洁净压缩空气管道工程施工方案.doc

China New MSD Facility-Hangzhou Project杭州默沙东制药有限公司新生产基地项目 WMS of Clean Compressed Air System洁净压缩空气工程施工方案 General工程概况 The system of clean and compressed air belongs to the work scope of Qian. The clean and compressed air was distributed from Packaging Building L2 to each single level with a total pipe length of 250m, which uses ASME BPE 316L material.本工程洁净压缩空气工程属于我司施工范围，洁净压缩空气从包装二楼配送至各单体，管道长度约250m，采用ASME BPE 316L材质。Basis of Compilation编制依据The compilation of this WMS is as per8232-M-SPEC-15211 Compressed Air System-03 and ASME BPE standards.根据S2F 15211 压缩空气系统规范及ASME BPE标准Technical Method of Metallic pipe Construction金属管道施工技术方案 The construction of metallic pipeline must be strict accordance with relevant standards and complied with operation process procedure and cleaning measures.The construction of ASME BPE 316L pipeline shall be strictly in accordance with ASME BPE standards, meanwhile it shall also comply with certain operation process flow and adopt relevant cleaning measures.对于ASME BPE 316L管路的施工必须严格按照ASME BPE标准进行，同时需遵循一定操作工艺流程和保洁措施。 1. Preparation施工准备Preparatory work shall be done for the construction as the followings: 施工准备按以下几个过程： Visual check直观检查 Sampling: confirm that no damages on the pipes and meet the requirements. Check whether there is plastic cap.抽样检查，确认无损伤并符合要求，检查是否有塑料帽密封 Check the model, quantity and certificates.检查型号，数量及证书 Verify the delivery list.核对送货单 Preparation of fabrication site.加工现场的准备 Acceptance and receiving shall be finished and confirmed by the person responsible.验收及接收由负责人完成确认 The material would be stored in specific area and classified according to the model, size and clean grade. 材料储存在指定区域内并根据型号、尺寸、洁净级别分类保存 Prevent the material from being bent, impacted, and extruded.材料运输不可弯曲，撞击，挤压等 There shall be detailed record of material distribution and usage.材料取用需有详细记录 Site measurement and inspection of relevant equipments.现场测量，相关设备的检查 Production of sample.样本制作 Material fabrication: pipe cutting, chamfering, bending and precast welding. 材料预制：管道切割，面处理，弯曲及预制焊接1.1 Construction Procedure施工步骤Site welding includes:其中现场焊接包括： Pipe positioning, site welding and quality inspection. In order to ensure that no oxidation and change of color on the surface of every weld joint, high-purity argon shall be used and ensure that shielding time is not less than 30min. 管道定位，现场焊接，质量检查。为保证每一焊缝内表面无氧化变色,必须使用高纯度氩气，保证冲气时间不小于30分钟。 Non-welding connection: fittings and equipment connection.非焊接连接：配件、设备连接。 Post-construction treatment: pipeline inspection and pneumatic pressure test.施工后处理：管道检查,气压试验。 Document handover: sample record, construction record and test report.文件移交：样本记录，施工记录及测试报告。1.2 Flow of Piping QI配管质量检查流程 管道焊接 否 外观检查 否 是安全检查耐压检查泄漏检查 否 是机能检查移交给客户 是1.3 General Rules of Welding 焊接总则 This specification is applicable to the welding, assembling and installation of hygiene pipes.本规范适用于卫生管道的焊接、装配和安装； This specification is applied specifically in the connection of circumferential butt welding head between ASME BPE stainless steel 316L pipe fittings本规范特别用于ASME BPE不锈钢316L管件间之圆周对接焊头之连接； Welding in this specification shall meet ASME BPE acceptance standards.本规范中的焊接连接将需要符合ASME BPE的验收标准； The term maker of this specification means Qian, which is responsible for assembling and installation of pipes. 本规范中术语装配者是指启安公司，他负责管道的装配和安装； “Client” means the end user or other representative. “业主”是指用户或其代表； “Welding inspector” means the client or representative of end user, who will be responsible for inspecting the welding work of piping contractor. “焊接检查员”是指业主或用户代表，他将负责检查管道承建商的焊接操作。