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上海赛科石化项目管道施工手册,上海,石化,项目,管道,施工,手册
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Contract Title 合同标题 Shanghai Secco Petrochemicals Company Limited 上海赛科石油化工有限责任公司上海赛科石油化工有限责任公司 Integrated Project Management Team 一体化项目管理组一体化项目管理组 Caojing, Shanghai, P R China 中国中国 上海上海 漕泾漕泾 Document Title 文件标题 FABRICATION OF PIPING 管管道道制制作作 DOCUMENT NUMBER 文件号文件号 SD-00-TSC-PP-0004 English language is the “original“ language and if inconsistencies exist between English and Chinese versions, the English version takes precedence and the English version is the legally binding version. 原本以英文书就，如果英文和中文版本之间存在不一致，以英文版本为准，英文版本具有法律约束力。 A00 The Chinese translation done on A00（从 A00 版开始有中文翻译) 29/11 /02 A00APPROVEDBW17/6/ 02 BN W 17/6/ 02 N/AN/AHYC20/06 /02P02Reviewed by SJECYJC05/06 /02 P01 No Comments by SEIYQZ30/05 /02 ZBJ30/05 /02P00FOR REVIEWBW25/4/ 02Issue Rev Issue or Revision DescriptionOrig in by DateChe ck by DateAppro ve by DateAppro ve by Date This Document is Owned by 本文件持有人本文件持有人 HENRY CHENBrian Winter (BW) IPMT Authority IPMT 授权批准 HARD COPIES ARE UNCONTROLLED 硬拷贝为非受控文件硬拷贝为非受控文件 SECCO Purchasing Specification for Fabrication of Piping SD-00-TSC-PP-0004-AP00 Purchasing Specification for Fabrication of Piping Page 2 of 2806/01/19 FABRICATION OF PIPING 管管道道制制作作 TABLE OF CONTENTS 目目录录 1.0GENERAL 总则 1.1SCOPE范围 1.2DEFINITION OF SPECIFIC TERMS术语的定义 1.3CONFLICTS争议 1.4DIVISION OF WORK分工 1.5INDUSTRY CODES AND STANDARDS行业规范和标准 1.6APPLICABLE DOCUMENTS适用文件 2.0CONTRACTORS RESPONSIBILITIES 承包商的责任 2.1DOCUMENTS TO BE SUBMITTED BY THE CONTRACTOR承包商应提交的技术文件 2.2DOCUMENTS TO BE RETAINED BY THE CONTRACTOR承包商应保留的文件 2.3SUB-CONTRACTORS分包商 3.0DESIGN 设计 3.1GENERAL总则 3.2CONNECTIONS连接 3.3FLANGES, BOLTS AND GASKETS法兰，螺栓和垫片 3.4BUTTWELDING AND SOCKETWELDING END VALVES对焊和承插焊阀门 3.5MISALIGNMENT-INTERNAL内部错边 4.0MATERIALS 材料 4.1GENERAL总则 4.2BACKING RINGS衬环 5.0FABRICATION 制作 5.1BEVELING坡口 5.2THREADING螺纹 5.3SOCKETWELDING承插焊 5.4BACKING RINGS衬环 5.5FORMING成型 5.6BENDING弯曲 5.7MITER ELBOWS虾米弯 5.8HEAT TREATMENT热处理 5.9PLASTIC LINED PIPING塑料衬里管道 5.10TOLERANCES公差 6.0LOW TEMPERATURE PIPING FABRICATION 低温管道制造 7.0WELD INSPECTION AND PRESSURE TESTING 焊缝检验和压力试验 SECCO Purchasing Specification for Fabrication of Piping SD-00-TSC-PP-0004-AP00 Purchasing Specification for Fabrication of Piping Page 3 of 2806/01/19 7.1WELD INSPECTION焊缝检验 7.2PRESSURE TESTING压力试验 8.0CLEANING 清洗 9.0PAINT AND COATINGS 油漆和涂料 10.0REJECTIONS/REWORK 拒收和返修 11.0MARKING AND IDENTIFICATION 标记和标识 11.1SPOOL PIECE MARKING管件标记 管段应按以下内容进行标识： 每条预制管道在法兰边缘用钢印打上其管线号和管段号（11.1.3 节除外） 12.0VENDOR DIMENSIONAL VERIFICATION 厂家尺寸核查 13.0PACKAGING AND SHIPPING 包装和运输 14.0FIELD APPLICATIONS 适用范围 14.1UNDERGROUND PIPING地下管道 14.2HOT TAPPING热分接 14.3DIMENSIONS尺寸 14.4SEAL WELDING OF THREADED CONNECTIONS螺纹连接的密封焊 14.5PIPE SUPPORTS管架 15.0MATERIAL SUBSTITUTIONS 材料代用 SECCO Purchasing Specification for Fabrication of Piping SD-00-TSC-PP-0004-AP00 Purchasing Specification for Fabrication of Piping Page 4 of 2806/01/19 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 SECCO Purchasing Specification for Fabrication of Piping SD-00-TSC-PP-0004-AP00 Purchasing Specification for Fabrication of Piping Page 5 of 2806/01/19 1.0GENERAL 总则总则 1.1SCOPE范范围围 1.1.1This standard describes SECCOs minimum requirements for the material, fabrication, heat treatment, inspection, testing and painting of shop and field metallic piping. 