ATT_TP-60 工艺管道安装技术规范 PROCESS (A1) PIPING工艺（A1）管线

1 TECHNICAL PROVISIONS 技术规范技术规范 SECTION 60 第第 60 章章 PROCESS A1 PIPING 工艺 工艺 A1 管线 管线 TABLE OF CONTENTS 目录目录 TECHNICAL PROVISIONS 技术规范技术规范 1 TABLE OF CONTENTS 目录目录 1 I SCOPE范围范围 2 II QUALITY STANDARDS质量标准质量标准 2 III GUARANTEE保修保修 4 IV DEFINITIONS定义定义 4 V FABRICATION AND INSTALLATION制作和安装制作和安装 6 VI CLEANING AND PROTECTION清洁与保护清洁与保护 10 VII ACCEPTANCE TESTS验收检测验收检测 11 VIII SHIPPING AND STORAGE PROTECTION货运和储存保护货运和储存保护 12 January 2007 Update 2 I SCOPE 范围范围 A This section of the Technical Provisions together with the Contract Documents and the applicable Design Drawings covers process A1 piping as required by the drawings and specified herein 技术规范之本章节 连同 合同文件与有关设计图纸适用于设计图纸以及本规范要求的工艺和动 力管道工程 B All work shall comply with all local codes and all applicable codes specifications and standards as referenced in Table I Applicable dates for all codes specifications and standards will be the dates of the latest revision in effect at the time of contract award 所有的施工必须符合职业安全与卫 生条例 所有当地规范及一切适用的规范 技术规定及标准 有关规 范及标准由表 1 列出 适用本工程的上述法规 技术要求及标准之版 本 应该是在承包合同签订之日实际有效的最新修订版本 II QUALITY STANDARDS 质量标准质量标准 A The latest edition of applicable Chinese national and local codes in effect at the time of Contract award as applied to process piping shall apply to materials fabrication and installation of the entire piping system 在中标时 有效的联邦 州及地方之工艺及动力管道适用规程的最新版本 应适 用于整个管道系统工程的材料 制作及安装施工 B The Contractor shall have available for reference all the latest editions of Chinese national and local codes in effect at the time of Contract execution which are referred to or apply to process piping materials welding testing fabrication and installation of the entire piping system 承包商应备有在实 施合同时有效的联邦 州及地方工艺及动力管道适用规程的最新版本 承包商将就整个管道系统的工艺与动力管道工程的材料 焊接 测试 制作及安装施工而参阅这些有关法规并予以应用 C Materials and Equipment 材料与设备 1 All materials and equipment shall be free from defects and imperfections of recent manufacture new and unused and per specifications cited 所有的材料和设备必须无缺陷及瑕疵 应为 新近生产之产品 应为崭新未使用过的的产品 且符合所引用 的有关规范要求 2 A certification of compliance with specified codes and standards shall be provided for all materials and equipment except those whose manufacturer is listed by name in this specification The testing laboratory certifying compliance shall be approved by Owner 3 除了其生产厂家已由本规范在此列名的那些产品之外 所有其 他材料及设备必须附有证书 证明这些材料及设备符合规定的 有关规程 测试产品之合格性的试验室必须由业主认可 3 All materials and equipment which are not covered by detailed specifications shall be standard products of reputable manufacturers and suitable for the intended use Certificate of origin shall be provided on owner s request 详细技术规范未述及的材料及设备 应为由信誉良好的生产厂家所生产的标准产品 并适用于设计 使用要求 在业主要求时 应出示原产厂家证明 4 All piping specialty fittings of an individual device designation shall be of one manufacturer 某一单个设备所有管道特殊配件应为同一 生产厂家所生产的产品 5 Cadmium or cadmium plated materials are not permitted 不得使用 镉或镀镉材料 6 All stainless steel pipe shall be labeled with a continuous inkjet stripe or laser etching to identify the grade of alloy material pipe spec