站内露空管道系统安装方案K03.doc

施工组织设计施工组织设计/方案审查意见方案审查意见 review comments on construction organization design/method statement 承包单位承包单位 contractor: 四川石油天然气建设工程有限责任公司（四川石油天然气建设工程有限责任公司（spc） 监理单位监理单位 supervision company: 四川华成油气工程建设监理有限公司（四川华成油气工程建设监理有限公司（spcs） 合同号合同号 contract no.: cw682719 编号编号 no.: cdb-0000-tec-pln-sc2-000-00100-00 工程项目名称 engineering project name： 川东北高含硫气田宣汉开县区块气田工程内部集输工程 internal gathering system of chuandongbei high-sulfur gas field xuanhan/kai block gas field project 方案描述 description of ms： 站内露空管道系统安装方案 method statement for installation of exposed pipeline in well pad and gathering station 编制依据 compilation basis： 相关标准、施工图等 relevant standards and construction drawings, etc. 编制总说明 compilation instruction： 指导内输各井站露空管道系统预制、安装 instruct prefabrication and installation of exposed pipeline in well pad and gathering station 承包商报审意见 comment for approval from contractor： 承包单位 contractor（章 seal）： 项目负责人 project leader： 日 期 date： 审查意见 review comment： 项目监理机构 project supervision organization cdb 专业工程师 cdb disciplined engineer cdb qa 工程师 cdb qa engineer cdb hes 现场经 理 cdb hes site manager cdb 现场施工经理 cdb site construction manager 签字 sign 签字 sign 签字 sign 签字 sign 签字 sign 日期 date 日期 date 日期 date 日期 date 日期 date cdb-0000-tec-pln-sc2-000-00100-00 川东北高含硫气田宣汉开县区块气田工程内部集输工程川东北高含硫气田宣汉开县区块气田工程内部集输工程 internal gathering system of chuandongbei high-sulfur gas field xuanhan/kai block gas field project 站内露空管道系统安装方案站内露空管道系统安装方案 method statement for installation of exposed pipeline in well pad and gathering station 川庆油建公司川东北高含硫气田工程施工项目部 spc chuandongbei high-sulfur gas field project construction department 版次 rev. 安全 safety日期 date 编制 compiled日期 date 审核 reviewed日期 datek03 批准 approved日期 date 站内露空管道系统安装方案 method statement for installation of exposed pipeline in well pad and gathering station 目目 录录 contents 1.工作范围工作范围 scope of work.1 1.1.简介 brief introduction.1 2.相关活动和方案相关活动和方案 related activities hard barricade maybe required when it is necessary to avoid accessing into it without permit. 作业现场必须按照每“50 名作业人员：1 名安全员的比例进行配备，以保证现场人员、物资的安 全。 provide safety officer in a proportion of “50 workers: 1 safety officer” on worksite to ensure safety of personnel and material. 作业过程中，每名员工有权利且有义务对不安全行为 “叫停”。 during working, every employee has right and responsibility to “stop” the unsafe behaviors. 现场文明施工管理，需要规划临时设施、管道堆放地点并有序摆放。 house keeping on site. make plan for temporary facilities and pipe laydown area and make sure they are placed orderly. 作业现场非指定区域禁止吸烟，现场设置吸烟点。 no smoking in operation area, except the designated smoking area which will be set on site. 废物的管理，包括防腐涂料、液体清洁剂的使用与回收，需设置垃圾回收箱，按照 cdb 废物管 理要求处理到指定地点，确保环境不受污染。 站内露空管道系统安装方案 method statement for installation of exposed pipeline in well pad and gathering station 4 waste management, including use and recycle of anticorrosion paint and liquid cleaning agent. garbage tin should be provided. the waste should be disposed at designated location according to cdb waste management requirements to ensure no pollution to the environment. 物料的搬运，按照 cdb安全工作规范手册要求，超过 20 公斤的物料或设备不能用人工搬运， 应使用机械搬运。 transportation of materials. materials or equipments exceed 20kg can not be manually hauled but by mechanical means according to cdb safe work specification manual. 在任何有运输车辆进出的施工地点，设置车辆监护员，特别是在倒车、卸货时。 any transportation vehicle entering or exiting construction location should have vehicle guardian, especially when backing or unloading. 确保在实施前所有的相关活动和方案都已获批准，否则应立即停止。 ensure all relevant activities and method statements be approved before execution, otherwise they will be stopped at once. 承包商应负责此方案中所描述活动的执行。 