本标准是赛科公司关于车间和现场制作金属管道在材料、制造、热处理、检验、试验 和油漆方面最基本的要求。 1.1.2The technical requirements outlined herein are equally applicable to piping sub- assemblies (frequently called “shop fabricated piping), and to final erected piping systems (frequently called “field fabricated” piping). 本技术要求同样适用于管道预组装（通常叫“车间制作的管道”）和管道系统最终安 装。（通常称“现场制作的管道”） 1.1.3This specification together with vendor data requirements and the Requisition cover the requirements for the fabrication of metallic piping. 本标准及供货商的数据要求和需要适用于金属管道的制造。 1.1.4The requirements specified in the attached documents and the referenced Industry Codes and Standards shall apply. 附件以及引用标准的要求并应同样遵守。 1.1.5Jacketed piping, tubing, orifice runs; lined or coated metals and fabrication by methods other than threading, welding, bending and flanging are not within the scope of this specification. 本标准不包括夹套管，小管子，孔板管路；衬里、涂层；以及螺纹焊接、弯曲、法兰 以外的制作要求。 1.1.6“Onshore” refers to materials bought in China, while “offshore” refers to materials bought outside of China. “Onshore”是指材料在中国采购，而“Offshore”是指材料在境外采购。 1.1.7Whenever in this standard the word supplier is used, it shall be understood as referring to the party providing a service to Secco. 供货商在本标准中定义为赛科提供服务的机构。 Whenever in this standard the word Contractor is used, it shall be understood as referring to the party supplying all material and/or labour, etc. as described in Paragraph 1.1.1 above. 本标准中，承包商是指提供所有如上述 1.1.1 节所述材料和劳务等单位。 1.2DEFINITION OF SPECIFIC TERMS术语的术语的定义定义 SECCO Purchasing Specification for Fabrication of Piping SD-00-TSC-PP-0004-AP00 Purchasing Specification for Fabrication of Piping Page 6 of 2806/01/19 1.2.1“Lot(s)”- A lot shall consist of all components of the same size, type and wall thickness, manufactured from one heat of material however they shall not be charged to the Supplierss account. Materials for backing rings shall be in accordance with the Secco standard SD-00-TSC-MS-0025 “Piping Welding”. 采购单中允许时，可采用衬环，但不应由供货商承担。衬环应符合 SD-00-TSC-MS- 0025“管道焊接”的要求 5.0FABRICATION 制作制作 5.1BEVELING坡口坡口 5.1.1Pipe and fittings shall be beveled for welding in accordance with ASME B16.25, ASME B31.3, ASME B31.1, GB50235, SH3051 or GB 50316, whichever is applicable. In no case shall the weld bevel preparation reduce the material thickness below the minimum required thickness inclusive of any corrosion allowance. 管道和管件应按照 ASME B16.25，ASME B31.3，ASME B31.1，GB50235，SH3051 或 GB50316 的坡口要求。任何情况下坡口减薄的厚度不应小于包括腐蚀余量的最小厚 度。 