number and heat number All fittings shall be identified as to material with an etched label All labeling shall be performed by the manufacturer 所有的不锈钢管子均须用一连续的不溶解墨水条纹 线以标别合金材料的等级 管子规格号及热处理编号 所有的 管道配件应以一刻蚀的标签作为起材料的标记 所有上标签的 工作应有生产厂家进行 7 All welding rods used to weld stainless steel piping must be identified as to the grade of material If rods identified only at one end are cut in half the remaining unidentified end must be painted in accordance with paragraph 6 above to provide a permanent identifying mark 用于焊接不锈钢管的焊条必须标明焊接材料的 等级 若将仅一端标有标识的焊条切为两段 未予标识的一端 应涂上永久性标识 涂标识的方法应依从上述第 6 条之规定 8 Mill Reports The Contractor shall obtain the necessary mill test reports from the pipe or fitting manufacturer as required by applicable ASTM material specifications They shall be approved by the Owner or the authorized inspector before fabrication and shipment of pipespools to jobsite The quantity and distribution of the test reports are to be as specified by the purchase order The requirement for mill test reports may be waived by the Owner at the request of the Contractor 生产报告 承包商应依照适用美国材料 试验学会的规范要求 从管道及管道配件生产厂商获取产品随 带的生产试验报告 在管道和管道配件制作 以及将其运送至施 工场地之前 必须先由业主或得到授权的监察机构对这些报告 予以认可 该试验报告的份数及发送范围将在定货单中予以说 明 如果承包商提出获得产品试验报告的要求 业主可以放弃 提出该要求 4 III GUARANTEE 保修保修 The Contractor shall furnish a guarantee that the work installed under this section of the Technical Provisions is in accordance with the requirements of applicable standards referenced in Table I of this section and that defects not due to ordinary wear and tear and improper use which may develop within one year from the date of final payment will be made good at no additional cost to Owner The Contractor shall make such inspection tests and adjustments as are deemed necessary by the Owner to ensure efficient operation of the equipment installed 承包商应提交一份 承诺函 保证按照本技术规范进行的安装工作与本章节表 1 中有关标准的要 求想符合 保证自最后付款之日起一年内对工程实行保修 即在不增加业主 费用的条件下 对一年内一切不属于正常腐蚀 耗损以及使用不当而致的缺 陷给予免费修复 若业主认为必要 承包商应对设备进行检查 测试 调整 以保证所安装之设备的有效运行 IV DEFINITIONS 定义定义 A Owner Means either the Anheuser Busch Company that owns the facility in to which the piping work is to be installed or that company s appointed representative 业主 指拥有管道安装工程事实之所在处所的安海斯 布希公司 或者指由该公司所指定的代表 B Field Fabricate Means to fabricate on the construction site using tools and facilities normally available to construction crews 现场制作 指使用通常 提供给制作人员的工具及设施在使用现在事实制作 C Shop Fabricate Means to fabricate in a facility either on site or off site having special fabrication tools and equipment and facilities for heat treating chemical cleaning or other special treatment 车间内制作 指在 车间内事实的制作 既可在施工现场 也可在施工现场以外区域 使 用特殊制作工具 设备及设施进行热处理 化学清洗或其他特殊处理 D Pipespool Is a unit of fabricated piping consisting of pipe and fittings Its dimensional limits are defined by flange faces or pipe ends prepared for field welding 短管件 指由管子及配件组成的制作件 其尺寸又法兰面或 经备制以事实现场焊接的管端而定 E Field Weld shown as FW on drawings Is the welding of piping panel or manifold to other piping equipment or piping assembly in the field 现场 焊接 图中标有 FW Field Weld 者 指在现场将管道 