TEAMB衬里管道安装方案.doc

Content 目录1.Generation 工程概况22.Reference 施工依据23.Piping installation precondition 管道安装条件34.Material acceptance 材料的验收35.Material release and control 材料的领用与控制46.Piping installation 管道安装57.QC Plan质量控制计划168.construction safety and civilization安全与文明施工171. Generation 工程概况 This method statement is prepared for Dow Corning Asia third pillar project phase II Team B of area B1(A21 A24), B2(A35 A36 A40) site lining pipeline installation work. lining pipe is 3858m in these specific area.本管道工程主要是道康宁亚洲第三支柱项目第二期项目TEAM B(B1(A21 A24) B2(A35 A36 A40)的衬里管道的现场安装工作。安装工作量:衬里管道约为3858米(包括PTFE、PVDF、PGL及钛衬里)。2. Reference 施工依据Process pipe layout, ISO drawings工艺管道布置图，单线图0136-OBJ-100014013 Specification for erection of metallic work0136-OBJ-100014013 金属管安装规范0136-OBJ-100210004 ZJG Standard for Painting and Protective Coatings0136-OBJ-100210004 管道油漆和保护层标准0136-STD-100710003 Pipe Support Standard0136-STD-100710003 管道支架标准0136-STD-100270006 Flange tightness procedure0136-STD-100270006 法兰紧固程序0136-STD-100795812 Care & Protection Procedure0136-STD-100795812 成品保护程序Industry metal pipe construction and acceptance specification GB50235-97工业金属管道工程施工及验收规范 GB50235-97Industry metal piping construction quality inspection and acceptance specification GB50184-93工业金属管道工程质量检验评定标准GB50184-93Industry equipment, pipe anti corrosive construction and acceptance specification HGJ299-91工业设备，管道防腐蚀工程施工及验收规范 HGJ299-91Process piping specification ASME B31.3 and ASME B31.1工艺管道规范ASME B31.3及ASME B31.1CRANE (ASIA PACIFIC) PTE LTD INSTALLATION AND MAINTANCECRANE (亚太) PTE 公司的安装及维护手册3. Piping installation precondition 管道安装条件3.1. All the civil, mechanical and steel structure related to the piping is inspected and satisfied with the requirement. 与衬里管道安装有关土建、设备及钢结构工程已检验合格，满足安装要求。3.2. Design drawing and other technical document is complete and all the drawing is inspected. 设计及其它技术文件齐全，施工图纸已汇审。3.3. Construction method is approved, all the party both for management and construction personnel is in position and have clean acknowledge of the site situation, construction drawings, technical standard and related procedure. 施工方案已经批准，参加现场管理及施工的人员已到位，并熟悉施工现场、施工图纸、技术标准和相关工作程序。3.4. Vendor technician have issued technical explanation/training for piping construction team and administrators and guidance at site.管道生产厂家的技术人员已对管道施工及管理人员进行安装技术要求交底、培训，现场施工技术指导等。3.5. Construction machinery preparation: all the related machinery are inspected and aligned as well as the paper work. 施工机具准备：所有工机具已按校验程序校正，有合适的文件记录并能正常使用。3.6. The lined pipes and fittings were arrived and inspected which can form into a integrity pipeline and also ensure continue work and schedule. 衬里管及所需的安装材料已运到现场并且检验合格，且到场的管段及管件能组成完整的管线并能保证连续施工和安装进度的要求。4. Material acceptance 材料的验收4.1. Piping accessory acceptance 管道附件验收4.1.1. Inspection should be taken to the accessories as the rules, the rated allowance should be standard as well as standard satisfied material.对统一到货构配件按规定进行检查，其尺寸偏差应符合现行标准，材质符合设计要求。4.1.2. Keep the flange surface clean and free of burr and groove.法兰密封面应平整光洁，不得有毛刺及径向沟槽。 4.1.3. Rubber, plastic nonmetal shim should be of smooth character, no aging and layering. No damage crippling, wrinkling on the surface.橡胶、塑料等非金属垫片应质地柔和，无老化变质或分层现象。表面不得有折损，皱纹等缺陷。4.2. Valve inspection and acceptance 阀门检查验收4.2.1. The delivered valve should be inspected for the rotating and operation device, which should be flexible and no hanging defect.阀门到货后应逐个检查其传动装置和操作机构，要求动作灵活可靠，无卡涩现象。