5.1.2Beveled ends may be cut, shaped and beveled for welding in accordance with the Secco standard SD-00-TSC-PP-0025 “Piping Welding”. SECCO Purchasing Specification for Fabrication of Piping SD-00-TSC-PP-0004-AP00 Purchasing Specification for Fabrication of Piping Page 19 of 2806/01/19 焊接坡口的端部的切割，磨削成形应符合赛科公司 SD-00-TSC-PP-0025“管道焊接” 规定 5.2THREADING螺纹螺纹 5.2.1Threading of pipe shall be preferably be done after bending, forging, or heat treatment operations. When this is impractical, threading may be done prior to these operations, but precautions shall be taken to properly protect pipe threads from damage. 管道的攻丝应在弯曲、锻造、热处理之后进行。如不可能，应采取防护措施和保护管 螺纹不被损坏。 5.2.2Threads shall be concentric with the outside barrel of the pipe and shall conform to ASME B1.20.1. 螺纹应与管子外壁同心，并符合 ASME B1.20.1 的规定。 5.3SOCKETWELDING承插焊承插焊 5.3.1For socketweld construction, the pipe shall be inserted to a depth of approximately 21.6 mm (1/16-inch) from the bottom of the fitting. 承插焊接时，管子应插入到离管件底部 2mm(1/16”)的深度。 5.4BACKING RINGS衬环衬环 5.4.1Backing rings, if used for circumferential welds, shall be in accordance with the Secco standard SD-00-TSC-MS-0025 “Piping Welding”. 环缝的衬环应符合赛科公司的 SD-00-TSC-MS-0025“管道焊接”标准。 5.5FORMING成型成型 5.5.1Forming, when applicable, either hot or cold, which results in more than 10 percent extreme fiber elongation shall be followed by heat treatment in accordance with applicable ASTM or Chinese Material Standard. 无论热成型或冷成型，如果最终产生了大于 10%的变形，则应按 ASTM 或中国的材料 标准的规定进行热处理。 5.6BENDING弯曲弯曲 5.6.1Bends, when allowed in the Purchase Order, shall be in accordance with the Purchasers Specification SD-00-TSC-PP-Hold, “Pipe Bending”. 采购单规定许可的弯曲应符合采购说明书 SD-00-TSC-PP-待待定定“管道弯制”规定。 5.7MITER ELBOWS虾米弯虾米弯 5.7.1Miter elbows shall be designed and fabricated per the Purchasers Piping Specialty Item Data Sheets and welded and examined in accordance with the requirements of the Secco standard SD-00-TSC-PP-0025, ”Piping Welding”. SECCO Purchasing Specification for Fabrication of Piping SD-00-TSC-PP-0004-AP00 Purchasing Specification for Fabrication of Piping Page 20 of 2806/01/19 虾米弯应按买方的特殊件数据表进行设计和制作。其焊接和检查应符合赛科标准 SD- 00-TSC-PP-0025“管道焊接”的要求。 5.8HEAT TREATMENT热处理热处理 5.8.1Heat treatment, annealing, stress relieving or heating and cooling shall be under controlled conditions in accordance with the requirements of ASME B31.3, ASME B31.1, or GB 50316, whichever is applicable and the Secco standard SD-00-TSC-MS- 0025, “Piping Welding”. 热处理，退火，消除应力或加热，冷却都应按照 ASME B31.3，ASME B31.1 或 GB50316 的规定和赛科标准 SD-00-TSC-MS-0025“管道焊接”的规定。 5.8.2The details of any special stress relieving, stabilizing or other heat treatment required to improve the corrosion resistance or physical properties of materials fabricated in accordance with this specification will be specified in the Secco standard SD-00-TSC- MS-0025 “Piping Welding”, with the proper cross references in the Secco standard SD-00-TSC-PP-0001 “Piping Materials”. 对特定的消除应力、稳定化处理或者其他改进材料的防腐性能和加工性能的热处理的 细节应符合赛科标准 SD-00-TSC-MS-0025 中详细说明的内容，或参照赛科标准 SD- 00-TSC-PP-0001“管道材料”中的规定。 5.8.3If heat treating is performed, all traces of paint or surface compounds shall be removed and flange gasket faces, ring grooves and threads shall be protected against damage. All threaded ends shall be gage-checked for fit and roundness following heat treatment. If the thread is not acceptable, the thread shall be chased with a tap or die. 