配盘 多支管焊接至其他管道 设备或管道组合件 F Fit up Weld shown as FU on drawings Is a welded connection prepared as follows Note FU location will be determined and added by the piping fabricator at his discretion Refer to Paragraph 14 f herein 装配焊 5 接 图中标有 FU Fit up Weld 者 指按如下步骤而一步一步实 施的焊接连接工作 注 装配焊接 FU 位置由管道制造单位自行 决定并可由管道制造单位另予添加 参考本规范 14 f 段落 1 At all fit up weld locations indicated on the piping isometric drawings contractor shall provide at least three inches of additional length on all pipe for field make up purposes 在管道等角图所指明 须装配焊接 FU 的位置 承包商至少应额外留下 3 英寸长的 空间 以供现场装配施工 2 Where a fit up weld occurs at a flange the flange shall be supplied and installed in the field 若需在法兰处实施装配焊接 则该法兰 应予提供并在现场予安装 G Dummy Weld shown as DW on the drawings Is a weld connection used to attach a pipe extension to pipeline for the purpose of support It is not cut through into the fluid stream Dummy weld pipe supports shall be fabricated as part of the pipespool Dummy welds are allowed for Sch 40 or heavier wall carbon steel pipe only 贴壁式焊接 图中标有 DW Dummy Weld 者 指一种焊接连接 用于将一关在延伸件连接到管道而起 到支撑作用 实施该焊接不可将管壁切破而伸及管内流体 贴壁式焊 接管支撑件应作为短管件之一部分予以制作 仅可对管标号 40 或更重 型管壁的碳钢管施以贴壁式焊接 H Piping Equipment Items Are standard catalog items that are identified by part model or figure number in Appendix I 管道设备项目 指在附录 I 中按零件 型号 图号示明的标准目录项目 I Specialty Item List This list is job specific and is used for unique piping items that may have a one time application These items are as identified in Appendix II and will be issued as a part of TP 60 Supplement 特殊项目清 单 该清单系开列某一具体工作项目 并专门用于仅作一次性使用的 独特管道物项 这些物项由附录 II 予明示 并作为本技术规范章节 60 之补充文件予下达 V FABRICATION AND INSTALLATION 制作和安装制作和安装 A Welded Austenitic Stainless Steel Joints 1 All welds shall be made using the Tungsten Inert Gas TIG welding process using tungsten nonconsumable electrodes and 100 percent commercially dry and pure argon gas for internal pipe purging and for electrode shielding Prepare ends of pipe for girth butt welding by using a pipe facing squaring and deburring tool or by machining abrasive cutting grinding sawing or any combination of these methods using saw blades cutting and grinding tools suitable for austenitic stainless steel pipe which have never been used on carbon steel 所有焊接点的焊接必须采用钨极电弧焊 TIG 之焊接方法 使 用钨非自耗电极及100 干纯商品氩气用作内部清洗与电极保护 实 6 施环形对焊之前 应对管道各端加以预备处理 使用端面车刀 方头 刀具 去毛刺工具进行处理 或者采取机械进行切削 磨切 打磨 锯切或对任何这几种方法加以混合使用 即使用适合于奥式体不锈钢 的锯片 切割 打磨工具等 而用于处理加工的机械必须是从未对碳 素钢进行过加工的机械 2 Thoroughly clean weld areas and remove all burrs and scale Remove all foreign substances such as cutting oils marking crayons kerosene material containing sulfur lead or zinc metal particles grinding compounds etc Clean only with carbon free aluminum oxide flap wheels Norton Metalite R265 Merit Grind O Flex or equal 彻底清洁焊接部位 去除所有毛刺及鳞皮 去除所有异物 如切削油污 记号笔印 火油 及含硫化物 铅或锌 金属颗粒 研 磨合成剂的物质等 清洁时仅可使用不含碳的氧化铝 翼片砂轮 Norton 公司的 Metalite R265 Merit 公司的 Grind O Flex 或相 等的 3 Align work accurately in jigs or fixtures Keep aligning benches clean at all times Do not allow austenitic stainless steel pipe or fittings