1.4 Welding specification焊接规范This specification covers the tungsten arc SS welding equipments that use automatic orbital welding machines. 本规范覆盖用自动轨迹焊接机的气体钨电弧不锈钢焊接设备。 “Pipe” shall includes all components that require welding. “管道”应包括所有需要焊接元件。1.5 General requirements总体要求 Operators of automatic welding machine shall take welding test to confirm their qualification. pipe material of common size of the project shall be used in the welding test.自动焊接机的操作人员将用样品材料做焊接测试以确认其资格。焊接测试应该选用项目常用的管材尺寸材料； Tack welding of the module shall avoid ill effect on complete welding. 组件的定位点焊必须避免对完全焊接的不良影响； Tack welding shall be as light as possible to reduce internal structural change caused by overheating of the material. 定位点焊应该尽可能的轻，以降低过热而导致材料的内部结构变化； Tack welding shall prevent penetration of the internal surface.定位点焊不应焊透内表面； After the tack welding, inspect the alignment of the welding and the weld joint.定位点焊完成后，需要检查定位焊接的对准性和缝隙。1. Material 材料 The welding materials shall be complied with the technical specification of MSD.用于焊接的材料须符合甲方的技术规格； All pipes and fittings shall be fully welded. 所有管道和配件须完全焊透； The welding electrode shall be 2%thoriated tungsten electrode with square butt.采用的焊接电极为2%涂钍平头钨焊电极； The welding electrode shall be replaced if any stain is found.焊接电极如有污染须更换； The purity of argon as shielding gas inside and outside the welded pipes shall be at 99.99%. 焊接管道内、外部保护氩气的最低纯度为99.99%； Argon shall be injected during the welding as protective gas to prevent oxidation of the internal welding surface. Blow out all the oxygen in the welding area before the welding. 焊接过程中必须要通入氩气进行保护，以防止焊接的内表面被氧化。在开始焊接前，吹走焊接区域的所有氧气。2. Welding Preparation 焊接准备 Welding shall be prevented when the welding surface is damp. No outdoor welding shall be done in extreme hot whether, strong wind or adverse atmospheric condition, unless appropriate protective measures are adopted. 当焊接表面潮湿时，不得进行任何焊接。除非有适当的保护措施，在严酷气候或风速高或不良大气条件下不得进行室外焊接； It is essential that the end faces of the welding joint be clean, level and straight.焊接接头两端面的清洁，圆整和平直是重要的； The processing method of metals shall ensure that the welding surface is smooth, free of scratch and other harmful abnormity.金属加工方法应确保焊接端表面光滑，无划痕或其它有害的不规则形状； It is suggestive that +GF+ or equivalent equipments be used in the cutting and final treatment.建议采用+GF+或同类设备来处理切割和最终处理； The cutting shall be level and straight, and pipe deformation or damage shall be prevented. Abrasive dust or burr on the end face of pipe shall be cleaned and removed. 切割必须平直和不会造成管件变形或损坏。切割的管件端面必须清洁以除去磨屑； No carbon steel cutting tools can be used under any circumstance.碳钢切割工具在任何情况下都不得使用； Tools for the treatment, assembling and installation of welding end face, shall be inspected before using, to confirm whether it is approved or rustless alloy steel, and whether it is clean, free of grease and residual of other dirt. 用于焊接端面的处理、装配和安装工具，在使用前须检查是否是没有生锈的认可合金钢，清洁无油脂，和无其它污染残留物； No sulfenyl cutting oil shall be used, unless all residual grease has been thoroughly cleaned inside and outside the pipe fittings before the welding.不得使用硫基切割油，除非在焊接前管件的内外表面都被彻底清除所有残留油渍； Welding equipment setting is required to be done with the welding inspector.需与焊接检查员一起设定焊接设备； This inspector shall, sign the welding log with his signature and the date after checking whether all the settings conform with the main program.