管系通用手册.doc

75/75 Nanjing Wujiazui Shipbuilding Co.,Ltd. STEEL SHIP PIPING GENERAL MANUAL钢质船舶管系通用手册 Number编号 DRAW UP：编制 TRANSLATION：翻译 VERIFY：核对 EXAMINE：检查 AUTHORIZE：批准 CATALOG目录1. Scope of application适用范围. . . . . . 12. Piping name and code管子名称和编码. . 13. Pipe classes、 material and size管子类型、材料和规格. . .24. Principles and requirement to piping管子原理和要求. .45. Technical requirement for pipe processing管子处理的技术要求. .96. Pipe connection type and requirement管接形式和要求. .167. Pipe treatment管子处理. . . .248. Material of gasket in pipeline管路垫圈材料 . 249. Arrangement and mounting of fittings in pipeline管路附件布置和安装. . . . . . . . . . . . . . . . . . . . .2510. Requirement for installing AC ducts &refrigerating pipe安装空调和冷却管路的要求. . . . . . . . . . . . . . . . .2811. Pipe supporter管子支架. . . . . .3012. Installation of pipes管子安装. . . . . . .4213. Requirement for pipe passing through hull Structure管路贯穿船体结构的要求. . . . . . . . . . . . . . . . .4414. Testing of pipe管子的测试 . . . . . . . .5015. Insulation绝缘. . . 5216. Paint color & insignia of pipeline管子油漆和铭牌.551. Scope of application适用范围This manual specifies the requirements of processing、arrangement and mounting for pipes、 fittings and supports.本手册规定了船舶管系、管系附件、管子支架的加工、布置、安装要求及检验规则。This manual is suitable for pipe-laying design, and pipe processing、arrangement and mounting for ships which will be built at our shipyard. For special required pipes, the processing and mounting should be according to special drawings or special workmanship for the single vessel.本手册适用于我厂建造船舶的管系设计和管子加工、布置、安装。对有特殊要求的管子加工、安装以图纸要求为准或另编单船专用工艺。This manual isnt suitable for plastic pipes processing and mounting.本手册不适用于塑料管的加工和安装。2. Pipe system name and code number系统名称与编码代号21 Pipe system name and code number see Table 1. 管路系统编码代号见表1Table1 Pipe system name and code number表1系统名称与编码代号Code No.编码代号Name名称ACAir Conditioning Duct空调风管ALAcetylene Pipe乙炔管AOAir Pipe, Oil Tank油舱透气ASCompressed Air, Starting 起动空气AWAir Pipe, Water tank水舱透气BFBoiler Feed Water锅炉给水BLBilge Line全船舱底水BPBallast Piping全船压载水CACompressed Air, Control & Service低压(杂用及其他)压缩空气CFCooling , Fresh Water淡水冷却CHCargo Tank Heating System货油舱加热系统CLCondense Line蒸汽回汽凝水CSCooling , Seawater海水冷却DADrainage, Over All全船疏排水DCDraining, Condensed Water凝水排放DWDeck Washing System甲板冲洗EPExhaust Piping 排气(烟)管EMExtinguishing, Machinery Space机舱化学灭火FBFuel for Boiler锅炉燃油FCCO2 System二氧化碳管FDFuel Oil Drainage燃油泄放FEFire-Extinguishing System消防水FFFoam Fire Extinguish Line泡沫灭火FLFilling Line , Oil Tank油舱注入FOFuel Oil Supply燃油供给FPFuel Oil Purifying燃油净化FTFuel Oil Transfer燃油输送(驳运)HCHeat Oil Coil燃油加热HOHeat Oil热油系统HYHydraulic oil pipe液压管LCCargo Loading Manifold输油(货油装卸)LDLubricating Oil Draining滑油泄放LMLevel monitoring pipe液位遥测管LOLubricating Oil Supply滑油供给LPLubricating Oil Purifying滑油净化LTLubricating Oil Transfer滑油输送OFOverflow pipe溢流管OXOxygen PIPE氧气管PCCable Pipe电缆管RPRefrigerant pipe制冷剂管RWRefrigerated water pipe冷冻水管SADrainage ,over all soil全船粪便污水排放SCCargo Stripping System货油舱扫舱SOSounding Tube, Oil tank油舱测深SPSteam Piping蒸汽SSSprinkle System洒水SWSounding Tube, water tank水舱测深VPVoice pipe传话管VSVentilation System通风WDDrinking water system饮用水WFFresh water supplying system淡水供给WHHot water system热水WSSea water supplying system海水供给Explanatory notes:说明 XX AO 13 一 01 XX - Part I of system code number : two numbers , stand for pipe area.