELTUBESWITHNOMINALDIAMETER50USINGMECHANICALCUTTINGFORCARBONSTEELTUBESWITHNOMINALDIAMETERLESSTHANDN50USINGOXYGENACETYLENECUTTING,FORSTAINLESSSTEELTUBESUSINGAPPLIEDMECHANICALORPLASMACUTTING,FORSTEELTUBESWITHSPECIFICATIONOF304L,314LAND317LUSINGABRASIVEWHEELCUTTINGORANOTHERALTERNATIVEUSINGSPECIALEMERYPLATETOGRINDTUBECUTTINGSHOULDBEFLATANDSMOOTHANDNOCRACKING,SANDCRUST,FINS,UNEVENOPENTRACK,MELTEDRESIDUE,SCRAPANDOXIDIZATION65预制好的管段，按单元或区域摆放整齐，以便于运输和安装。管道施焊时，按规定的焊接工艺执行。管道焊接、无损检测工作完成后，应在预制厂内除锈、喷砂和防腐，但焊口两侧各100MM的范围内不允许涂漆，焊工钢印号、管道编号以及管线号不允许涂漆，待系统水压试验合格后再进行防腐涂漆。为保证焊接质量，工艺管道焊接均采用氩电联焊的工艺进行。PREFABRICATEDPIPINGSECTIONSHALLBELAIDINORDERTOTRANSPORTATIONANDERECTIONWEWILLWELDCOMPLYINGWITHREGULATEDWELDINGPROCESSAFTERPIPINGWELDINGANDNONDESTRUCTIVETESTTHEDERUSTING,BLASTINGANDANTIROTTINGSTEPSSHOULDBEDONEINTHEPREFABRICATIONYARDBUT100MMAWAYFORMTWOSIDESOFWELDINGJOINTSANDWELDERSSIGN,PIPINGNUMBERANDPIPELINENUMBERARENOTPERMITTOPAINT,ITSHOULDBEDONEAFTERSYSTEMWATERPRESSURETESTQUALIFIEDINORDERTOENSUREWELDINGQUALITY,ALLTHEPROCESSPIPINGUSEARGONCONTINUATIONWELDING66预制完成的管段进行管线号、预制管段号标识，并用人工或压缩风将管膛内清除干净，用塑料布封闭管口分门别类摆放。不锈钢和碳钢在切割和存放时，严格区分开。WEMAKEIDENTIFICATIONTAGSFORPIPELINENUMBERANDPREFABRICATIONPIPINGSECTIONNUMBERWHICHARECOMPLETEDTHEPREFABRICATION,CLEANPIPINGINSIDEBYHANDANDPRESSUREWIND,CLASSIFYANDLAYDOWNTHEMWITHPIPINGMOUTHCLOSEDBYPLASTICCLOTHWHENCUTTINGANDSTORING,STAINLESSSTEELANDCARBONSTEELSHOULDBEDIVIDEDSTRICTLY7管道焊接PIPINGWELDINGPTA装置焊接工程中，工艺管道母材的不锈钢比例在60以上，且有钛一类特殊材质的管道，焊接难度大、工艺标准要求高是该工程的主要特点。焊接质量直接决定整个安装工程的质量，因此，我们应从焊接材料、焊接工艺、施焊过程、焊接检验诸方面对焊接质量进行严格控制，确保每个焊接环节都处于受控状态。INPTAASSEMBLYWELDINGPROCESS,BECAUSETHEREIS60OFSTAINLESSSTEELINPROCESSPIPINGPARENTMATERIALANDPIPINGHASTHEESPECIALTITANIUM,THEMAINCHARACTEROFTHEPROJECTISTHEDIFFICULTWELDINGANDHIGHREQUIREMENTSOFPROCESSSTANDARDWELDINGQUALITYDETERMINETHEOVERALLERECTIONPROJECTQUALITYWEWILLCONTROLTHEWELDINGMATERIAL,WELDINGPROCESS,WELDINGOPERATION,WELDINGINSPECTIONANDSOONTOENSUREWELDINGQUALITYANDEVERYWELDINGSTEPSINCONTROL焊材型号和规格选用应严格执行焊接工艺评定。