此检查员将检查所有设置是否符合主程序。他将签署焊接日志和注明日期； Every welder shall take a welding test before the work everyday. The welding sample shall be tagged and forward to the welding inspector. Each automatic welding machine shall be subject to test.每天开始时，每个操作人员要作焊接测试。这些焊样将编号，并呈交给焊接检查员。每台自动焊接机都需做测试。3. Warm-up temperature预热温度 Warming up is not needed if the temperature of welding materials is not lower than 10C 在焊接材料的温度不得低于10C。一般来说，不需要预热。4. power supply供电 The electric current shall be in conformity with corresponding welding form.电流应与注明在相应的焊接表相符。5. Welding procedure焊接程序 Welding procedures such as welding sequence, setting of welding procedure and position of welding electrode shall be also in conformity with corresponding welding form. 焊接工艺，如焊接次序，焊接程序设置，焊极位置等，都将与相应的焊接表相符。6. Procedure of automatic welding自动焊接程序 All main programs have specified parameters for the welding of pipe and fittings with different diameters or sizes.所有主程序都规定了不同尺寸管件焊接的一组参数； The welding procedure of automatic pipe welding system shall comply with the procedure made by welder and the inspector.自动管道焊接系统的焊接程序都须符合焊接操作员与检查员一起制定的程序； Approved welding procedure shall be used for both formal and test welding.正式和测试焊接需采用已认可的焊接程序； Welding sample shall be numbered in order(such as T1, T2). The welding sample shall have complete traceability and shall subject to inspection by independent institution. 焊接样品必须按顺序编号(如T1，T2等)。焊接样品，具备完全的可追朔性，将备独立机构检验； All samples on site everyday shall be left to the client during the whole construction phase.在整个施工阶段，所有每天的现场样品将留予业主； The calibration of automatic pipe welding system shall be comply with the procedure made by welder and the inspector.自动管道焊接系统的校正都须符合焊接操作员与检查员一起制定的程序。7. Document 文档 Qian is responsible for providing all reports of welding record of this system. The reports shall be filled in completely which should includes at least:启安将提供此系统所有焊接记录报告。此焊接记录报告表格，必须完全填写，最少包含： System name系统名称 Weld joint number焊接号 Name of the welder焊接工姓名 Equipment no.设备编号 Welding date焊接日期 No. of welding procedure焊接程序编号 Signature of operators(if any, the inspector)焊接操作工(如有，还加上检查员)签名 Record of automatic welding shall be printed by the equipment and there shall be weld joint number in the welding report.设备将打印相应自动焊接记录。在此焊接记录中要有焊接编号。 Welding map (with corresponding groove, size and length, and all weld joint numbers marked on it) shall be used and updated throughout the construction period and a completion drawing shall be generated when the project is completed.焊接图 (标示相应的坡度，尺寸和长度，所有焊点编号)将在整个施工期间使用并且更新，在工程完成生成竣工图。 Each weld joint shall be numbered in a progressive manner, all weld joints shall be marked in the welding map and welding report.每个焊点以累进方式编号。所有焊点标示在焊接图和焊接报告中。8. 内窥检查 Endoscopic inspection When required by specific terms or provision of the contract, endoscopic inspection shall be done under the terms or provision thereof, and time delay shall be taken into consideration therefore. 当相应的条例或合同规格要求时，内窥检查将在符合条例或合同规格下进行。须考虑到因此而造成的时间延误。 评定标准 AWS D18.1:1999 Specification for welding of austenitic stainless steel tube and pipe systems in sanitary (hygienic) applications 卫生洁具用奥氏体不锈钢管和管道的焊接规范1-4是可以接受的 From 1 to 4,it is acceptable.Discolouration / Oxidation变色和氧化Amount of oxygen in ppm in the backing gas per sampleNo. 1 10No. 3 50No. 5 200No. 7 1 000No. 9 12 500No. 2 25No. 4 100No. 6 500No. 8 5 000No. 10 25 0009. Daily welding test piece每日焊接样品 Equipment welding procedure shall be used for daily welding samples, which shall be numbered in order (such as T1, T2). All these samples shall be submitted to the client throughout the construction period on a regular basis.