区域代号-系统编号代码第一部分(二位): 数字码,代表管件区域代号；AO- Part II of system code number : two letters, stand for pipe system.系统代码-系统编号代码第二部分(二位): 字母,代表管件系统代码；13- Part III of system code number : two numbers, stand for pipe item.管件代号-系统编号代码第三部分(二位): 数字码,代表管件代号；01- Part of system code number : two numbers , stand for pipe item.管件序号-系统编号代码第四部分(二位): 数字码,代表管件序号。3. Pipe grade 、material and size管子等级，材料，规格3.1 Pipe grade管子等级3.1.1 Normally, pipes are divided into I、 II、 III three grades based upon the pressure and/or temperature the pipes need to undertake, see table 2船舶耐压管系按其设计压力和温度，一般分为I、II、III三级见表2。具体管子等级应根据所入级船级社规范而定Table 2 Pipe grade管系等级Pipe system管系 grade I 一级 grade II 二级 grade III 三级 Design pressure设计压力MpaDesign tempera.设计温度 Design pressure设计压力MpaDesign tempera.设计温度 Design pressure设计压力MpaDesign tempera.设计温度Steam and thermal oil蒸汽和热油1.6or3001.6and3000.7and170Fuel oil燃油1.6or1501.6and1500.7and60Other medium其他介质4.0or3004.0and3001.6and200Note:注1. Other medium means air、 water、 lubrication oil and hydraulic oil, etc.其它介质指空气、水、滑油和液压油等2. Open-ended pipes i.e. drainage、overflow and vent pipes of boiler are grade III pipes.不受压的开式管路，如泄水管、溢流管、透气管和锅炉放汽管等为III级管系。3.2 Material and size材料和规格3.2.1. Pipe material, for grade I & II pipe, 10# steel to be chosen (stander number: GB5312-87); And for class III pipe, 10# steel to be chosen (stander number: GB8163-87).管子材质：I 、II级管选用10#、20#（标准号：GB531287），III级管选用10#、20#（标准号：GB816387)。 Seamless steel pipe will be chosen mainly according to Table 3. If conflicting occur, rules of class society to be obeyed. 无缝钢管的规格优先选用表3。若特殊系统管子外径、壁厚按规范要求与表3不符合时，则以规范要求为准。Table3 Seamless steel pipe 表3 无缝钢管规格优先选用表Nominal diameter管径OutsideDiameter管子外径Thickness厚度ABC10172.52.53.215222.53.54.020272.53.54.025342.53.54.532423.53.54.540483.54.07.050603.54.07.065764.55.57.080894.55.57.01001145.06.08.51251405.57.08.51501685.57.59.52002196.58.511.02502736.59.513.03003257.511.015.03503779.012.015.04004269.013.015.03.2.2 Copper pipe will be chosen mainly according to table 4 紫铜管的规格优先选用表4。Table4 Copper pipe 表4 紫铜管规格优先选用表Outside diameter(mm)Pipe which will prior to be chosenCopper pipeAlloy pipe8-101.00.812-201.21.025-44.51.51.050-762.01.53.2.3 All pipes upon arrival in the yard should have makers certificates of qualification, and all pipes which will be used as grade I & II should have certificate of class society、 heat number and batch number. 到厂的各种管材必须具有制造厂质量保证书，所有I级和II级管子应具有船检证书及制造生产罐号，并按管子的材料、级别、规格分类妥善保管。3.2.4 Upon arrival in the yard, before stowing, visual inspection is to be conducted to the pipes against technical documents. For seamless steel pipe, the faults of crack、 clinker-built 、folding 、rolling and delaminating etc are not allowed on pipe internal and external surface, if there are above-mentioned faults, they should be cleaned up. The pipe thickness reduction caused by cleaning up should not exceed value that rule and/or standard permitted. For seam steel pipe internal and external surface, the faults of crack、undercutting、 splash and depression etc which may caused by welding are not allowed. And for the non-ferrous pipe surface, it should be smooth and clean , and the faults of crack、 pin holes、 air-bubble、 delaminating and corrosion etc are not allowed. 