焊前检查、修正接缝的间隙、错边量等；焊接作业期间，注意自然环境对焊接作业的影响，焊后检查焊缝表面质量、角变形，及时作出质量评定，并按要求进行无损检测，及时填写焊接施工记录。THEUTILIZATIONOFTHEWELDINGMODELSANDSPECIFICATIONSHALLBESTRICTLYCOMPLIEDWITHWELDINGPROCESSQUALIFICATIONSUCHASCHECKINGBEFOREWELDINGANDCORRECTINGTHEDISTANCEINCONTINUEDJOINTSANDMISALIGNMENTWEWILLNOTICEWELDINGOPERATIONEFFECTSBYNATIVEENVIRONMENT,CHECKWELDINGJOINTSSURFACEQUALITYANDTWISTEDANGELSAFTERWELDING,MAKEQUALITYQUALIFICATIONINTIME,EXECUTENONDESTRUCTIVEINSPECTIONWITHREQUIREMENTSANDMAKERECORDOFWELDINGCONSTRUCTIONINTIME71焊接施工一般要求GENERALREQUIREMENTOFWELDINGCONSTRUCTION711焊工应在合格的焊接项目内从事管道的焊接，且在有效期内。WELDERSSHALLWORKONPIPINGWELDINGINACCEPTABLEWELDINGPROJECTANDINAVAILABLEPERIOD712焊材应有产品合格证明书，并经复验合格。WELDINGMATERIALSHOULDHAVEQUALIFIEDPRODUCTIONCERTIFICATESANDACCEPTABLEAFTERCHECKINGAGAIN713焊条应按说明书或焊接作业指导书的要求进行烘干，并在施焊过程中，使用保温筒保持焊条干燥。WELDINGRODSHALLBEDRIEDBYINSTRUMENTSANDGUIDEBOOKOFWELDINGOPERATIONINSULATIONTANKSHALLBEUSEDFORELECTRODEDRYINGINWELDINGOPERATION63514焊工按指定的焊接工艺卡（焊接作业指导书）施焊。焊接工艺卡应按与之相对应钢材的焊接工艺评定进行编制，并按程序进行审批。WELDERSDOTHEIRJOBWITHWELDINGTECHNIQUECARD,WHICHWILLBEPREPAREDANDREVIEWEDBYEQUIVALENTSTEELWELDINGPROCESSQUALIFICATIONANDPROCEDUREEQUIVALENTSTEELWELDINGPROCESSQUALIFICATIONANDPROCEDURE715当出现下列情况如没有防护措施时，应停止焊接工作WELDINGOPERATIONMUSTBESTOPINCASEFOLLOWINGPROBLEMHAPPENEDWITHOUTPROTECTA手工电弧焊时，风速8M/S，氩弧焊时，风速2M/S；THEWINDVELOCITYIS8M/SINSMAW,THEWINDVELOCITYIS2M/SINARCWELDINGB相对湿度90；RELATIVEMOISTUREIS90C下雨；RAINING716焊接完毕后，及时在焊缝两侧50MM范围内打上焊工钢印号，不锈钢钢管不做钢印标识，但是应在管道单线图上标注清楚。WELDERSSTAMPSNOSHALLBEMADEINTHE50MMRANGEAWAYFROMWELDINGJOINTSINTIME,REBARMARKSWILLNOTBEDONEINSTAINLESSSTEELTUBES,BUTITSHOULDBEINDICATEDINPIPINGISOLATEDDRAWINGS72焊接材料的选择WELDINGMATERIALALTERNATIVE焊接材料选用表51LISTFORWELDINGMATERIALALTERNATIVE序号NO管道材料PIPINGMATERIAL焊丝WELDINGWIRE焊条WELDINGROD备注REMARKS1API5LGRBER1052E7016152ANSI304ER308E308163ANSI304LER308LE308L164ANSI316ER316E316165ANSI316LER316LE316L166ANSI317LER317LE317L167C276ERNICRMO4ENICRMO48TI1ERTI173奥氏体不锈钢管道焊接STAINLESSPIPINGWELDING731奥氏体不锈钢焊接坡口形式和尺寸应符合下表的规定THEGROOVESPECANDSIZEOFSTAINLESSSTEELTUBESSHOULDCOMPLYWITHFOLLOWINGREGULATION焊接坡口形式和尺寸WELDINGGROOVETYPEANDSIZE52序坡口尺寸GROOVESIZE备注REMARKS号NO厚度MMTHICKNESS坡口类型GROOVETYPE坡口形式GROOVETYPE间隙BMMDISTANCE钝边PMM坡口角度GROOVEANGLEANGLE123I型坡口TYPEIGROOVE015单面焊SINGLEWELDNG2368V型坡口VTYPEGROOVE0202655单面焊SINGLEWELDING732奥氏体不锈钢管道焊口组对质量应符合以下要求STAINLESSPIPINGWELDINGMOUTHTOMOUTHSHOULDCOMPLYFOLLOWINGREQUIREMENTS7321管口应做到内壁平齐，其错边量不应超过壁厚的10，且应05MM；THEINSIDEWALLOFPIPINGMOUTHSHALLBEFLATANDSMOOTH,THEMISALIGNMENTSHALLNOTBEMORETHAN10OFWALLTHICKNESS,ANDSHOULDBELESSTHANOREQUIVALENTTO05MM7322焊接坡口应经砂轮打磨，坡口应整齐光洁，坡口表面的油污、锈蚀和坡口两侧各1015MM范围内的氧化层应清理干净，清理范围内应无裂纹、夹层等缺陷。WELDINGGROOVESHOULDCLEANEDBYABRASIVEWHEEL,GROOVESHOULDBEFLATANDSMOOTH,THEOIL,RUSTINGANDOXIDIZATIONOFGROOVESURFACESHOULDCLEANEDVERYWELLINCLEANRANGESHOULDHAVENODEFECTSSUCHASCRACKINGANDDOUBLELAYERS733奥氏体不锈钢焊接时，应采用小规范、短电弧、快速焊和窄焊道工艺进行焊接，并应控制层间温度不得超过150，必要时，应采取强制冷却措施。INSTAINLESSSTEELWELDINGOPERATIONS,WEWILLWELDWITHPROCESSSUCHASSMALLSPECIFICATION,SHORTARC,ANDHIGHSPEEDWELDINGANDNARROWWELDINGANDWILLCONTROLTHEINTERPASSTEMPERATURELESSTHAN150IFNECESSARYWEWILLUSECOOLINGMEASURESINFORCE734为保证管口背面焊接成型质量，奥氏体不锈钢管道焊接全部采用氩弧焊打底。打底焊接时，管道内应充氩保护。预制管口焊接时应采用整体充氩，充氩时管子两端应进行封堵，焊口处应用医用胶布密封，随焊接随揭开；安装管口焊接时，应在焊口组对前，在焊口内部放置易溶纸，采取局部充氩的方法进行充氩保护。充氩时，应将管口内部的空气置换干净，待坡口处有氩气均匀流出时方可进行焊接。氩弧焊打底焊接后，应及时进行打底焊缝的检查，确认打底焊缝合格后方可进行次层焊道的焊接，以防产生打底焊接缺陷。INORDERTOENSURETHEWELDINGSHAPEQUALITYOFPIPEMOUTHBACKING,ALLSTAINLESSTUBESWELDINGSHOULDUSEARGONARCWELDINGTOMAKEABOTTOM,WHENMAKINGTHEBOTTOMARGONSHOULDBEFILLEDTHETUBESWESHOULDFILLARGONWHENPREFABRICATEDTUBESMOUTHWELDING,ITSHOULDBEDONEINTHECONDITIONOFTWOTUBEMOUTHSARECLOSEDTHEWELDINGAREASHOULDSEALEDWITHHOSPITALADHESIVETAPEANDOPENEDWITHWELDINGPROGRESSWHENERECTINGTHETUBESWELDING,WEWILLLAYDOWNLYOTROPICPAPERINWELDINGMOUTHINSIDEBEFORECORRECTINGTHEWELDINGMOUTHGROUPANDUSEFILLEDARCLOCALLYTOPROTECTWESHOULDCHANGEAIRINTHEINNERTUBEUNTILTHEARCINTHEGROOVEFLOWINUNIFORMAFTERTHEFIRSTPASSWELDING,WENEEDCHECKTHEFIRSTWELDINGJOINTANDCONTINUETOWELDNEXTWHENQUALIFIEDTOAVOIDTHEWELDINGDEFECTS735奥氏体不锈钢管道焊接过程中，应避免横向摆动，焊道不宜过宽，焊接应连续，要一次完成，不应中断。