to come in contact with carbon steel benches jigs or fixtures Place a sheet of stainless steel between bench the carbon steel jig or fixture surfaces that will come in contact with the pipe or fittings or other method acceptable to the Owner 在夹具或调直固定台中将管道予以精 确调直 调直台必须任何时候都保持清洁 不容许奥式体不锈钢管子或 管配件与碳素钢钳台 碳素钢夹具及固定台相接触 可在使用碳素钢钳 台 碳素钢夹具及固定台相接触时用一片不锈钢将奥式体不锈钢管子或 管配件与碳素钢夹具表面隔开 也可采用为业主所认可的其他方法 4 Ends to be welded are to be butted together and alignment maintained throughout welding by either tacking or the use of jigs Do not penetrate to the interior of the pipe with the tack The weld will be rejected for tacks that are not made correctly 要予以焊接的管 端应以 对焊而连接在一起 整个焊接过程中 或者用点焊定位或者使用夹具来 保持焊接的校平 用点焊定位时 不得让焊点穿透到管子内部 如果点 定焊不当 则焊接将属不合格而不为业主所认可 5 The space gap between the two ends butted together shall not exceed 0 25mm at any point in the joint 用对焊而连接在一起的两管端之间的 距离 间距 在任何情况下都不得大 0 25mm 6 Misalignment of ends to be welded due to out of round shall not exceed 0 8mm for pipe sizes up to DN100 and 1 2mm for pipe sizes greater than DN100 A stainless steel mandrel shall be used for DN50 DN80 DN100 and DN150 sizes to assure roundness for proper alignment of joint 出于变径差所造成的焊接管端不平直 对于管径尺 寸为DN100的管子 不得超过0 8mm 对于管径尺寸在DN100以上的管 子 不得超过1 2mm 实施管端焊接时 对于管径尺寸为 7 DN50 DN80 DN100 DN150的管子 必须使用一根不锈钢芯棒以保证连 接平直所需的圆度 7 All welds shall have 100 penetration and smooth lines of fusion on the exterior and interior The interior must be flush and smooth no porosity or sugar The weld concavity shall not exceed 10 percent of the wall thickness 所有管端焊接点必须达到100 的透入度 且管子的内 外表面 焊缝融合线必须平整 焊接的内部部位必须平接而光滑平整 无砂眼及 颗粒状物 焊缝凹陷不得超过管壁厚度的10 8 All welds in austenitic stainless steel pipe size DN150 and smaller with the exception of DN15 shall be accomplished by fusion only without the use of filler metal These welds shall be made by hand or an automatic welding machine The type of automatic welding machine used shall be approved by the Owner based on satisfactory weld samples 所有管径尺寸DN150或DN150以下的奥式体不锈钢管 DN15除外 的焊接 必须采用融合焊接之唯一方法 并不得使用填料金属 实施此 类焊接 必须采用手工或自动焊接机进行 其所使用的自动焊接机之类 型必须经业主认可 即经检查其焊接样品而满意后所确认的认可 9 All welds for DN15 and DN200 and larger austenitic stainless steel pipe shall have the first pass made by fusion and the second pass made with the use of filler metal if required The ends of DN15 and DN250 and larger pipe shall be beveled T316L filler rod shall be used to weld all 300 series austenitic stainless steel piping where the use of filler rod is required 所有 DN15 和 DN200 以及更大的奥式体不锈钢管子的焊接 必 须用融合焊接方式焊接第一道 如有必要 则在第二道焊接使用填料金 属 DN15 DN250 或更大的管子的焊接管端应予以开坡口 在进行所有 300 系列奥式体不锈钢管子的焊接时 若需要使用嵌条 必须使用 T316L 嵌条 10 Purge dam material water soluble paper and tape may only be used when owner s approval is obtained and shall be physically removed from the pipe after welding when accessible Otherwise water shall be used to flush the purge dam out of the pipe prior to cleaning of the system 只有在预先取得业主批准的条件下才能使用清洁用隔料圈材料 水可溶纸及水可溶带 并应在管子焊接完成而成通路之后将这些水 可溶纸及水可溶带予以清除 否则 应在对系统实施清通之前 用水将 这些清洁用隔料圈冲洗出管子之外 The material shall be DISSOLVO WLD