管子入库前，应对管材内外表面质量进行检查。无缝钢管内外表面不得有裂缝、裂纹、折叠、结疤、轧折、分层等缺陷存在，如有上述缺陷应予清除，清除部位的壁厚减薄量不得超过材料标准允许的负偏差；有缝钢管内外表面不允许存在由于焊接引起的裂纹、咬口、飞溅、凹陷等缺陷；有色金属管子表面应光滑清洁，不应有针孔、裂缝、气泡、离层、锈蚀等缺陷。3.2.5 When ordering carbon steel pipe、 Stainless steel pipe、 copper pipe and aluminum pipe, the requirement of annealing treatment should be forwarded to the maker. 碳素钢管、不锈钢管、铜管、铝管在订货时，应向制造厂提出退火处理要求。3.2.6 The connecting fittings, e.g. pre-fabricated bends and reducers etc. refer to GB12459-90, should be supplied makers certificates of qualifications before stowing in warehouse. 定型弯头、异径接头等连接件，可参照GB1245990，必须有材料质量保证书方可入库。4. Principles and requirements of piping layout管系布置原则与要求4.1The pipeline should try to keep straight and reduce the bends at most possible. Anyway, the piping layout should be compliance with the requirement of international ship building rules 、 regulations and also the authority requirement of the country which the flag is flied. The pipeline should have enough reliability and easy operation for the crews.管路尽可能直线布置，弯头尽可能少，同时要符合有关船舶建造规范、国际公约、国际规则以及挂旗国港口法规，并应有足够的可靠性和经济性，力求满足船员使用要求。4.2 The spacing of parallel pipes i.e. adjacent two pipes (including pipe fittings) or pipe and hull construction normally should exceed 20mm, shown as Fig .1, but the smallest spacing (after pipe being insulated)is not less than 10mm . At some places where the space is very tight, its allowed that the spacing exceed 2mm.并行管或交叉管或邻近的二根管子（包括管子附件）或与船体结构间距宜在20mm以上，图1所示，但最小间距（管子包扎后）不少于10 mm，在空间非常紧的位置上，允许间距2 mm以上fig.1图14.3 The distance between following pipe and cable should exceed 100mm. 下列管子与电缆的距离应在100 mm以上1） Outside surface of insulation for steam pipe. 蒸气管绝热层外表2） Outside surface of insulation for exhaust pipe. 排气管绝热层外表4.4 The arrangement of pipeline and its fittings should ensure operation, maintenance and repair conveniently during the period of servicing, and also to avoid collision and influence people passing through.管路及其附件的布置，应保证在营运期间能方便地操作和维修，同时能有效地避免碰撞，不影响人通过。4.5 According to the requirement of each equipment, the necessary free space for the equipment dismantling、 maintenance、 repairing and checking should be considered . Pipes are not allowed to arrange inside these spaces. 应根据各设备的要求考虑其拆装、维修、检查等必要的空间，在此空间内不宜设置管路。4.6 When cables、 pipes and vent ducts go through the same vertical cross section, it should be arranged from up to down according to the sequence of cables-pipes-vent ducts, when pipes are over cables unavoidably, its not allowed to have removable connectors . 当电缆、管子、风管位于同一垂直位置时，一般应由上而下按照电缆管子风管的顺序布置，当管子不可避免地穿过电缆上方时，不得有可拆接头。4.7 For the pipes which may endure expansion or other strengths, the necessary compensation steps e.g. bending pipes or adding expansion joints or flexible joints are always taken. 对承受热胀冷缩或其它应力的管子，应采取管子弯曲或加膨胀接头或伸缩接头等必要的补偿措施。When the pipelines are arranged in long distance straight line, e.g. thermal oil pipe、exhaust pip、 boiler smoke exhaust pipe、 steam pipe、 cargo oil pipe、 stripping pipe and ballast pipe etc, the expansion / shrinking of pipes and hull deformation etc are to be taken into consideration, and the grade of connecting bolts are also need to be considered. 尤其要注意热油管、排气管、锅炉排烟管、蒸气管、货油管、扫舱管、压载管等长距离直线布置时，管子的热胀冷缩、船体的变形等，同时要考虑到连接螺栓的强度等级。