工艺管道安装方案中英文.doc

3.9 工艺管道安装方案Construction method for process piping works工艺管道安装方案Construction Method for process piping works1 概述Summary本方案是针对加蓬电解锰及硅锰项目中工艺管道进行编制的，本工程工艺管道材质主要有Q235B、20#、0Cr18Ni9、00Cr17Ni12Mo2、CPVC、CS+PTFE等。The program is for manganese and manganese Gabon pipeline project preparation process, the engineering process piping materials are Q235B, 20 #, 0Cr18Ni9, 00Cr17Ni12Mo2, CPVC, CS + PTFE and so on.2 编制依据Reference2.1 本工程招标文件；Bidding documents of the installation work for Gabon Eramet EMM & SIMN project2.2 工业金属管道工程施工及验收规范（GB50235-97）；Code for construction and acceptance of industrial metallic piping2.3 现场设备、工业管道焊接工程施工及验收规范（GB50236-98）；Code for construction and acceptance of field equipment, industrial pipe welding engineering3 施工准备Construction Preparation3.1 安装前，施工技术人员应根据设计文件、施工图及标准规范结合装置实际情况编制详细地切合实际的施工方案，并经逐级审批完毕后，向各工种施工人员进行技术交底。The technical personnel in charge of construction shall, prior to the installation, develop detailed and practicable construction schemes based upon the requirements of the engineering documents, the construction drawings and the standards and codes in integration with the actual scenario of the plant, and clarify such schemes to the workmen involved in the individual types of work, following the step by step review and approval processes. 3.2 参加施工人员应认真熟悉施工图、设计文件及标准规范规定和方案要求，深刻领会设计意图，了解管道施工的方法、工艺、技术要求和质量标准。All the people involved in the construction activities shall get themselves acquainted with the regulations specified in the construction drawings, design documents and the standards and codes as well as the requirements of the construction schemes, have a good mastery of the engineering design intents and know well about the methods, processes, technical specification and quality criteria with respect to the piping installation works.3.3 根据施工方案准备工装，搭设平台设置管道预制加工厂，设置管道、配件存放仓库和场地。Prepare for tools and facilities; build platforms, set up a warehouse and field for storing piping and fitting on basis of construction schemes.3.4 做好施工机具、设备的准备工作，切割机、电焊机、空压机、烘干箱等应性能良好，随时可用。计量、调校及测量用仪器业经校验合格，并在复检期内。Make available for construction machineries and tools and the equipments. The cutters, welding machines, air compressors and electrode ovens required by construction should be maintained at good working conditions for ready use. The instruments and apparatuses for metering, calibration and measurement purposes should have been verified for conformity and be within their validity period. 4 材料检验Materials Inspection 4.1 管材、管件检验Inspections for Piping and Piping Fittings4.1.1 压力管道工程用管材、管件，应按照相应标准组织实施对管材、管件的检验。Inspections for piping and piping fittings of the pressure piping works shall be organized and implemented as per the applicable standards. 4.1.2 管材、管件的表面不得有裂纹、折叠、重皮等缺陷，锈蚀凹陷和机械损伤深度，不应超过管材、管件相应标准厚度的负偏差。No defects such as cracks, folding or double skins should be expected on the surfaces of the piping and piping fittings, the extent of the rust hollows and mechanical damages should not exceed the minus deviations required by applicable standard thickness for the piping and piping fittings.4.1.3 管材、管件的外径、壁厚和不圆度等尺寸偏差应符合相应标准的规定要求。弯头、异径管和管帽的尺寸偏差，应符合规范规定。 The deviation of outer diameter, wall thickness and the out of roundness of the piping and piping fittings should comply with the applicable standards. The dimensional deviations for elbows, reducers and caps should meet the requirements of the relevant codes.4.1.4 法兰密封面的加工精度及粗糙度应符合制造标准；法兰密封面、金属环垫、缠绕垫片不得有径向划痕、松散、翘曲等缺陷。The machining precision and the roughness of the sealing surfaces of the flanges should comply with the requirements of the manufacturing standards; no defects as scratches, loosening or warps are allowed on the sealing surfaces of the flanges, metal rings and spirally wound gaskets.4.1.5 螺栓、螺母的螺纹应完整，无划痕、毛刺等缺陷。螺栓、螺母配合良好，无松动或卡涩现象；The threads of the bolts and nuts should be integral with no defects as scratches or burrs. The nuts and bolts should be properly matched with no looseness or blocking. 