热处理前应清除油漆和表面涂层，法兰密封面，环槽和螺纹应有保护措施。螺纹端在 热处理后应用螺纹规检查。如果不合格，应用丝攻和板牙修理螺纹。 5.8.4Post weld heat treatment at Integrally Reinforced Forged Branch Outlet Fittings/branch attachment welds is required per ASME B31.3. when the thickness through the weld in any plane through the branch is greater than 38 mm (1-1/2”) for P1 material or 25.4 mm (1”) for P4 and P5 material. 整体加强支管台/支管，焊缝需按 ASME B31.3 进行焊后热处理。 5.8.5Post weld heat treatment at Integrally Reinforced Forged Branch Outlet Fittings/branch attachment welds is required per ASME B31.1 when the thickness through the weld in any plane through the branch is greater than 19 mm (3/4”) for P1 material or 12.7 mm (1/2”) for P4 and P5 material. 整体加强支管台/支管，厚度大于 19mm(3/4”)的 P1 组材料或大于 12.7mm(1/2”)的 P4 和 P5 组材料的焊缝需按 ASME B31.3 进行焊后热处理。 5.9PLASTIC LINED PIPING塑料衬里管道塑料衬里管道 5.9.1The manufacturers recommendations and specifications must be followed during shipping, storing, handling, installation, erection, testing, final painting / insulating and for removal / maintenance requirements. SECCO Purchasing Specification for Fabrication of Piping SD-00-TSC-PP-0004-AP00 Purchasing Specification for Fabrication of Piping Page 21 of 2806/01/19 运输、储存、加工、装配、安装、试验、最后的油漆/保温操作过程必须遵照制造商提 供的使用说明书和注意事项。 5.9.2Field installation Note for plastic lined piping system: Shop spools made to the required length with flanged ends are preferred and shall be used whenever possible. Field cutting and molding may be performed only when approved by project and shall be done in accordance with manufacturers techniques, equipment and recommendations. Prior to installation, pipe liners and liner forming the flange gasket sealing surface of pipe and fittings shall be thoroughly examined for pinholes, cracks, gouges, nicks, or inclusions of foreign particles. If any of these items measured greater than 10% of liner thickness or reduce dielectric capacity below 10,000 volts, liner is subject to rejection. 塑料衬里管道现场组装的注意事项：带法兰的管段优先采用在制造厂预制。现场切割 和成型仅在项目规定许可时才能进行，并应使用制造商的技术，设备和要求。在组装 前，应对管道衬里和管件法兰垫片密封面的衬里进行彻底检查，不允许存在气孔，裂 纹，沟痕，刻痕或杂质，如果存在大于 10%衬里厚度的任何一种缺陷或衬里材料电容 率低于 10000 伏，则可视为不合格材料。 5.10TOLERANCES公差公差 5.10.1The tolerances on fabricated piping shall be in accordance with PFI Standard ES-3, except that linear dimensions shall be maintained within plus or minus 3 mm (1/8 inch). 管道的制造公差应符合 PFI 的 ES-3 规定，管线长度尺寸偏差应控制在3mm(1/8”)之 内。 5.10.2The maximum allowable gap between reinforcing pads and the curvature of the pipe shall not exceed 3 mm (1/8 inch). 补强板与管子外表面之间的最大间隙应不超过 3mm(1/8”) 6.0LOW TEMPERATURE PIPING FABRICATION 低温管道制造低温管道制造 6.1Unless a part is specifically noted as “non-impact tested”, all parts welded to impact tested parts shall be of impact tested materials. 除非特别注明“不做冲击试验”，所有与有冲击试验要求的材料焊接的零件，必须做 冲击试验。 6.2Non-pressure parts bolted to impact tested material need not be impact tested. 非承压零件与有冲击试验要求的材料以螺栓形式连接时，不需做冲击试验。 