4.2.2. All the received the materials should be lay down as the supplying list as well as the classification and tag, mean while keep the clearance of the lay down area. Any material without quality certificate or being unacceptable should be refused. During storage, separate the SS material and CS material to avoid pollusion.所接收的所有材料要根据供货商材料清单分类储存堆放并标识标签，同时保持堆放场地清洁。要拒收任何不可接受的或没有质量合格证的材料。在储存期间，不锈钢材料与碳钢材料应分开堆放，避免污染。5. Material release and control 材料的领用与控制5.1. The installation schedule should be prepared as per the delivery by the engineer, material release should be as per the approved installation method statement.工程师应根据材料到货情况编制管道安装计划，根据批准后的安装计划，按每张施工图纸编制施工领料清单。5.2. Release works should be as per the ISO drawings, no mistake should be happen to the releasing work.现场管段及管件的领取严格按照ISO图领取，不得误领。5.3. The piping (if not used currently) will be lay down on the pillar to avoid directly contact with the ground.现场不及时安装的管段应放在枕木上以避免直接接触地面。5.4. The remain material should be returned to the stock, irregular use or alternation should be prohibited. 对于变更后的多余材料应及时退库，严禁私自乱用、代用材料。6. Piping installation 管道安装6.1. Piping brunch rack installation管道支吊架安装6.1.1. Prior to being into the site, marks should be given to the pipe rack for the control pipe 500mm or 1000mm basic elevation. 进入现场施工前，应先在装置中或管廊结构上标出500mm或1000mm基准标高线以控制管道安装标高。6.1.2. Pipe rack should be fabricated and installed prior to the site pipe erection works. Prefabricate and paint the support as per the style on the drawings. 现场管道安装前必须先制作、安装支架；按照图纸上设计的支架形式预制支架并进行油漆。6.1.3. Pipe rack installation work should be done as per the elevation.按照标高安装支架。6.1.4. While the piping installation, the brunch and the lifting frame should be fixed and adjusted. 管道安装同时，进行支、吊架的固定和调整工作。6.1.5. All the supporting should be satisfied with the special function, the guide support or slide support surface should be clean and tidy, no deflection and hanging occurred to the support as well as a good contact of the supporting surface. 现场安装支架必须满足支架的特殊的功能,导向支架或滑动支架滑动面应洁净平整，不得有歪斜和卡涩现象，管子和支承面接触良好。6.1.6. Installation for pipe support must meet the Pipe Support Standard 管道支架的安装应符合管道支架标准6.1.7. After spring support installed, the positioning pin cant be taken off. This shall be done by Dow Corning. 弹簧支架安装后，限位销钉不能取下，限位销钉的拆除由DC执行。6.1.8. If formal support cant be installed during pipe installation, use temporary support and remove it after the formal one installed.在安装管道时，如果正式支架没法安装，先做临时支架支撑管道，等正式支架安装后拆除临时支架。6.2. Site pipe installation 现场管道安装This kind of pipes are prone to being damaged, it should be avoided when handling and piling lined pipes to meet the acute shake and collision.由于该类管道受到碰撞、强烈震动容易受到破坏，所以在搬运、堆放和安装衬里管段及管件时，应避免强烈震动或碰撞。故在安装此类管道时应注意及满足以下要求:6.2.1. When installing lined pipes , no welding and heating 、hitting shall happen to the pipeline.衬里管道安装时，不得施焊、加热、扭曲或敲打。6.2.2. To barricade and maintain the installed pipes, crush and compact are strictly forbidden.对安装完成的管道应做好维护，严禁碰撞。6.2.3. after installing in position, fix them to avoid falling down. If some can not be installed by one time, use leading chain to pull the pipe, during this procedure, keep good protection to avoid collision.管段吊装就位后，将管段用吊装带固定好以免坠落。不能一次吊到位的，用导链接牵引做二次人工吊装就位，该过程一定要做好对管道的保护,避免发生碰撞。6.2.4. When the piping moved in to position, the weld joint should be checked for the seal end to ensure the termination before tie-in. 管道移到位后，检查管道的封口是否脱落，保证管道在对接前管口的封闭。6.2.5. Do protect the finished product and paint during construction. Use cloth or soft things to protect the place where the friction or contacting is easy to happen.