contractor shall be responsible for execution of activities described in this method statement. 现场应安排专职安全检查员，应制定警戒线和树立警示牌，并安排现场巡查。 the site should arrange full time safety inspectors, set up warning line and warning signs. site patrol inspection is required. 检查施工的电源线应完好无损，布置合理，固定牢固。 check the power cable in good condition and arrange it properly on site. 工作场所应设置警示、标识牌，必要时设置硬维护以防止擅自入内。禁止在同一施工区域同时进 行两项作业。 warning sign, tag board will be set up at work area; hard barricade maybe required when it is necessary to avoid accessing into it without permit. forbid performing two items of work simultaneously in one construction area. 3.3.应急救援应急救援 emergency response 施工作业现场配备急救箱。急救箱内包含的内容应符合川东北项目要求。 first-aid kit will be needed on construction site. the articles in first-aid kit will be conforming to requirements of chuandongbei project. 在施工中若发生紧急事件，按照事故管理程序cdb-0000-hes-pcd-sc2-000-00014-00 进行上 报。 if emergency happens in construction, report procedure will be accordance with accident management procedure cdb-0000-hes-pcd-sc2-000-00014-00. 应急救援按照应急总预案cdb-0000-hes-pln-sc2-000-00001-00 执行。 execute emergency response in accordance with general plan of emergency rescue cdb-0000-hes- pln- sc2-000-00001-00. 如遇到任何医疗、安保意外或安全事件、事故，工作人员应按照相关程序联系以下人员。联系人 先后顺序的选择应本着对处理事件或伤者最有利的方式。 workers will contact following personnel in accordance with corresponding procedures if any unexpected medical, security incidents or accidents happen. the sequence of contact shall be based on the best interest of handling the incidents or the injured. 联系单位(所在地址) contact (location) 联系电话 tel number cdb 南坝安全控制中心 nanba safety control center0818-3951111 救护中心联系电话（南坝境内） emergency center( in nanba)0818-5520999 救护中心联系电话（开县境内） emergency center (in kai county)023-52663222 4.培训和人员资质培训和人员资质 training and competency of personnel 承包商应对方案里描述的工作执行情况负责。 contractor shall be responsible for execution of the activities described in this method statement. 承包商为所有人（包括其分包商人员）提供所有的监督人员和必要的 hse 培训。并且按照所有人 员在进场施工前都必须经过入场训且合格。 站内露空管道系统安装方案 method statement for installation of exposed pipeline in well pad and gathering station 5 contractor shall provide all supervisors, the required hse training to all personnel including subcontractor personnel. all personnel shall have an hse passport prior to mobilization to site. 特殊工种作业人员必须取得相应工作的资质证件，且报审合格。 operators of special works must obtain relevant qualification certification of corresponding works and qualified in verification before work. 操作人员进场施工前应参加 cdb 的 hse 培训，并取得相关证件。 operator should attend the hse training by cdb and obtain relevant vouchers before operation. 为了提高所有人员的环保意识，将进行班前讲话和必要的培训课程。 all personnel will be made aware of the environmental aspects of the works through toolbox talks and where necessary training sessions on the certain aspects of the works affected by the environment. 5.工艺工艺 process 5.1.施工准备施工准备 preparation for construction 施工机具和人员的准备：所有机具设备齐全完好，经过 cdb 检查合格且报审后方可进场使用； 施工人员必须经过入场培训合格且报审后才能进场施工。 preparation of construction machine and personnel: all machinery equipments shall be complete and intact, it only can be used after passing cdb inspection and being reported; construction personnel must pass orientation training, certified and be reported prior to work on site. 施工技术准备：按施工程序要求先后完成施工图会审、设计交底和施工技术交底，并组织相关人 员熟悉设计要求和相关技术质量标准与规范。 construction technical preparation: according to requirements of construction procedure, it should complete ifc drawing review, design clarification and construction technical clarification firstly, and organize relevant personnel to learn about the design requirements and related technical quality standards and specifications. 