4.8 Generally, it is not allowed that fresh water pipes pass through oil tanks or that oil pipes pass through fresh water tanks. If its unavoidable, the pipes should go through the pipe tunnel or the jacket pipe. If other pipes except fresh water pipes pass through oil tanks, the pipes should be thickened, and removable connectors should be avoided at most possible. 淡水管不得穿过油舱；油管不得穿过淡水舱。若不可避免时，应在密封通道或套管内通过，其它管子通过油舱时，管壁应加厚，并不得有可拆接头。4.9 Arrangement of sewage pipes 粪便管的布置4.9.1. Sewage pipes are not allowed to pass through fresh water tanks. 粪便管不得穿过淡水舱。4.9.2 When sewage pipe being horizontal arranged, it should have 50:1 slope along flow direction 粪便管水平布置时应按流向50：1的斜度。4.9.3 At special position when the sewage pipes can only be horizontal, the length should be short as far as possible and short socket for cleaning need to be added at necessary positions. 特殊部位只能平直时，管子长度应尽量短，在必要位置增设疏通接头4.9.4 Sewage pipes can not arranged above the beds inside the cabin, if unavoidable, it can not have removable connectors. 粪便管尽量不布置在床铺上方，若需布置时不应有可拆接头。4.10 The fuel oil tank、 vent pipes、overflow pipes、sounding pipes and filling pipes of tanks should not pass through cabins generally. If unavoidable, removable connectors can not be fitted inside the cabins. 燃油舱、柜的空气管、溢流管、测深管、注入管应避免通过居住舱室。不可避免时则通过该舱室时，不得有可拆接头。4.11 In the range of appropriate distance around the switchboard、electric control boxes、electric motors and important instruments, the steam pipes、 exhaust pipes、boiler smoke exhaust pipes、water pipes、 oil pipes and their fittings are not to be fitted. If its unavoidable, the removable connectors can not be fitted, or the effective protection steps should be taken. 配电板、电控制箱、马达及重要仪表的上方或前后适当距离的范围内，不得设置蒸气管、排气管、锅炉排烟管、水管、油管及其附件。不可避免时，则不得设置可拆接头，或采取有效的防护措施。4.12 Above the boiler smoke ducts、steam pipes、 exhaust pipes and silencer ,the oil pipes or oil tanks should be avoided. If its unavoidable, the removable connectors can not be fitted, or the effective protection steps are to be taken. 锅炉、烟道、蒸气管、排气管及消音器上方，应避免设置油管或油柜。不可避免时，则不得设置可拆接头，或采取有效的防护措施4.13 For the vent pipes, generally condensed water block should be avoided. And when the vent pipes are arranged on freeboard deck or deck of superstructure, the heights see Fig.2. 空气透气管，一般应避免冷凝水滞留现象产生。对于海船空气透气管布置在干舷甲板或上层建筑的船楼甲板上时，其高度应符合图2要求。Fig.2图24.14 The pipes of double bottom tanks and deep tanks leading upward to free board deck, can not be arranged inside cabins/tanks. 双层底舱及深舱的空气管，必须向上引至干舷甲板上，不得布置在室内4.15 The overflow pipes and drainage pipes are generally cline downward, and the vent pipes are always cline upward. 溢流管，甲板疏排水管等应向下倾斜，对于空气管则应向上倾斜。4.16 When the scuppers are arranged, the thickness of deck covering and heat-insulating layer are to be noted. 甲板漏水口的布置应便于排出积水，其安装要注意甲板敷料和隔热层的厚度。4.17 Domestic water pipes and drainage water pipes etc. generally can not have removable connectors inside the cabin, except which connect to the WC-module and washing-basin. 生活管系在居住舱室内布置时，除与卫生单元和洗池连接处外一般不宜用可拆接头。特殊情况，应征得船东同意4.18 The pipes and ducts for superstructure cabins are generally arranged in the corridors. If its difficult to put all these pipes and ducts together, the AC ducts and ventilation ducts can layout inside cabins, and the water pipes and steam pipes should avoid passing through the cabins at most possible. 