在施工过程中，一定做好产成品、油漆的保护，对可能出现接触、摩擦的地方要用布片、软质物品等进行包裹保护。6.2.6. Before flange bolting, timber under the flange should be kept to avoid deformation by pipe liner rolling works. Keep clearance inside the pipe during installation. 衬里管在法兰栓接之前，封盖法兰端口的木板不要取下，防止衬里翻边变形。管道安装时,要注意保持管道内部清洁。6.2.7. lined pipe can classified by fixing flange and loose flange, different bolt will be assigned to the specific flange strictly as per drawings.衬里管的法兰有固定法兰和活套法兰之分，不同的法兰所用的螺栓不同，应按严格按图纸使用。6.2.8. During flange connection, attention shall be given to same material with lined pipe spools, no gasket is necessary between flange. If the liner is of difference material, gasket is needed as well as cuniform gasket for pipe with groove.法兰栓接时，要注意，衬里管段衬里材料相同时，法兰间不需要垫片，衬里材料不同时需要用垫片，管道有坡度要求时，可按要求用楔形垫片。6.2.9. Every lined pipe spool has a discharging hole beside the flange, it can not be plugged during installation to avoid blockage. Keep the discharging holes downward. After pipeline installation, the draining holes on pipeline without insulation shall be plugged by pipe plug supplied by vendor. For the draining holes on pipeline which need insulation shall be pulled outside of insulation by short pipe.衬里管段每段在靠近法兰的地方都有一个排放孔，在安装时不能将此孔封堵，且排放孔朝下，以免堵塞。管线在安装完成后，不保温的管道排放孔安装特制的丝堵（供货商提供）。要保温的管线排放孔应用特制的短管引到保温层外。6.2.10. For the approved and undelivered value, short pipe should be fabrication for temporary connection as per the valve size(include the delivered valves). Use temporary short pipe and washer to install instead of valves, when pass the pressure test, then install. 对业主允许和未到货阀门,应根据阀门（包括已到货仪表阀）尺寸,制作相应临时连接短管,管道安装时先用临时连接短管、垫片代替阀门安装，管道试压冲洗合格后，再安装。6.2.11. Keep the flange parallelism when installing, the allowance should not be more than 1.5/1000 of the O.D. of the flange and less than 2mm, never adjust the deviation by locking bolt. No force assembly to the pipe connection. 法兰连接时应保持平行，其偏差不大于法兰外径的1.5/1000,且不大于2mm，绝对不得用强紧螺栓的方法消除歪斜。管道连接时不得强力组对。6.2.12. Keep the flange connection surface concentration, the allowance of the bolt hole center should less than 5% and the bolt can go through freely, the same specification and material bolt should be used to connect the flange. The explosive length of the bolt should not be more than 3 threads. According to the DC specification, before installation, Molykote HSC plus lubricate should be given to the bolts. 法兰连接面应保持同轴，其螺栓孔中心偏差一般不超过孔径的5%，并保证螺栓能自由穿入，法兰连接应使用同一规格、同一材质的螺栓。紧固后露长度不大于3螺距。根据DC规范要求螺栓在安装前必须涂以Molykote HSC plus润滑脂进行润滑。6.2.13. Pipes connected to the rotating equipment, installation work should be form the rotating equipment, firstly the pipe racks. The force of the pipe and valve or other should not give to the nozzle, and the allowance meet Dow Corning specification 与转动机器连接的管道，宜从机器一侧开始安装，应先安装管支架。管道和阀门等的重量和附加力矩不得作用在设备接口上，并且容许偏差符合Dow Corning 的要求。6.2.14. The flange should be inspected freely prior to the connection between pipes and rotating equipment flange. 在管道与传动设备法兰连接前应自由状态下检查法兰的平行度和同轴度。6.2.15. Pipe installation allowance 管道安装允许偏差:Project 项 目Allowance允许偏差Coordication 坐标Pipe rack and trench架空及地沟Inside room室内25Outside room室外15Embed 埋 地60Elevation 标高Pipe rack and trench架空及地沟Inside room室内20Outside room室外15Embed 埋 地25Horizontal piping levelness水平管道平直度DN1002L，most 502L，最大50DN1003L，most 803L，最大80Vertical pipe verticality 立管铅垂度5L，most 305L，最大30Space between pipe in line 成排管间距15Cross pipe exitine or insulation layer 交叉管的外壁或绝热层间距206.2.16. After the pipe pressure test and blasting and being standard, the connection between pipes and equipment should be inspected and the allowance shall apply to the follows, if have, adjustment should be done till being standard. 