4.1.6 管材、管件的材质，应根据管材、管件的质量证明文件和管材、管件上的出厂标识进行核查确认；The construction materials of the piping and piping fittings shall be checked and confirmed as per the relevant quality certificates and the corresponding ex-works identifications of the piping and piping fittings.4.1.7 合金类管材、管件的材质，在进行质量证明文件和出厂标识核对确认的基础上，必要时，根据业主的要求应采用光谱检验等方法进行核查确认。For the construction materials of piping and piping fittings made of alloy, spectrum inspections shall be performed base on checking of certificate and mark, if necessary, for further checks and confirmation in addition to the checks and confirmation of the quality certification documents and the ex-works identifications according to the Owners requirements. 4.2 阀门检验Valves inspection4.2.1 供货的阀门型号、规格、铭牌、编号、材质、压力等级等均应符合图纸设计要求。The specification, type, nameplate, number, materials, pressure degree of supplied valves shall be in accordance with design drawing requirement.4.2.2 外部和可见的内部表面、螺纹、密封面应无损伤、锈蚀现象，安全阀的铅封应良好。Make sure there has no damage & rust-eaten on outside & visible inside surface, thread & sealing face. Lead seal of safety valve shall be complete & good.4.2.3 阀门进入现场后，应按规范要求进行阀门的耐压试验，低压阀门应按每批同制造厂、同规格、同型号抽查10%，但不得少于2个，公称直径小于40的低压阀门仅做外观检查，高、中压和有毒及易燃易爆介质用的阀门应逐个进行试验。Valve compression test shall be done in accordance with code requirement after valves arrived at the site. Low pressure valve shall be 10% random inspection, but not less than 2 for the same manufacturer, same specification & same type. Low pressure valves with nominal diameter less than 40 shall only have visual inspection. High & medium-pressure valves & valves with toxic, inflammable & explosive medium shall be inspected & tested one by one.4.2.4 阀门的壳体试验压力不得小于公称压力的1.5倍，试验时间不少于5min，以壳体填料无渗漏为合格，气密试验以公称压力进行，以阀瓣密封面不漏为合格。Test pressure for valve shell shall be not less than 1.5 times of nominal pressure. Test period shall be not less than 5min. No leakage of shell packing means qualified test. Air tight test pressure shall be nominal pressure, no leakage of valve clack means qualified test.4.2.5 试验合格的阀门，应及时排尽内部积水，并吹干。除需要脱脂的阀门外，密封面上应涂防锈油，关闭阀门，封闭出入口，做出明显标记，并填写阀门试验记录。Water inside qualified valves shall be discharged completely & be dried after test. Rust prevention oil shall be coated on sealing face for valves need degreasing. Valves shall be shut down, the inlet & outlet shall be closed & be marked obviously. Valve test record shall be filled in.5 管道预制Piping pre-fabrication管道预制基本流程如下:The basic piping prefabrication process is as follows: 坡口加工测量切割涂刷底漆钢管除锈材料检验图纸转换无损检测热处理三维组焊填充盖面组对打底产品出厂Drawing transformationmaterial inspectionsteel piping rust removalprimary coatingmeasurementcuttingGroove preparation Assembling root passfilling cover pass3 dimension combined weldingheat treatmentNDTproduct deliver from the plant6 管道安装的方法、顺序及程序Method, sequence and procedure for piping installation6.1 管道安装方法Piping installation method6.1.1 管道安装基本要求Basic requirement for piping installation:6.1.1.1 管道全部采用工厂化预制加工，现场将预制的管段按单线图、施工图进行安装。All piping will be prefabricated in the plant. The prefabricated piping sections are installed on site in accordance with isometric drawings and construction drawings.6.1.1.2 根据管道安装位置、重量，分别采用吊车吊装、卷扬机吊装或拖拉及人力安装，安装时采取顺序安装方法，确保管道工程顺利进行。Depending on installation location and weight of the piping, installation will be completed via cranes, hoisting machines for hoisting or pulling, and human force, in the sequential way so as to ensure smooth progress of the piping engineering.6.1.1.3 工艺管道采用氩弧焊打底手工电弧焊盖面(氩-电联焊)，公用工程管道采用手工电弧焊接。Process piping adopts argon arc root pass and cover pass by manual arc welding (argon-arc welding), and utility piping uses manual arc welding.6.1.2 管廊管道安装Pipe rack piping installation6.1.2.1 装置管廊管道大部分采用分段安装，根据管廊的布置走向将管廊结构预留几处敞开段，该段的管廊管道均由敞开处吊装进管廊，并搭设一平台用于管道管段连接焊口的组对焊接和管道托架的焊接，组装一段用卷扬机在铺好胶皮或木板的横梁上向前拖一段，直至该条管道安装完毕，然后，进行下一条管道的组装、安装。