管道安装-中英对照.doc

附件 07 施工方案 Appendix 07 Execution Statement Page 1 of 174 6 管道施工方案管道施工方案 Construction Schemes for Piping Works 6 1 概述概述 General Statement 乙烯装置一标段的管道施工 主要是裂解区 急冷区 压缩二区 裂解汽油加氢区和废碱处 理区管道安装 管道安装工程量 91034 米 管道材质有碳钢 低温钢 不锈钢及铬钼合金钢 管 道安装的主要工程量见表 1 The construction of the piping works for the tendered Works I in the ethylene complex covers mainly the piping installation for the cracking heater area quench area compression area 2 pyrolysis gasoline hydrogenation area and the spent alkali treatment area The quantity for the piping installation works amounts are about 91 034 meters and the involved construction materials of the piping include carbon steel low temperature steel stainless steel as well as chrome molybdenum alloy steel For the major quantity of piping installation works refer to Table 1 一标段管道工程量 表 1 Table 1 Quantity of Piping Installation for Tendered Works I 序号 S N 名称 Description 规格 Specifications 单位 Unit 数量 Quantity 备注 Remarks 碳钢管 CS Piping 0 5 2 m38680 碳钢管 CS Piping 2 m41688 不锈钢管 SS Piping 0 5 2 m3569 不锈钢管 SS Piping 2 m2669 铬钼钢管 Cr Mo Piping 0 5 2 m1842 铬钼钢管 Cr Mo Piping 2 m2586 附件 07 施工方案 Appendix 07 Execution Statement Page 2 of 174 合计 Total m91034 碳钢阀门 CS Valves 0 5 2 个 set 8525 碳钢阀门 CS Valves 2 个 set 1324 不锈钢阀门 SS Valves 0 5 2 个 set 619 不锈钢阀门 SS Valves 2 个 set 82 铬钼钢阀门 Cr Mo Valves 0 5 2 个 set 125 铬钼钢阀门 Cr Mo Valves 2 个 set 163 合计 Total 个 set 10838 方案编制依据 Basis of the Schemes Preparation SECCO 提供招标文件中的技术资料和标准规范 Technical Information and standards and codes provided in SECCO s bid inviting documents 国内的有关标准和相应的施工及验收规范 Applicable national standards and the relevant construction and acceptance specification 我公司在其他乙烯工程施工的经验 Our experience of construction on other ethylene projects 乙烯装置工艺管道全部采用工厂化预制加工 现场分段安装 All the process piping used in the ethylene plant shall be prefabricated in shop and installed segment by segment on site 6 2 施工准备施工准备 Construction Preparations 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 附件 07 施工方案 Appendix 07 Execution Statement Page 3 of 174 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 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 engineering 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 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 To prepare for tools and facility build platforms set up a warehouse and field for storing pipingand fitting 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 To 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 6 3 材料检验材料检验 Materials Inspection 6 3 1 管材 管件检验 Inspections for Piping and Piping Fittings 检验准备 Preparations for Inspection 附件 07 施工方案 Appendix 07 Execution Statement Page 4 of 174 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 管材 管件 检验由供应部长组织 技术人员和质量检验人员参加 Inspections for piping and piping fittings of the pressure piping works shall be organized and implemented as per the applicable standards The inspections for piping and piping fittings of piping shall be organized by the Director of the Material Supply Department and participated by the relevant technical personnel and quality inspectors 管材 管件检验应设有独立的检验场地 并划分出待检区 检验区 合格品区和不合格品 区 An independent inspection field shall be provided for the piping and piping fittings It shall be divided into four zones that is waiting inspection zone inspection zone acceptable zone and non acceptable zone 管材 管件检验前 应进行检验作业技术交底 Prior to the inspections for the piping and piping fittings a technical clarification for the inspection operations should be implemented 管材 管件检验程序 Inspection procedures for the piping and piping fittings 检验程序 管材 管件检验程序见图 3 1 Inspection procedures refer to Fig 3 1 for the inspection procedures for piping and piping fittings 图 3 1 管材 管件检验程序图 合 格 不 合 格 管材 管件接收和 品种 规格 数量检验 进行产品 标识 和检验状 态标识 管材 管件 入 库保管 材质核查及质量 验证 管材 管 件外观质 量检验 不合格品处置 Receiving and inspections on varieties specs and quantity of piping and piping fittings Product identification no defects as scratches loosening or warps are allowed on the sealing surfaces of the flanges metal rings and spirally wound gaskets 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 