管道经试压、吹扫合格后，应对该管道与设备的接口进行复位检查，其偏差符合下表，如有偏差应重新调整，直至合格。Rotate speed of equipment (turn/min)设备转速（转/分）Flatness平直度（mm）Coaxiality同轴度（mm）3000-60000.150.560000.10.2.6.2.17. After finishing the system, all the bolt on the line should be inspected one by one by hand to ensure technology completation. 系统完工后，应对所有管线上的螺栓用手进行逐个检查，以保证螺栓已按技术要求完成。6.2.18. The piping construction standard which needs static electricity earth complies with general piping construction standard, but jumper need to be used to connect flanges. Pipeline must be grounded in certain distance. Earth plate, distance, jumper type/size, connection type, type of earth wire and space shall as per specification, drawing and technical instructions.需进行静电接地管道施工要求，与一般性管道施工要求一致，但法兰连接处都需连接跨接线，管线每间隔一定距离有接地线。接地板、接力矩值、跨接线规格、连接形式、接地线规格、间距等根据规范、图纸、技术规格书执行。6.3. Flange connection 法兰连接6.3.1. Prechecks / requirement 预检 / 要求6.3.4.1. Visually inspect nuts and bolts for signs of damage (burring, stretching, corrosion, bending) and replace when necessary.目测检查螺栓螺母上是否有破损痕迹（毛刺、划痕、蚀痕、弯曲），必要时进行更换。6.3.4.2. Identify gasket, nut / bolt specification is correct to the flange type and size.如用垫片，确认垫片、螺母/螺栓规格是否与法兰类型和尺寸吻合。6.3.4.3. Do not tape gasket into place across the sealing surface as this can cause potential leak paths.如用垫片，垫片不应通过密封面敲入，否则会导致泄露。6.3.4.4. Gaskets should be new and undamaged NEVER RE-USE AN OLD GASKET.垫片应是全新无损的-不允许使用旧的垫片。6.3.4.5. Lubricate all threads and bearing surface of the nut with Molykote HSC plus before assembly.组装前，应使用Molykote HSC plus 润滑所有螺纹和螺母的承压面。6.3.4.6. All tolerances should be applied to correctly supported unrestrained piping the use of chain blocks and temporary weld tacks NOT PERMITED.所有公差应适用于正确支撑不受力的管线 不允许使用倒链和临时点焊。6.3.4.7. All torque wrenches must be calibrated and rechecked as per the manufacturers specification.按照厂家规范校正并复检所有的力矩扳手。6.3.4.8. All wrenches/spanners must be suitable open ended / ring type. NO HOME MADE OR ADGUSTABE WRENCHES ARE TO BE USED NO PIPE CONNECTIONS.所有的扳钳/扳手必须是合适的开口/梅花扳。管道接口不允许使用自制的或活动扳手6.3.4.9. Hydraulic tensioning for all critical flanges or when stud/bolt diameter 25mm. This must be carried out by qualified (specialized) contractors.直径大于等于25mm的螺杆/螺栓以及所有重要法兰的张紧都必须由合格的、专业的承包商来完成。6.3.2. Bolting procedure 拴紧程序6.3.2.1. Insert two bolts diametrically opposite each other, and place one bolt halfway between these (on the underside for horizontal lines) to support the gasket. Engage all nuts.直径方向相反地插入两个螺栓，再将一个螺栓半插入其间（水平线的下面）来支撑垫片。安装所有的螺母。6.3.2.2. Insert the gasket and ensure that is positioned correctly between the two sealing faces. Hands tighten the nut.如需垫片，插入垫片，并确保其位于两个密封面之间的正确位置。手动上紧螺母。6.3.2.3. Insert and hand tighten all nuts and bolts taking care to not move gasket. If bolts do not fit through the bolts holes or interfere with the gasket inform construction supervisor.插入并手动上紧所有的螺母螺栓，注意不要移动垫片。如果螺栓与螺栓或垫片尺寸不符或相互妨碍，应告知施工主管。6.3.2.4. If bolt does not extend 1 thread past nut, inform construction supervision.如果螺栓无法上紧到超出螺母一道丝扣时，告知施工主管。6.3.2.5. If bolt extends more than 4 threads past nut, inform construction supervision.如果螺栓无法上紧到超出螺母4道丝扣时，告知施工主管。6.3.3. Torque tightening procedure 力矩上紧程序6.3.3.1. Obtain the correct torque value for the flange type不同类型的法兰选择正确的力矩值。