Most of pipe rack piping will be installed in sections. On all the open sections reserved on the pipe rack according to its layout, the piping will be installed in the rack via the crane. A platform is to be set up for assembling weld between the piping section and the welding orifice, as well as for welding of the piping bracket. The assembled section will be pulled forward by the hoisting machine on the beam covered with rubber sheet or wooden plate until the entire pipe is installed, before the assembling and installation of the next pipe starts.6.1.2.2 管廊管道的型胀力、管路附件、自管廊引至设备的管段采用单件、单段吊装安装，先将管廊管道安装就位，再进行胀力、附件及至设备管段的逐件安装，采用吊车吊装或(小件)人力安装。Pipe rack piping type expansion, pipeline accessories, and the pipe section from the pipe rack to the equipment will be installed via the crane for each piece and each section. Install the pipe rack piping in position firstly, and then install expansion, accessories and pipe sections leading to the equipment one by one by using the crane or in the manual way (for small pieces). 6.1.3 设备配管安装Installation of equipment tubing6.1.3.1 设备配管采用单件、单段安装，大管道及较重管路附件采用吊车吊装，安装时先将管路附件、至设备管段的支撑件、管架安装，连接处搭设平台组对、焊接。Equipment tubing will be installed by piece and by section. Large piping and heavy pipe accessories will be installed by the crane. Pipe accessories, and supports and brackets to the equipment section will be installed firstly. Platforms will be set up at junctions for pairing and welding.6.1.3.2 机组、机泵类设备配管采用单件、单段安装与地面组装分段安装结合，可采用大件吊车吊装到位，倒链和人力安装组对，管道和支撑件、管架同时安装。Machine set and pump unit tubing will be installed by piece/ section in combination with section installation on the base of ground assembling. Large pieces can be positioned by the crane, and pairing will be completed through chain blocks and manual installation. Piping will be installed at the same time with the supports and pipe brackets.6.1.3.3 机组的油系统配管采用预装安装，管道预制后安装调整，合格后拆下化学清洗，清洗完毕回装冲洗，油系统配管采用倒链和人力安装。Tubing of the machine set oil system shall be pre-installed, and shall be adjusted after piping prefabrication. After tubes are proved to be in conformity, dismantle them for chemical cleaning. After completion of cleaning, re-install and flush tubes. Oil system tubing shall be installed through chain blocks and in the manual way. 6.2 安装顺序Installation sequence管道安装顺序基本要求Basic requirement for the piping installation sequence:6.2.1 先安装管廊管道，后进行设备配管；先安装大直径管道，后安装小直径管道；先安装公用工程系统管道，后进行工艺管道安装。First install pipe rack piping and then set on equipment tubing. First install large-caliber pipes, and then small-caliber pipes. First install piping of utility systems, and then process piping.6.2.2 管道安装施工过程中，应先进行不锈钢管道及其它特殊管道的安装，然后进行普通碳钢管道的安装。During piping installation, SS piping and other special piping shall be installed firstly, then install normal carbon steel piping.6.2.3 根据设备安装顺序先进行大型设备附属管道的预制安装，再进行地面一般设备配管的预制安装。According to the equipment installation sequence, the piping attached to large equipment shall be firstly pre-installed, and then pre-install normal equipment tubing on the ground.7 管道安装Piping installation7.1 管道安装一般要求General requirement for piping installation7.1.1 管道安装一般程序 General procedure for piping installation管道焊接缺陷消除管道试验、吹扫(清洗)气密管道安装共检管道焊缝检查及无损检测管道焊接管道组装、点固焊接管道支撑件、管架安装预制管段、管路附件检查、清理土建结构、设备安装交接安装准备不合格管道安装一般程序Check and clearance of prefabricated pipe sections and fittingsBuilding structure and equipment installation/hand-overInstallation preparationPiping weld check and NDTPipingweldingPiping assembly tack weldingInstallation piping supports and bracketsremoval of piping welding defectsnon-conformingPiping test, purging (cleaning), tightnessJoint inspection of piping installationNormal piping installation procedure7.1.2 管道安装要求Requirement for piping installation7.1.2.1 管道必须按施工图位置、预制管道的编号标识采用顺序安装方法进行安装。安装时，对封闭物(塑料管帽、塑料布或堵板等)已损坏的管段、管路附件、阀门等，应重新进行内部检查清理，合格后进行组装连接、焊接。