施工材料的准备：根据本工程的实物工程量和施工计划要求，提出工程材料供货计划和领料使用 计划，并落实有关消耗材料和加工件。材料报审合格后才能使用。 construction material preparation: according to physical work quantity and construction plan requirements of this project, it will propose material supply plan and material withdrawal plan and get the relevant consumables and processed members done. materials can not be used unless been reported, inspected and qualified. 施工关系协调：施工前会同 cdb 和监理单位以及有关协作单位对本工程的施工范围、施工作业 区域、施工作业界限以及其它特殊事项进行确定，从而确保工程的顺利开展和交接。 construction relationship coordination: prior to start of construction, it will confirm with cdb, supervision unit and other co-working unit on construction scope, construction operation area, construction operation boundary and other especial issues, so as to guarantee successfully development and shift of this project. 落实现场的用水用电以及施工场地的平整，施工区域的清理等。 carry out site water and power supply, construction site preparation and construction area cleaning etc. 5.2.流程流程 process flow 管道系统施工流程如下： construction flow of pipeline system is as below: 站内露空管道系统安装方案 method statement for installation of exposed pipeline in well pad and gathering station 6 材料的检查 及验收 acceptance inspection of materials 管段预制 prefabrication 运到现场 delivery to the site 现场组装焊接 assembly pipe prefabrication yard and temporary laydown area see temporary facilities method statement for temporary facilities of individual constrution of all well pads and gathering stations. b 集气站： 埋地管道材 料堆放 material pile up of underground 塔架材料堆放与加工 material pile up and processing area of tower structure 临时厕所（已建） temporary rest room（ have been built） 防腐喷砂区域（已建） area for sand blastong and derusting（have been built） 拟定的库房(未建) the stock area(plan to build) 钢结构与工 艺管道预制 场地(已建) fabrication yard for steel structure and pipes(have been built) c 井站： c 井站管道预制区设在净化厂集气末站区域内，预制完成后拉运至 c 井站进行安装； 站内露空管道系统安装方案 method statement for installation of exposed pipeline in well pad and gathering station 8 组装 fitting （1）预制管道组装前，管道主管应检查以下内容： prior to fitting the pre-fabricated pipes, the following checks shall be carried out by the piping foreman: a 对比图纸检查管段的长度 length of spool against the drawing(s) b 材料应符合设计图纸要求的规格和等级。尺寸/标签错误应根据不合格品控制程序cdb- 0000-qac-pcd-sc2-000-00007-00 处理。 material should be comforming to required specification and class in design drawings. dimentional / tagging errors shall be processed in accordance with procedure “control of non-conforming product”, ref. cdb-0000-qac- pcd-sc2-000-00007-00. （2）当要求切割直管时，根据管道材质及焊接工艺要求实施火焰切割或机械切割（热处理管道）， 切割后标识应进行移植。 when cutting straight pipe is required, torch cutting or mechanical cutting (heat treatment pipe) will be applied according to pipe material and requirements of welding procedure. the identification will be transplanted after cutting. a 火焰切割采用手持式火焰割俱和半自动机械割俱进行切割，然后采用打磨机或坡口机进行加工 坡口。 hand-type flare cutting tools and semi-automatic mechanical tools will be applied for flare cutting, and then it will apply sander or electric bevelling machine to process bevel. b 机械切割采用一体式机械加工机（切断及坡口一次成型）和管道切割机。 one-piece mechanical processor (one time of forming for cut off and bevel)and pipe cutting machine will be applied for mechanical cutting. c 切割后的管段，对没有标识的，应对应原管段标识进行移植。 for pipe sections which have been cut off, it should transffer identification of original pipe sections for pipe sections without identifications. （3）磨工应对所有的磨光活动负责。磨工应佩戴面罩和手套等附加 ppe。 the grinder shall be responsible for all grinding activities. the additional ppe for grinder includes face shield and gloves. （4）管道预制应考虑运输和安装的方便，并预留可调整的活口，预制完毕的管段应将内部清理干 净，密闭管口，防止杂物进入。 