purge dam material and DISSOLVO WAT tape manufactured by Gilbreth International Corporation or owner approved equal 上述材料应为 Gilbreth 国际公 司所制造的 DISSOLVO WLD 清洁用隔料圈材料及 DISSOLVO WAT 水可溶带 或者为业主所批准的同类产品 8 The purge dam shall be applied to the interior of the pipe by cutting the paper to a circular shape with a diameter several inches larger than the pipe being welded Fold the outer edge of the paper to form a 90 lip and to fit the inside diameter of the pipe Insert the dam into the pipe with the folded lip towards the weld area and placed far enough from the weld area to avoid exposure to temperatures in excess of 150C Apply tape strips to the lip of the dam and pipe to fasten the dam in place Punch a small hole in the dam to facilitate the evacuation of air when purging After the dam is in place Argon gas may be introduced through the root gap or through a hole at the bottom of the dam 在施用清洁用隔料圈于要予以焊接之管子 的内部时 应将水可溶纸剪成一个环形 其直径比之要予焊接之管子的直 径应大数英寸 将水可溶纸的外缘折叠成 90 度的外边缘 并使之有合适 的大小以适合管子的内径 将此隔料圈插入管子内 让折叠的外缘朝向焊 接部位 并使之离开焊接部位有足够的距离以避免其处在温度高于 150 度 的位置 在此隔料圈之折叠外缘和管子两者之上贴上条状水可溶带 以便 将隔料圈固定在其位置 在隔料圈上开一个小孔 以便在进行清空时能够 让空气抽出来 在隔料圈固定于其位置之后 可通过焊缝根部缝隙或通过 一个位于隔料圈底部的孔洞将氩气引入其中 11 Oxygen analyzers are to be used for all stainless steel welding and must have a 2 or lower reading before welding 实施所有不锈钢焊 接之前 应采取氧分析仪进行分析检测 焊接前该分析仪给出的读数 必须是 2 或 2 以下 g B Cleaning Welded Joints 焊接连接的清洁处理 1 Stainless steel welds shall be cleaned using stainless steel hand wire brushes which have and will be used only on stainless steel material Power driven brushes shall not be used on stainless steel 不锈钢焊缝 的清洁处理 应使用专供不锈钢清刷用的手工钢丝刷 不得使用电动刷清洁不锈 钢材料 3 The exterior of all shop fabricated stainless steel welded joints shall be cleaned with the Walter Surfox electrochemical weld cleaning system by J Walter Inc Hartford CT in accordance with manufacturer s procedures Any rust that occurs on stainless steel shop or field welded joints prior to Owner s final acceptance of the piping system shall be cleaned by Contractor at no additional cost 所有车间制作的不锈 钢焊接连接之外部应予以清洁处理 清洁处理应使用由J Walter Inc Hartford CT 公司制造的 Walter Surfox 电气化学焊接清洁系统 其 做法应依照制造厂商的技术规范 在管道系统交由业主作最终验收之前 所有车间制作或者现场制作的不锈钢焊接连接之上的锈迹应由承包商予以 清除 不增收费用 C Pipe and Tubing 管子 9 1 Full lengths of pipe and tubing shall be used to keep joints to a minimum All piping and or tubing shall be reamed to full bore after cutting 为了尽可能减少接头 应使用全长管材 管材切割后应打 磨去毛至原来的管径 D Fittings Welded 管配件 焊接 1 Elbows Use long radius elbows for piping systems unless otherwise shown on Contract Drawings Short radius or other special radius elbows shall be used only where called for on Contract Drawings Standard long radius welding elbows shall be cut off to form elbows other than 45o or 90o 弯头 除非合同图纸另作有标记 否则管道系统 均应使用长半径弯头 只有在合同图纸作有要求的地方 方才可使用短 半径弯头或其他特殊弯头 对标准长半径焊接弯头应予以切割 以形成 非45度或非90度弯头 2 Mitered elbows will not be permitted unless specifically noted on Contract Drawings 除非合同图纸另作有明确的说明 否则不允许使用 斜接弯头 3 The schedule of fittings shall match the schedule of the pipe line with which they are used Where