材质核查 Materials identification 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 附件 07 施工方案 Appendix 07 Execution Statement Page 7 of 174 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 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 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 质量验证 Quality Verification re test 管材 管件在进行品种 规格 数量检验和外观质量检验及材质核查的基础上 如设计或标 准对管材 管件有进一步的质量检验要求时 应按设计要求或标准规定 对管材 管件进行质量 验证 In addition to the inspections on the varieties specifications and quantities as well as the visual quality inspection and materials checks of the piping and piping fittings quality verifications shall be carried out as per the engineering design requirements or applicable standards in case further quality inspection activities are specified in the engineering documents or standards 若到货管材的炉批号与质量证明书不符或对其特性参数有异议时 应按相应标准作校验性检 验或追溯到产品制造单位 但在异议未解决前 该批管材不得使用 Should inconsistency between the heat No of the received piping and the attached quality certificates be observed or else there be doubt regarding the property data of the piping a checkout inspection should be performed as per the applicable standards or tracebility back to the vendors be carried out And this lot of piping should not be put into use until the discrepancies are properly handover 产品标识和检验状态标识 Product Identifications and Inspection Status Marks 附件 07 施工方案 Appendix 07 Execution Statement Page 8 of 174 质量验证合格入库后的管材 管件 应按品种 材质 规格和产地 分批进行合理摆放 并 按规定进行产品标识 Piping and piping fittings which have been put into storage following an acceptable quality verification shall be properly arranged by lots for different varieties construction materials specifications and origins and should be identified as per the relevant stipulations 入库保管的管材 管件 应按批进行检验 试验状态标识 The piping and piping fittings stored in the warehouses shall be identified by lot No to indicate the inspection and test status 质量记录文件 Quality Records Documents 管材 管件质量证明书 The quality certificates for piping and piping fittings 管材 管件接收验证记录 Receiving and verification records for piping and piping fittings 管材 管件检验 试验报告 Inspection and test reports for piping and piping fittings 6 3 2 阀门检验 试验 Inspections and Tests of Valves 按国外标准制造的阀门 应按国外相应的检验标准进行检验 设计文件或顾客对阀门检验 试验有特殊要求时 应按设计文件或顾客的特殊要求进行检验 试验 Valves manufactured as per foreign standards shall be subject to inspections in accordance with the applicable international inspection standards In case special inspection and test requirements for the valves are specified in the engineering design documents or required by the client then the inspections and tests shall be carried out in compliance with the special requirements of the relevant engineering documents or as required by the client 检验 试验准备 Preparations for the Inspections and Tests 压力管道工程用阀门 应专门成立阀门检验 试验小组 统一进行检验 试验 The inspections and tests for the valves used in the pressure piping works shall be 附件 07 施工方案 Appendix 07 Execution Statement Page 9 of 174 performed by a special inspection and test team for integrated inspection and test performance 阀门检验 试验小组应由阀门检验 试验作业人员 技术人员和质量检验人员组成 The valve inspection and test team shall comprise the valve inspection and test operators technicians and quality inspection personnel 阀门检验 试验前 必须编制阀门检验 试验技术措施并设计制作相应的工装设备 Prior to the inspection and test activities it requires to develop relevant technical measures for valve inspection and test design and fabricate corresponding jigs and facilities 阀门检验 试验前 必须进行检验作业技术交底 必要时 应组织作业前的专业技术培训 A technical clarification for inspection operations should be implemented prior to the inspection and test activities if necessary a professional technology training course should be conducted before the commencement of the inspection and test operations 阀门检验 试验应设有独立的作业场地 并划分出待检区 检验区 合格区和不合格区 An independent field shall be provided for the valve inspections and tests operations It shall be divided into four zones that is waiting inspection zone inspection zone acceptable zone and non acceptable zone 检验 试验场地应平整 照明应良好 并应保证道路畅通 The field used for inspection and test purposes should be flat with good illumination and free access 检验 试验流程 