pipe prefabrication shall have the transportation and installation into consideration and reserve adjustable movable opening. prefabricated pipe section should firstly clean its inside, close the orifice to avoid entering of foreign matters. （5）预制组合件不允许长期处于临时固定状态。 prefabrication units shall not be temporarily fixed for long. 天然气厂集气末站预制场 站内露空管道系统安装方案 method statement for installation of exposed pipeline in well pad and gathering station 9 （6）管道组成件预制应根据单管轴测图和现场设备、管廊的实际分布情况测量尺寸，选择合理的 自由管段和封闭管段； pipe component prefabrication shall be in accordance with the monotube axonometric drawing, site equipments and the measuring size of the pipe gallery distribution to select proper free pipe and blind pipe stretch. （7）管道组成件预制时并应按单管轴测图标明它所在的管道系统。 各管道组成件应标明其预置 顺序。 the pipe system shall be marked where the pipe component prefabrication is in accordance with the monotube axonometric drawing. each component is numbered on its prefabrication sequence. （8）对口前应将焊接端的坡口面及内外管壁 1520mm 内的铁锈、泥土、油渍等脏物清除干净。 before joint, the rust, soil, grease on the welding slope and 15-20mm within external tack welds shall be at least 25 mm in length and shall be equaly spaced around the circumference in sufficient number to support the pipe or fitting. heavy piping components, which are to be tack welded shall be adequately supported at all times. any defective tack welds are to be completely removed prior to welding. 所有的桥接焊和根部定位焊缝应在焊接程序中规定的接头位置，并由合格的焊工施焊，并满足预 热要求。 all bridge and root tack welds shall be welded in accordance with the weld procedure specified for the joint and performed by qualified welders including pre-heating requirements. 若移除临时焊接后，不锈钢和碳钢材料的定位焊缝在坡口外，视检这些区域并确保他们符合磁性 探伤和渗透试验。 whenever tack welds on stainless steel and carbon steel materials are outside the groove after removal of the temporary weld, visual inspection shall be carried out on these areas and they shall be subjected to magnetic testing or penetrant testing. 不锈钢上的焊缝必须在从一个地方移到另一个地方去以前完成根焊道和热焊。 welds on stainless steel must have the root pass and hot pass completed before being moved from one place to the other. 若焊接奥氏不锈钢，管内充气保护应使用 99.99%的纯氩气。气瓶应在框架里围起来，离框架 7m 远并配置氧气仪表。允许的最大氧气含量百分比为 1.0。焊接监理应负责氧气的百分比经检查合 格后使用。 in case of welding austensic stainless steels, back purging shall be applied by 99.99% pure argon. gas cylinders shall be enclosed inside the frame kept 7 meters away and shall be fitted with oxygen meter. the maximum % of oxygen allowed is 1.0. the welding supervisor is responsible for the checking of percentage of oxygen. 关于低温碳钢，坡口外的定位焊缝只允许使用在将要立即进行焊后热处理的焊缝上。此项工作完 成后，焊缝移除的区域需要进行磁性探伤和渗透试验。 for low temperature carbon steel, tack welds outside the groove are only permitted on welds which are to be subsequently post weld heat treated. after this operation magentic testing or penetrant testing will be applied to the areas where tacks were removed. 关于电弧划伤，需要完全的磨边并根据材料和重要性进行磁性探伤和渗透试验。 arc strikes, if any, shall be ground off completely and penetrant testing / magnetic testing shall be carried out depending on the material if there is required diameter reducing in installation of the pipe, utilize eccentric reducer to ensure the same elevation of the pipe bottom. （3）成排管道及交叉管道的间距应符合设计或规范要求。 the spacing of pipes in row and cross pipes should be consistent with design or specification. （4） 由于内输各井站均是单层管廊，管线架设过程中可以直接用手拉葫芦或吊车配合将管段 （合 适长度，一般小于两榀管架长度）安装进管廊中。 due to single-store pipe rack in all well pads and gathering stations, pipe scetion (approriate length, generally less than 2 pipe racks) can be directly installed into the pipe rack utilizing chain block or crane. 安装的管道应有充分的支撑。 