DURINGTHESSPIPINGPROCESS,WESHOULDCOMPLETEONETIME,WITHPROPERWIDTHOFWELDINGPASS736奥氏体不锈钢管道焊接时，严禁在被焊工件表面引燃电弧、试验电流；施焊过程中，应注意接头和收弧的质量，收弧时应将溶池填满，多层焊的焊接接头应错开。MATERIALSURFACEISPROHIBITEDFROMFIREDARCANDTESTEDCURRENTWHENWELDEDPAYATTENTIONTOTHEQUALITYOFBUTTANDARC,THEFILLEDPOOL,THEDIVIDEDCOMPLEXBUTT737为确保氩弧焊焊接成型质量，在每瓶氩气正式投用施焊前，均应对每瓶氩气的纯度进行试焊检查，试焊检查不合格的氩气不得用于正式焊接施工。TOMAKESURESHAPEQUALITYOFARCWELDING,WESHOULDTESTTHEPURITYOFARCPRIORTOFORMALWELDINGIFUNQUALIFIED,ITISNOTPERMITTEDTOUSE738焊接检验WELDINGINSPECTION7381奥氏体不锈钢管道的焊缝外观成型应良好，且应平滑过渡；焊缝宽度应以每边不超过坡口边缘2MM为宜；焊缝表面不得低于母材表面，焊缝余高H应102B（B为焊缝宽度），且应15MM。THEWELDINGCONFIGURATIONISINSHAPE,THEWELDINGJOINTWIDTHISWITHIN2MMOFTHEGROOVEEDGE7382奥氏体不锈钢焊缝表面不允许有裂纹、未熔合、气孔、夹渣和飞溅等缺陷存在；焊缝无损检测质量，应符合设计规定的无损检测质量要求。SUCHDEFECTSARENOTPERMITTEDTOSTAND,SUCHASCRACK,NONFUSION,BORE,ANDSPLASHTHENDTQUALITYCOMPLIESWITHSTANDARD7383奥氏体不锈钢管道的焊缝咬边深度应05MM，连续长度应100MM，且焊缝两侧咬边总长度不得超过该焊缝长度的10THEHEIGHTISWITHIN05MM,THELENGTHISWITHIN100MM,ANDTHETOTALLENGTHISWITHINTHE10OFTHEWELDINGJOINTLENGTH74钛管道焊接TITANIUMPIPEWELDING741一般规定GENERALREGULATIONS7411钛管焊接采用钨极氩弧焊，电弧采用高频电源，焊接设备采用性能稳定的直流氩弧焊机，正接法。TUNGSTENARGONARCWELDINGANDARCWITHHEATRONICELECTRICALPOWERAREAPPLIEDFORTITANIUMWELDINGDIRECTCURRENTARGONARCMACHINEOFSTABLEPERFORMANCEAREAPPLIEDFORWELDINGEQUIPMENT,USINGPOSITIVEPOLARITY7412所有母材金属的接头表面，热影响区根部及表面在温度达到200以上时，应完全处于气体保护状态，保护气体应选用高纯度氩气（99。99），气体含水量不应大于50MG/M3，保护气体输送采用透明塑料软管。WHENTHETEMPERATUREREACHESOVER200DEGREE,WHICHINCLUDETHESURFACEBUTTSOFALLBASEMETALS,THEROOTANDTHESURFACEOFHOTEFFECTEDLOCATION,THETITANIUMPIPESHOULDBEINPROTECTEDGASESTATETHEPROTECTEDGAS,WHICHHASHIGHPURITYARGONWITHMOISTUREOF50MG/M3,CONVEYEDBYCLEARINGPLASTICTUBE7413焊接作业均应在无风区进行，且场地洁净，因此必须在施工现场搭一封闭的作业篷。THEWORKOFWELDINGCANBECARRIEDOUTINNONWINDLOCATIONWITHCLEANNESS,THEREFORE,WEHAVETOCASTANOBSCURESAILATTHECONSTRUCTIONSITE7414参加钛管焊接的焊工必须先按ASME要求考试合格，并配备铰刀、不锈钢丝刷、氧化锆铝砂轮、丙酮洗剂、保护罩等专用工具。焊前应根据WPQR编制焊接工艺卡。THEWELDERSFORTITANIUMTUBEWELDINGSHOULDHAVEATESTREQUIREDFORASMEIX,EQUIPPEDBYEXCLUSIVEUSETOOLS,