Inspection and Test Process 检验 试验工艺流程 阀门检验 试验工艺流程见图 6 3 2 Inspection and test process flow for the process flow for valve inspection and test refer to Fig 6 3 2 图 6 3 2 阀门检验 试验工艺流程图 合 格 不 合 格 工装设计制作 检验场地准备 编制技术措施 进行技术交底 成立阀门检 验 试验小组 质量证明文 件核查 确认 阀门外观质量 检查 强度试验 严密性试验 检验 试验 状态标识 阀门理化检 验 不合格 品处置 交付 安装 附件 07 施工方案 Appendix 07 Execution Statement Page 10 of 174 阀门检验 试验 Valve Inspections and Tests 证明文件 Certification Documents 质量证明文件核查阀门必须具有出厂合格证和制造铭牌 铭牌上应标明公称压力 公称通径 工作温度 工作介质和阀号型号 The quality certification documents applicable for checks of valves must be with ex works certificates and manufacturing nameplates indicating the nominal pressure and bores operating temperatures services media and the model of the valves Fig 6 3 2 Process Flow for Valve Inspection and Test acceptableUnacceptabl e Design he surfaces of the casting should be flat and smooth and free of shrinkage cavity burr stuck sand sand carry over scale or cracks etc the forged surfaces should be free of such defects as interlayer double skin crack scar or unfilled corner etc 阀门的手柄或手轮操作应灵活轻便 开闭时不得有卡涩现象 阀杆的全开与全闭位置应符合 要求 阀杆和阀杆螺母 连接螺母的螺纹应光滑 不得有毛刺与开裂等缺陷 The lever or hand wheel of the valve should be of agility for operations with ease and there should be no blocking during the opening or closing operations of the valve The full opening and full closing positions of the stem should satisfy the relevant requirements The stems and the nuts on the stems as well as the connection nuts should be smooth with no defects as burrs or cracking 闸阀 截止阀 节流阀 调节阀 蝶阀 底阀等阀门应处于全闭的位置 旋塞阀 球阀应完 全处于未开启位置 以防止灰尘沾染密封面 The valves as gate valves stop valves throttling valves control valves butterfly valves and root valves etc should be in their fully closed positions Cock valves and ball valves should be in their unopened positions to prevent from the contamination of sealing surfaces by dust 结构尺寸检查 附件 07 施工方案 Appendix 07 Execution Statement Page 12 of 174 Check of structure Dimensions 阀门的结构长度 通径 法兰螺纹等应符合规定 对同型号 同规格的阀门按 10 的比例 进行抽查 但抽查数量不得少于 1 个 The structural length bores and the threads of the flanges should comply with the relevant specifications 10 of the valves of same model and specifications are subject to being spot checked however the quantity of valves to be spot checked should not be less than 1 直通式铸钢阀门的连接法兰密封面应相互平行 在每 100mm 的法兰密封面直径上 平行度 偏差不得超过 0 15mm 直角式铸钢阀门的连接法兰密封面应相互垂直 在每 100mm 法兰密封 面直径上 垂直度偏差不得超过 0 3mm The sealing surfaces of the connection flanges on the cast steel through way valves should be parallel with each other and the parallelism deviations on each 100mm diameter of the sealing surfaces should not exceed 0 15mm The sealing surfaces of the connection flanges on the cast steel right angle valves should be perpendicular to each other and the perpendicularity deviations on each 100mm diameter of the sealing surfaces should not exceed 0 3mm 闸阀的闸板密封面中心必须高于阀体密封面的中心 当闸板密封面磨损时 关闭位置下降 但阀体 闸扳密封面仍应完全吻合 闸板密封面磨损余量应符合有关规范的规定 The centerline of the sealing surfaces of the gates on the gate valves must be above that of the valve body Under the condition of the closing position being lowered due to the abrasion of the sealing surfaces of the gate the sealing surfaces of the gate and valve body should still remain well fitted The abrasion allowance of the sealing surfaces of the gate should comply with the applicable specifications 材质检查 Inspections on Materials 合金钢阀门的阀体应逐件采用光谱分析仪进行材质复查并做出标识 不符合要求不得使用 All the alloy steel valves bodies shall be re test one by one by means of spectrum analyzer for construction materials compliance and be properly identified Nonconformities should be rejected 阀门的填料 垫片材质应符合设计要求 对有特殊要求的阀门 其材质应进行 1 抽查且不 得少于 1 个 附件 07 施工方案 Appendix 07 Execution Statement Page 13 of 174 The construction materials of the packing and gaskets of the valves should comply with the relevant requirements For special purpose valves 1 out of the total but one as minimum shall be spot checked for material compliance 易燃 可燃介质压力管道的对焊阀门 应按批进行 5 的硬度值抽查 且不得少于一个 硬 度值抽查应在坡口附近进行 For the butt welded valves located on the pressure pipelines carrying inflammable or combustible fluids 5 out of