Piping must be installed in the sequential installation method in accordance with positions in the construction drawings and code identification of the prefabricated piping. Internal checks and clearance should be made again of the pipe sections, fittings and valves with damaged sealing (plastic cap, plastic cloth or block board), and they can only be assembled, connected and welded after they are proved to be in conformity. 7.1.2.2 合格的法兰、阀门、垫片密封面安装时不得发生损坏，若发生影响密封损坏要立即更换、修复，方可安装连接。Conforming sealing of conforming flanges, valves and washers should be damaged during installation. Damaged ones affecting the sealing should be replaced or repaired immediately before they can be installed and connected. 7.1.2.3 法兰连接应与管道同心，应保证螺栓自由穿入，法兰螺栓孔应跨中安装。法兰平行度偏差不大于法兰外径的1.5，且不大于2mm，不得用强紧螺栓的方法消除歪斜。Flange connection should be eccentric with the piping, and ensure free insertion of the bolt. Flange bolt hole should be installed in the middle. Deviation of flange parallelism is not greater than 1.5 of the outside diameter and not greater than 2mm. Do not eliminate obliqueness by tightening the bolt excessively.7.1.2.4 螺栓紧固件安装，同一连接处同一规格螺栓，安装方向应一致。螺母紧固后应与法兰紧贴，不得有楔缝，紧固后的螺母与螺栓端面宜齐平。螺栓宜采用对称拧紧、顺序二次拧紧或采用对称拧紧、间隔拧紧、顺序拧紧三次拧紧的方法进行紧固。管道的螺栓和螺母安装时，其螺栓和螺母应涂以二硫化钼油脂、石墨机油或石墨粉。Bolts of same specifications should be installed at the same connection & should be installed in the same direction. Tightened nuts should be close against the flange, leaving no seam, and should better be flush with the end surface of the bolt. Bolts should be tightened symmetrically and then sequentially, or tightened three times: symmetrically, at intervals, and sequentially. Piping bolts and nuts should be coated with molebdenum disulphite grease, graphite oil or graphite powder before installation.7.1.2.5 管道对接接口组对，按焊接要求对管口内外和坡口进行处理，管口组对用平板尺测量，在距管口中心200mm处测量平直度，如下图所示:For piping butt pairing, the interior and exterior of the orifice and the groove shall be treated in accordance with welding requirement. Measure orifice pairing with a flat plate ruler, and measure the straightness at 200mm from the orifice center, as shown in the figure below:a200钢板尺steel plate ruler管道对接口平直度测量Measurement of straightness of piping butt管道对接平直度测量允许偏差Allowable deviation for measured straightness of piping butt管道规格Piping specification允许偏差Allowable deviation全长允许偏差Allowable deviation over the entire lengthDN 1003L，max.最大80立管铅垂度Plumbness of vertical piping5L，max.最大30成排管道间距Distance between pipes in a row15交叉管的外壁或绝热层间距Distance between external walls or heat isolating layers of crossed piping207.2 压缩机组及机泵管道安装Installation of the piping for the compressor set and pump7.2.1 机组、机泵管道安装前，应检查预制管段、管路附件、阀门、垫片及紧固件的规格、材质、等级及管段编号标识与设计图纸一致。Before installation of the piping of the machine set and pump, check to make sure that the specifications, material and grades of the prefabricated pipe sections, fittings, valves, gaskets and fasteners, as well as the code identification of the pipe sections correspond with those indicated in the drawings.7.2.2 机组、机泵的管口应将封闭物拆除，清理、检查管密封面，核实机组、机泵管口法兰结构形式、等级同管道法兰相匹配，向上的管口应加镀锌铁皮盲板，防止管道安装时异物掉入机器内部。Sealing materials should be removed from the tubing ends of the machine sets and pumps. Check the sealing surface of the piping to make sure that structure and grade of the flanges at the tubing ends of the machine sets and pumps match with the piping flanges. Galvanized iron blinds should be fitted onto upward orifice to prevent foreign objects from falling into the machine during piping installation.7.2.3 管道安装时，管段、附件、阀门内部必须清洁无物，管道的支撑件、管道支吊架应同管道同步安装。大型机组应安装百分表，监测机组在管道安装时的位移。During piping installation, there should be no foreign objects left inside the pipe sections, fittings and valves. Piping brackets and piping hangers/supports should be installed together with the piping. Large machine sets should be equipped with dial gauges to monitor machine set displacement during piping installation.7.2.4 机组、机泵连接管道安装，宜从设备管口侧开始安装，并应在管道安装前先安装管道支架；管道安装时不得强力安装，其管道和阀门等的重量和附加力矩不得作用在设备上。Connecting piping for the machine sets and pumps should better start from the piping and