每日焊接样品应采用设备焊接程序。这些样品必须按顺序编号(如T1，T2等)。所有这些焊接样品将在整个施工期间提供给业主； The results of daily samples shall be recorded in the fully-filled test report of automatic welding equipment.每日样品结果必须收集在完全填写的自动焊接设备测试报告中。1.6 Assembly and Installation装配和安装1. Receiving, Storage and Disposal of Pipe Materials管件材料接收储存和现场处理 Pipe materials shall be confirmed and inspected by relevant personnel.管件材料需由专人确认和检验； The storage of pipe materials and the preassembled fittings shall free of contamination by grease, damp and other substance. pipe materials and the preassembled fittings shall be appropriately handled to avoid any possible deformation, scratching and other tangible damage. 管材和预装配件的存放应注意不会被油脂，潮湿或其它物质污染；管材和预装配件应处理得当，以避免变形，刮伤或任何有形损伤； All SS materials shall be separately inspected and stored with other construction materials. Storage area shall be indoor with protective measures against corrosive environment and temperature variation.所有不锈钢材料应与其它施工材料分开检查和储存。储存区必须在建筑物内，并且有防护任何腐蚀性环境和温度变化的措施； Access shall be strictly restricted in case of material loss or damage. Only when needed in the construction can material be withdrawn.通道应严格限制以确保材料不会受损伤和丢失。只有在施工需要时才能从储存区提取材料。2. Classification 分类 All material shall be classified according to specification and appropriately stored and disposed.所有材料将按规格进行分类，并且适当储存和处理以便于辨认。3. Assembly 装配 The assembling shall be in accordance with the requirements of this specification and current detailed installation requirements (drawings etc.) 装配应按照此规格的要求和已有的详细安装要求(图纸或其它)进行。4. pipe layout, cutting and assembling布管、切割和装配 The pipe fittings shall be cut precisely according to the size on the drawing to meet site requirement.管件应按图纸上的尺寸精确切割以适应现场情况； The burr on end face of pipes to be welded shall be removed, the cutting face shall be level and the chamfer shall be free of cutting arc. Terminal treatment tools shall be used in the treatment of end face of pipe edge and burr. The tolerance of pipe shall the consistent with that of the fittings to ensure welding linearity. 所有待焊接的管件端面需清理毛刺，并且切割面应平直，边角无切割圆弧。管件边缘的端面处理和清理毛刺应使用终端处理工具，并且其公差与配件一致以确保适当的焊接线性； Inspect the pipe end after the cutting to ensure that it is level and straight. 检查切割管件终端，以确保其平直； When removing burr, internal polishing that damage the inner and outer diameter or the pipe shall be prevented.清除毛刺应避免破坏内外径，或损伤管件的内抛光； Abrasive dust accumulated at the end of the pipe and fittings shall be cleaned and removed.在管件端口积聚的磨屑必须擦拭干净； All pipe and fittings of the pipeline shall refrain from excessive elasticity or assembled under stress.所有安装在管线上的管件不应受过分弹力和受力下装配； Heating and bending the pipe to achieve linearity is not allowable.不允许通过管件加热和弯曲以达到线性整齐。5. Acceptance of Welding Procedure and Qualification焊接程序和资格认可 All welders shall be qualified with 6 months of working experience and their operation on the site shall be subject to qualified test by LL. 所有焊工应得到LL考试合格确认后，方可进入现场施工； Welding procedure shall be submitted to the welding inspector for review and approval before the commencement of welding.在开始焊接前，焊接程序应提交给焊接检查员核准。6. Installation 安装 All pipe and fittings of the pipeline shall refrain from excessive elasticity or assembled under stress. No cutting or weakening bracket with shall be used in the installation of pipework. 所有组装管件应在不受过分弹力和受力下装配。