difficulties in fabrication of fittings require a slightly heavier wall thickness than that of the pipe line to which they are welded fittings shall in no case be made of pipe heavier than 3mm for DIN 11850 service and such fittings shall be bored out at ends to match bore of the pipe Bore shall have a taper of 11 to 1 or greater The interior finish at such ends shall match the finish on the remainder of the fittings 管配件的管径标号必须与其所配 套的的管径标号相匹配 若因管配件制造上存在困难 要求所制造管配件 之管壁厚比之其所焊接到的管子之管壁厚要更厚一些 则在任何时候均不 得采用超过3mm的管子 去制作DIN11850的管配件 而对这样的管配件 必 须在其管端将内孔径镗大以与管径的螺口相配 这样镗出的内孔径应有 11 1或者更大的坡度 这样的管末端的内部光洁度应与管配件其余部分 的光洁度相同 VI CLEANING AND PROTECTION清洁与保护清洁与保护 a A Cleaning and Protection of Pipe and Equipment The Contractor shall take precautions during fabrication and erection to prevent entrance of foreign matter into piping or equipment Loose rust slag weld splatter dirt oil grease or other foreign substances shall be removed from interior surfaces of piping prior to connecting piping to equipment Prior to fabrication in shop or field scale or foreign materials present in pipe shall be removed After fabrication open ends of pipe lines shall be capped or plugged to keep out dirt and other 10 materials until pipe lines are connected to equipment Completed piping shall be cleaned with air steam or water flushed to the satisfaction of the Owner before final connection to the equipment 管道及设备的清洁及保护 在制造与安 装过程中 承包商应小心谨慎 防止异物进入管道及设备中 在将管道连接至设备 前 应将疏松的铁锈 融渣 焊接溅散物 泥土 油污 滑脂及其他异物从管子的 内表面予以清除 在生产厂家车间或现场实施制作之前 应清除管子内的锈皮或异 物 在制作完成之后 对管道两端开口必须用帽盖或堵头予以塞紧 以防止泥土及 异物进入内中 在将管道最后连接至设备之前 对安装完成的管道必须用空气 蒸 汽清通或者用水冲洗 直至达到满足业主之要求 VII ACCEPTANCE TESTS验收检测验收检测 a A Inspection The Contractor shall provide the Owner s representatives with access to inspect all piping during fabrication The Owner s inspection will be at his option and may include 验查 业主代表在制作安装期间将对所有管道实施 检查 对此承包商必须为之提供便利 业主是否实施检查由业主自行决定 该项检查 包括如下内容 1 Visual checks of the interior of pipe with a Borescope 使用 内孔检视 仪 对管道环焊缝之内部进行目测检查 2 Radiography of welds selected by the Owner s representative 对业主代 表选取的焊缝进行射线探伤 a The Contractor shall prepare welds selected for radiography by removing all weld surface irregularities by grinding or other suitable means to the extent that radiographic contrast resulting from the remaining irregularities cannot mask or be confused with any objectionable defect in the weld The weld surface shall merge smoothly with the pipe surface 对选定作射线探伤检 查的焊缝 承包商应作如下的准备工作 通过打磨或其他合适的方 式 除去焊缝表面的不平整 一直要到打磨后表面尚存的不平整所 造成的射线相片对比度不至于掩盖焊缝中不容许存在的缺陷 或与 这种缺陷相混淆 焊缝表面必须与管道表面平整相接 b The acceptability of the welds shall be determined in accordance with the requirements of the Code 焊缝是否合 格 其依据是本规范所立定之要求 c The Owner s representative will bear the cost of preparing and radiographing all welds which are so tested and found acceptable The Contractor shall bear the cost of preparing radiographing and repairing all welds which are not acceptable to the Owner 为进行这样的检查所作准备的费用 射线探伤的费 用 在焊缝经测试被证明为合格的情况下 将由业主代表承担 为 进行这样的检查所作准备的费用 射线探伤的费用 以及返工修补 的费用 在焊缝经测试