total but one as minimum shall be spot checked in each lot of products for hardness compliance The spot checks for the hardness compliance shall be carried out at a certain position around the bevel 阀门试验一般规定 General Rules for the Valve Test 下列管道用阀门应逐个进行壳体压力试验和密封试验 不合格者不得使用 Shells of the following valves located on the pipelines shall be subject to pressure test and tightness test one by one and those failing to pass the tests should be rejected 可燃流体管道的阀门 Valve on pipelines carrying combustible fluids 输送设计压力大于 1MPa 或设计压力 1MPa 且设计温度小于 29 或大于 186 的非可燃 流体 无毒流体管道的阀门 Valves on pipelines transporting non combustible nontoxic fluids with a design pressure of 1MPa or such fluids with a design pressure of 1MPa but with 29 or 186 design temperatures 输送设计压力 1MPa 且设计温度为 29 186 的非可燃流体 无毒流体管道的阀门 应从 每批中抽 10 且不得少于 1 个 进行壳体压力试验和密封试验 当不合格时 应加倍抽查 仍不 合格时 则该批阀门不得使用 For valves on pipelines transporting non combustible nontoxic fluids with a design pressure of 1MPa and with 29 186 design temperatures 10 out of the total but one as minimum shall be selected randomly from each lot of products for pressure test and sealing test for the valve shells In case of unacceptable tests the spot check percentage should be doubled In case of still failing to pass the repeated test then this lot of valves shall be rejected 附件 07 施工方案 Appendix 07 Execution Statement Page 14 of 174 阀门试验前 应除去密封面上的油渍 污物 不允许使用防渗漏的涂层 但可进行无密封作 用的防锈处理 The oil and dirt present on the sealing surfaces should be properly removed prior to the valve test activity Application of coat for anti seepage purpose is prohibited however anti rust treatment without sealing effect can be implemented 阀门试验前 只允许一人以正常的体力进行关闭 当手轮的直径 320mm 时 允许两个人 进行关闭 The valve can only be closed by one person with normal physical strength before the valve test activity is performed In case of handwheel with a diameter of 320mm two persons may be allowed to close the valve 装有旁通阀的阀门 进行主阀强度和密封试验时 对旁通阀也应进行强度和密封试验 For the bypass valves strength and sealing tests shall also be performed for such bypass valve together with the main valve 试验用的压力表 必须经检定合格 其精度应不低于 1 5 级 安全阀试验时 应选用 0 5 级 或 1 级精度的压力表 量程应是试验压力的 1 5 至 2 倍 The pressure gauges applied in the test operations must be calibricated and acceptable the accuracy of such gauges should not be lower than Grade 1 5 While carrying out tests for safety valves pressure gauges with an accuracy of Grade 0 5 or 1 and the span shall be 1 5 2 times test pressure s 强度试验 Strength Test 阀门在安装前应按下列要求进行阀体的强度试验 Prior to the valve installation strength test for the valve body should be carried out in accordance with the following requirements 阀门应以 1 5 倍的公称压力进行液体压力试验 The valve shall be hydraulic tested under a pressure of 1 5 times the nominal pressure 带有蒸汽夹套的阀门 夹套部分应以 1 5 倍的蒸汽工作压力进行强度试验 For valves equipped with steam jacket strength test for the jacket should be performed under a pressure of 1 5 times the operation pressure of the steam 附件 07 施工方案 Appendix 07 Execution Statement Page 15 of 174 阀门强度试验介质采用洁净工业水 对于奥氏体不锈钢阀门 水的氯离子含量不得超过 25ppm Clean industrial water shall be utilized as the medium for the strength test of the valves For the valves made of austenitic stainless steel the chloride ion content in the water should not exceed 25ppm 阀门密封和上密封试验 Valve tightness Test and Backseat Test 起截断作用的各类阀门应根据 GB 50235 97 工业金属管道工程施工及验收规范 相应规定 在强度试验合格后进行密封试验 具有上密封结构的阀门均应进行上密封试验 The individual types of valves with block off functions are subject to sealing test as per the applicable specifications in GB 50235 97 Construction and Acceptance Specifications for Industrial Metal Piping Works following the acceptable strength test valves with backseat construction shall be subject to backseat test 密封和上密封试验应以公称压力进行 以阀瓣密封面不漏为合格 密封和上密封试验的保压 时间应符合表 6 3 2 的规定 The sealing test and backseat test shall be performed under nominal pressure and the test shall be deemed acceptable when there is no leakage at the sealing surfaces of the flaps The pressure holding time during the sealing test and backseat test shall comply with Table 6 3 2 密封和上密封试验保压时间 表 6 3 2 Table 6 3 2 Pressure Holding Time During the tightness