6.3.3.2. Set the torque wrench to 20% of the recommended torque and apply to flange bolts in a cross bolting sequence (figure 3) 将力矩扳手设定到要求力矩值的20%，按照十字顺序施加到法兰螺栓上。6.3.3.3. Increase by 20% of the recommended torque and apply to flange bolts in a cross bolting sequence. Set the torque wrench to 100% of the recommended torque and apply to flange bolts in a inverse hour sequence. 将力矩值按要求值的20%后递增，按照十字顺序拧紧法兰螺栓。将力矩值设定到要求值的100%后按照逆时针顺序拧紧法兰螺栓。6.3.3.4. When this procedure has been completed the flange should be fully leak tight. To identify the flange as complete, a torque tag shall be attached to EVERY flange using a secure and durable method. The tag will only be removed when the commissioning team carries out a leak test. The tag should contain the following information.当完成上述程序后，法兰应完全气密无泄漏了。应在每一个法兰上悬挂牢固持久的力矩标牌作为法兰施工完善的标识。 只有在调试队伍完成气密性试验后才可将标牌拆除。标牌如下所示：Flange法兰Torque Value扭矩值Gasket垫片Date日期Works作业人Tool ID工具编号CNI23 SVTOYO/AS SVThe information and signatures must be legible or the flange will automatically fail. 标牌上的信息和签名必须清晰可辨，否则法兰将被直接视为不合格。 6.3.3.5. After initial fastening and hot circle, it can be refastened with a duration of 24 hours. This duration can relieve the material and bolts. If the system runs under high temperature, it is suggested to form a hot water circulation at highest temperature of system for 24 hours(if possible). Let the system experience a hot circulation. After cooling, retighten the bolts as per the final torque. Tightening works can only be carried out in ambient temperature or state of cooling. Under no circumstance should fasten the flange sealing surface under high temperature & over pressure.在初拧或在第一热循环后至少24小时可以再次应用力矩值。这样可以让衬里材料和螺栓得到应力得到舒缓。如果系统是在很高的温度下运行， 建议在工艺最大的运行温度内热水循环24小时（如果可能的话）。这能让管道系统经历一次热循环。在冷却下来后， 系统螺栓需再次按最终力矩拧紧。拧紧只能在系统处于环境温度或冷却的状态， 决不能在系统还在高温或超压的情况下对法兰密封面施加力矩。6.3.4. Notes 注意The flange is now fully torque tightened an leak tight. If any adjustments are made to the flanged joint after this point then repeat all steps in this bolting procedure.6.3.4.1. 这样法兰经过力矩紧固后是完全气密的。如果需对法兰接口进行任何调整，必须重复该拴紧程序的所有步骤。6.3.4.2. If gas leakage found in flanges, increase the fasten bolt gradually but limited to 150%。 Once there is still a leakage when reach 150%, the flange must be inspected by dismantling. 如果气密时法兰泄漏，可将螺栓力矩逐渐增加拧紧螺栓。但是不能超过150%。如果增加到150%后还是泄漏，可能是法兰有问题，需拆开检查。6.3.4.3. In order not to damage the inner, under no circumstance should carry out welding, welding, torch cutting to lined pipes.内衬管道不能焊接、钎焊或用割炬， 因为这会损坏内衬。6.3.4.4. During transportation and storage, all the flange shall be covered to avoid damage. These covers can not be remove prior to installation, if need inspection, must be reinstate afterwards. 在运输中所有的法兰应该用盖子保护以防止在运输和存放中受损。 这些盖子只能在安装前拆除， 如果是移开做检查，应该立即复位Appendix Torque value 附力矩表Bolts torque value of lined pipeline 衬里管道螺栓力矩值表6.4. Instrument parts installation仪表部件的安装6.4.1. After the pipe pressure test and blasting and being standard, the instrument valve should be installed as well as the tag and direction. 管道试压冲洗合格后，安装仪表阀，安装时要注意仪表件的位号与安装方向。6.4.2. The instrument valve bolt recovery should be finished as per the related value by torque spanner as well as the record. 仪表阀门螺栓恢复工作也应按照相关技术参数用力矩扳手完成，并做好记录。6.4.3. The protection should be given to the finished products to avoid damage. 仪表阀安装后应注意成品保护，避免后续施工碰伤阀门。6.4.4. For in-line valve and instruments etc. which can not be used to pressure testing shall be replaced by short stub in the same length during installation. The formal valves shall be i