不允许有切割或弱化的支撑物作管道安装； Installation of pipe and fittings shall be able freely expand and contract, so that it wont damage the connectors and bracket.所有管件安装应可以自由膨胀和收缩，而不至于损坏连接和支撑； All pipes shall have appropriate gradient (0.5%, max 1%.) to ensure complete drainage. 所有管道必须有适当的坡度(0.5%最大1%)以确保完全排水。7. Welding 焊接接口 All welding shall be prepared and done in accordance with this specification and requirements stated hereinabove.所有焊接应按照本规格前文所述的要求进行准备和装配。8. Package joint快装接口 No screw joint shall be used.不得使用螺纹接口。9. Bracket and conduit installation 支撑和穿管 The bracket of pipe shall be designed, assembled and installed according to parameter and details of the drawing. 管件的支撑应按管件支撑图纸上的参数和细节设计、装配和安装； Stainless steel pipe and fittings shall be installed under the recommendations of the vendor. 不锈钢管件的安装按制造商的建议进行； Installation of hanger and bracket shall be economical and meanwhile meet requirements of drawings and specifications.吊架和支撑的安装应尽量的经济，并符合支撑图纸或规格上的描述； The gradient of pipe bracket shall be in accordance with that required in the drawings.管道的支撑应符合管道图纸上要求的坡度； The installed pipes shall at least meet specification of inspection and test.所有装配的管道应最少符合检查，检验和测试要求规格。1.7 Inspection 检查1. Scope范围 Inspection list of the welding log will be used in verifying major information, preparation and quality inspection.焊接日志检查清单将用于查核主要信息，准备和质量要求； Welding inspector shall inspect welding records, setting, endoscopic inspection and visual check of the contractors in accordance with welding requirements. This work can be done at any time as it is agreed and understood by both parties. 焊接检查员按照焊接要求，检视分包商的焊接记录、检查和设置、内窥检查，以及目检。在双方同意并理解相应的时间延误下，此工作须在任何时间进行； The welding inspector or his representative shall visually check all weld joints.焊接检查员或其指定代表应目检所有焊接。2. Fittings and welding No.配件和焊接编号 Each weld shall be numbered in the diagram.每个焊接应在其立体图中编号； The inspector shall keep the inspection list, which shall be used for distinguishing for actual welding spots.检查员应保留焊接检查清单，而且实际的焊点以此编号辨别； Record of each welding spot shall includes all items deserved.每个焊点的记录应包括所有相关的条目。Welding preparation焊接准备The welding inspector shall decide whether to make the following inspection and confirmation.焊接检查员决定是否进行下列检查/确认。 Confirmation of pipe section管道截面确认 Length of pipe shall be marked in the pipe drawing according to relevant requirements.管道的长度按要求在管道图纸中标示； Clean all possible sundries in the pipe end generated during the cutting.要去掉管道端口切割产生的任何可能之污物； Tools shall be prevented from being contaminated by carbon steel.工具不得被碳钢所污染； Confirm the roundness tolerance of pipe确认管道圆度公差。 Cleanness清洁确认 Approved ethanol shall be used for the cleaning of fittings. 用酒精清洁配件。 The cleaned and readily-prepared pipe end shall refrain from touching skin before the welding.在焊接前，已清洁和准备好的端口不得接触皮肤。 There shall be no visible foreign matters in the end of the pipe and components, including fiber from the cloth.在部件的端口不得有可目见的异物，此包括清洁布的纤维。 The tungsten electrode shall be clean and free of contamination.钨焊极必须清洁和无污染。 Joint preparation接口准备 Thickness of gap between the ends of welding components shall be measured with feeler gauge焊接组件端口间隙用厚度塞尺测量，不得超过0.25 mm。 The tungsten electrode shall be placed in the center of the welding spot.钨焊极应置于焊点中央。 Setting of welding machine焊机设置 The setting of parameter shall take reference from relevant welding forms in the welding procedure.参数的设置应按焊接程序中相应的焊接表进行。 Positioning of gas source确认气源就位。3. welding inspection焊接检验Each welding samp