7.0WELD INSPECTION AND PRESSURE TESTING 焊缝检验和压力试验焊缝检验和压力试验 7.1WELD INSPECTION焊缝检验焊缝检验 SECCO Purchasing Specification for Fabrication of Piping SD-00-TSC-PP-0004-AP00 Purchasing Specification for Fabrication of Piping Page 22 of 2806/01/19 7.1.1The examination of pipe welds shall be in accordance with the Secco standard SD-00- TSC-PP-0001, ”Piping Materials” and SD-00-TSC-MS-0025, “Piping Welding”. 管道焊缝检验应符合赛科标准 SD-00-TSC-PP-0001“管道材料”和 SD-00-TSC-MS- 0025“管道焊接”的规定。 7.1.2All welds requiring the extent of inspections over and above those defined in ASME B31.3, ASME B31.1, or GB 50316, whichever is applicable, shall be noted in the Secco standard SD-00-TSC-PP-0001, “Piping Materials”. 超出 ASME B31.3/ASME B31.1 或 GB50316 规定范围的焊接检验要求应在赛科标准 SD-00-TSC-PP-0001“管道材料”中注明。 7.1.3Non-destructive examination (NDE) of fillet welds and socketwelds in all pipe sizes and wall thickness, shall be in accordance with the Secco standard SD-00-TSC-MS-0025, “Pipe Welding”. 所有填角焊缝和承插焊的无损检测应符合赛科标准 SD-00-TSC-MS-0025“管道焊接” 的规定。 7.2PRESSURE TESTING压力试验压力试验 7.2.1Upon completion of all fabrication, the Contractor shall pressure test piping that is specifically noted in the Requisition as requiring a shop test. The test pressure for this group of piping shall be as specified by the Supplier. 制作完成后，承包商应按照采购单中规定，在制造厂进行压力试验。试验压力应由供 货商规定。 7.2.2The test fluid used for hydrostatic testing shall not be detrimental to the piping materials. 液压试验用的液体应对管道材料无害。 7.2.3When the shop test system includes fabricated items of austenitic materials, stainless steel clad materials, only clean potable water (maximum chloride content 50 ppm) shall be used. No salt or brackish water shall be used for cleaning or testing. 奥氏体材料或不锈钢复层材进行水压试验时，试验用水应是清洁的饮用水（氯离子含 量不大于 50ppm）。清洗或试验用水应是不含盐份或盐味的水。 7.2.3.1The inside surface of pipe shall be cleaned before hydrostatic testing. After hydrostatic testing, all water shall be drained and removed by blowing with air. 管道内表面在水压试验之前，先清洗，水压试验后，所有的水应放净排空，用空气吹 干。 7.2.4All reinforcing pads on pressure outlets shall be tested with air at approximately 0.173345 Mpa (2550 psi). All readily accessible welded surfaces subjected to such air pressure tests shall have a detection fluid applied to aid in detecting leaks. 支管的补强板要用大约 0.173Mpa(25psi)的空气进行测试。可进行气压试验的所有焊缝 表面应用检测液检测泄露情况。 SECCO Purchasing Specification for Fabrication of Piping SD-00-TSC-PP-0004-AP00 Purchasing Specification for Fabrication of Piping Page 23 of 2806/01/19 7.2.5Leak testing for field fabricated piping shall be in accordance with the Secco standard SD-00-TSC-PP-0009, “Field Pressure Testing of Piping” and the requirements of ASME B31.3, ASME B31.1, or GB 50316, whichever is applicable. 现场制作管道的气密性试验应按照赛科标准 SD-00-TSC-PP-0009“管道现场压力试验” 和 ASME B31.3/ASME B31.1 或 GB50316 的规定进行。 8.0CLEANING 清洗清洗 8.1All piping shall be cleaned in accordance with PFI ES-5. 所有管道应按 PFI ES-5 的要求进行清洗。 8.1.1Surfaces to be welded shall be clean and free from foreign material for at least 25 mm (1 inch) from the welding edge. 焊接坡口两侧不小于 25mm（1 寸）的距离内应予清洗。 9.0PAINT AND COATINGS 油漆和涂料油漆和涂料 9.1Following completion of inspection and testing, piping shall be coated or painted as required in the Secco standard SD-00-TSC-MS-0023, “Protective Coatings and Application Requirements”. 管道检查和测试完成后，应按赛科标准 SD-00-TSC-MS-0023“保护涂层和操作规定” 的规定进行油漆或涂层。 10.0REJECTIONS/REWORK 拒收和返修拒收和返修 10.1Fabricated pipe, components, or materials containing defects originating with the Vendors design, materials, or workmanship; or that are not in complete compliance with the requirements of the Requisition will be rejected. 由于供方的设计，材料或工艺或其它没有完全遵循申购单的规定之类原因而造成的管 子，元件或材料的不合格品将被拒收。 10.2Discovery of conditions warranting rejection, after inspection and acceptance of the pipe by The Purchaser, does not relieve the Vendor of responsibility to comply with the Requisition. 采购方对管道进行检测和验收后，发现问题可以拒收，但这不能免除供货商应遵循申 购单规定的职责。 10.3Pipe not in accordance with the original Inquiry may be rejected after award if the Vendor is discovered not to have submitted a proper base quotation or if all alternatives were not properly indicated. 当确认供方没有提交合适的报价单或所有选择不恰当时，可以拒收不符合询价要求的 管子。 10.4Any items rejected because of defects shall be repaired or replaced, and re- examined to the extent and by the methods and criteria that applied to the original SECCO Purchasing Specification for Fabrication of Piping SD-00-TSC-PP-0004-AP00 Purchasing Specification for Fabrication of Piping Page 24 of 2806/01/19 work, in accordance with this specification and the Code (ASME B31.3, ASME B31.1, or GB 50316, whichever is applicable.). 由于存在缺陷而拒收的产品应进行返修或更换，并按本规定和规范（ASME B31.3/ASME B31.1/GB50316）重新验收。 11.0MARKING AND IDENTIFICATION 标记和标识标记和标识 11.1SPOOL PIECE MARKING管件标记管件标记 All pipe, fittings and flanges shall be marked in accordance with industry standard to which they are manufactured. However, if no marking criteria exist, MSS-SP-25 shall be used as the minimum guideline. 所有管子，管件，法兰都应按相应的制造标准进行标记。如果没有相应的标准，则以 MSS SP-25 作为最低准则。 Pipe spools shall be identified as follows: 管段应按以下内容进行标识： 11.1.1Each pipe spool shall be identified with the line number and spool number stamped on the edge of a flange, using steel dies, unless prohibited by paragraph 11.1.3. 每条预制管道在法兰边缘用钢印打上其管线号和管段号（11.1.3 节除外） 11.1.2If a spool piece contains no flanges, steel die identifying marks shall be stamped on the pipe at one end. In place of steel die marks on the pipe, a paint stencil shall be used. Any painting material used for marking on stainless steel pipe shall be water- insoluble free of lead, zinc, sulphur and chlorides. Paint shall be non-injurious for ambient through elevated temperatures. (Paint for ferritic spool pieces-White paint shall be used to mark spool pieces, which are to be marked with paint.) Straight pieces shall be marked toward the center of the spool, other pieces shall be marked adjacent to elbows or bends on a straight portion, if practicable, piece number shall be located on side corresponding to the inner curvature of the elbow or bend. 不带法兰的管段，标记标在管子的一端。管子上的标识应使用油漆模板。用于不锈钢 管标记的油漆材料应非水溶性且不含铅，锌，硫和氯离子。在室温稳至高温范围，油 漆应是无害的。（铁素体管件的油
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