installed pipes should have sufficient support. 管道主管应确保在将管道安装进管廊前要进行废物清理。 piping foreman shall ensure the waste cleaning before piping into pipe gallery. 管道安装不应损害管道或者钢结构。 pipe shall not damage the pipeline and the steel frame. 不锈钢应做以下处理： stainless steel spools will be treated, as follows: （1）所有不锈钢管应与碳钢管分开保存。 all stainless steel spools shall be segregated from cs spools. （2）使用非金属吊带进行不锈钢管道和管子的吊装。 non-metallic slings shall be used for lifting stainless steel spools / pipe. （3）组对或连接到设备的时候才能移除管端盖板，并且在换班的时候，所有不锈钢开口端都要用防 尘盖盖好。 end cap / cover shall not be removed until fit-up or connection to equipment, and at the end of working shift shall alll stainless steel open ends shall be covered by dust roof covers. （4）架设管道或校直管子时，应务必保护管子使其不接触到其他金属。 during the erection of spools, or straight lengths of pipe, pipe will be protected against contact with other metals, at all times. 在不利天气的情况下，所有焊件都应进行防尘，防雨和防风保护。所有尚未安装的管配件的管口 都应用防尘盖盖好，直到管线走线和最后的连头全部完成。 in adverse weather, all weldments shall receive dustproof, rainproof and windproof safeguard. unerected pipe accessories nozzles shall be covered with dustproof lids until the pipe routing and the final linking head are completed. 如果需要在现场把附件焊接到管子上，遵循以下程序：管子应在剥落涂层露出其金属裸面；定位 到支撑的位置上；支撑应把金属完全的帖服到焊点上；然后由合格的焊工将支撑焊接到管子上。 if accessories welding to pipe on site needed, take the following procedures. pipes shall expose the bared metal surface in the spalt coating;fixed to the location of supporting; supporting requires an absolute metal docile and obedient to the welding spot; later professional welder will weld the support to the pipe. 5.10. 阀门安装阀门安装 valve installation 阀门应由卡车或人工从堆放区域运送到工作现场。阀门安装应采用合适的吊装设备，如吊车等， 并根据生产商的建议进行吊装。 站内露空管道系统安装方案 method statement for installation of exposed pipeline in well pad and gathering station 15 valves shall be transported to jobsite by boom trucks from the store laydown area. valves installation use proper lifting equipments, like cranes, etc., and lifted as per manufactrers recommendations. 管道主管应确保阀门控制的定位和流向与管线总体布置图一致，并符合 sid 及实际操作的要求。 piping foreman shall ensure that the positioning and flow direction of valve control are compliant to pipeline overall distribution drawing and be subject to sid and factual operation requirements. 阀门都应该邻近固定，即使是旋塞和球形塞。 valves shall be fixed nearby, even though cock plug and ball plug. 焊接类阀门在进行焊接和焊后热处理应保持半开状态。仪表控制阀，球阀及其他软座的阀门在进 行焊后热处理和管线冲扫作业前拆除，在要求的作业验收完成后再重新安装上去。阀门的拆除和 重新安装都应按照管线系统试压程序进行控制。当阀门从管线上拆除下来，应对其进行标签标记， 保护并储存在干净储存架上的封顶的场地直到重新安装。 welding valves shall be half opened when receiving welding and post-welding heat treatment. instrument-control valves, ball valves and other soft-seated valves shall be dismantled prior to post- welding heat treatment and pipeline purging work, as well as reinstalled after acceptance check of required works. the dismantlement and reinstallation shall obey pipeline system hydro testing procedure. after valves dismantled off the pipeline, they shall be tagged, protected and stored in capped site on clean stacks till reinstallation. 所有聚四氟乙烯底座阀门必须在焊接前拆除。 all polyfluortetraethylene seated valves should be dismantled prior welding. 应试压的阀门必须经试压合格方可进行安装。 valves, for which pressure test is required, must be installed after qualified pressure test. 5.11. 与设备管嘴的连接与设备管嘴的连接 connection to equipment nozzle 根据现场情况，架设由架设主管确定的临时支撑和通道，如脚手架或特殊构架等的方法应按照 安全工作规范手册执行. erecting the temporary support and access confirmed by the foreman. and scaffold or special frames will be put up according to security work specification book. 应注意以防止有预置管道和管件的重量引起的设备管嘴损坏，这些东西在安装设备管嘴和泵前就 应进行相应的支撑保护。在任何情况下管道都不能硬连接到设备管嘴上去。 pay a