上层建筑的管系、风管尽可能布置在内走道，内走道空间位置有困难时，优先将空调管布置在居住舱室内，压力管、蒸汽管尽可能避免穿过居住舱室。4.19 The pipes, which pass through the cabins vertically, should avoid passing through the places where the windows will be mounted. 上下穿过居住舱室的管子，应注意隐蔽，沿舷边上下的管子应避免通过有舷窗的位置。4.20 The pipes, which pass through the cabins insulation, should not have removable connectors. 绝缘层内不得布置可拆接头的管子4.21 The pipes, which pass through the cargo holds, should be protected. 穿过货舱区的管子应加以保护。4.22 The pipes, which are arranged near the man holes, should not influence opening the man hole covers and passing through for peoples. 人孔附近布置管子时，不得影响人孔盖的打开，也不能影响人的通过 For the pipes inside the double bottom tanks and other hull structure tanks, the pipes can pass through the light-weighted holes, but the enough space for people passing through should be considered. 对于双层底或各种船体结构舱柜内管子，可利用减轻孔布置，但要考虑到人能较方便地通过。 4.23 When the pipes are arranged, the technical characters of pipes fabricating、grinding、galvanizing and mounting should be considered. E.g. the pre-fabricated bends are generally not used in the pipes DN100, except some special crowded places. And the spaces between the end of vent pipes and shell should ensure the possibility of double welding etc. 管路布置时，应考虑管子制作、打磨、镀锌和安装的工艺性，如DN100的管子一般不用定型弯头拼接，特殊部位才选用定型弯头。透气管的端部距舷边（或船体结构）应保持一定的距离，以保证双面焊接的可能性。 4.24 Laying the pipes above the bilge wells should be avoided , if its unavoidable, necessary operating spaces for cleaning the bilge wells should be ensured. 污水井上方避免布置管路，不可避免时，应保证清洁污水井所需要的操纵空间4.25 The distance between the returned pipe and suction pipe for lubrication oil circulation tank should be laid as far as possible so as not to suck the air and impurities into the M/E. 滑油循环舱中的回油管和吸入管，应尽可能相互远离，以免气泡和杂质进入吸入管内4.26 About the mounting positions of overboard drainage valves, some factors e.g. ships draft、draft mark、ships name、 accommodation ladder、 lifeboat davit 、 the shell plate welding seam and block connection seam should be considered. 舷外排出阀的安装位置，应考虑到船舶吃水、外板水尺、船名、舷梯、救生艇升降，船体外板拼板板缝，大合拢缝等因素。4.27 The pipes except which belong to the refrigerating system should be away from the refrigerated room as far as possible. 非冷藏装置的管子应尽可能避开冷库。4.28 It should be avoided that pipes go through the provision stores and clothing store, if its unavoidable, the removable connectors can not be fitted inside these area. 粮食库、被服舱应避免管子任意穿越，凡穿过该类舱的管子，不允许有可拆接头。4.29 When laying pipes, it should be noted to prevent from generating air block in the water cooling system. It also should be noted to avoid siphon phenomenon occurring between the tanks and their pipes. 在布置管路过程中，应注意防止冷却系统和与热交换器连接的管子产生气囊现象，各种箱柜及其管路布置中，应注意避免虹吸现象的产生4.30 Filling pipes are normally arranged close to board side and bulkhead and convenient to operate. 注入管应尽量布置在靠近舷边和舱壁便于操作的地方。4.31 When laying the pipes, the possibility of fitting the pipes supports is to be considered. The pipes supports should be fitted on the hull structural components at most possible. If the supports have to be fitted on deck and bulkhead , shown as Fig.3, the supports pads should be added, indicated as table 5. 管路布置时，应考虑管子支架布置的可能性，应尽可能布置在船体构件上，若布置在非肋位甲板、壁板上如图3，一律加焊支架垫板如表5。Fig 3图3Table5 support pad表5 支架垫板规格No.序号Support angle steel side length支架角钢边长Pad垫板1L30*30*3，L40*40*4 60*82L50*50*5，L65*65*6100*83L75*75*