某气相二氧化硅项目管道与焊接中英文施工方案.doc

某气相二氧化硅项目的管道施工方案 Construction Method for Piping2.1概述 General本工程是xxxxx有限公司新建的4800吨/年气相二氧化硅项目，主要分为18个部分，管道的材料有20#钢、20/PP、0Cr18Ni9、RPM、FRP，镀锌钢管（Q235-A）。由于施工周期短，与土建交叉作业多，因此要合理安排施工任务，质量、安全、进度三者都必须保证。Cabot Blue Star Chemical (Jiangxi) Co., Ltd. 4,800t/a fumed silica project includes 18 sections, pipe material manly contains 20#steel, 20/PP, 0Cr18Ni9, RPM, FRP, galvanized steel pipe (Q235-A). Due to construction time is tight, installation works always cross civil work, so it is necessary to arrange construction reasonably, to ensure safety, quality and progress reached project target.2.1 编制依据 Compilation Basis21 设计公司的招标图 drawing for bid issued by xxx.22 GB50235-97、GB50236-982.3主要实物工作量 Major work quantity不锈钢管 S.S pipe 150m碳钢管 C.S pipe 4,900m铝合金管 Aluminum alloy pipe 370mFRP/PP 1,670m镀锌管 galvanized steel pipe 2,300m阀门 valves 680pcs.2.4施工技术措施 Construction Method2.4.1 管道安装工作程序 Piping installation procedure2.4.1.1 管道安装程序示意图 piping installation flow 管道预制管道支架预制管道清洁度检查管道支架安装质量检验射线探伤试压、冲洗、吹扫复位油漆、保温交工验收材料检验、除锈、涂底漆材料进场管道安装管道组装施工准备Piping fabricateSupport fabricateCheck cleanness of pipingErect supportQuality inspectionNDT testingTest pressure, flushing, blowing & recoverPainting & insulationCompletion & acceptanceInspect, remove rust, prime coatingMatl enter sitePiping erectionPiping fit-upPreparation2.4.1.2 施工准备（1） 技术交底：开工之前对所有参加施工的重点人员进行技术交底，使施工人员了解工程概况、工程工期、质量要求、施工程序、施工难度及技术要求，明确自己在施工过程中所承担任务的工作责任，对需持证上岗的人员进行检查。要求参加施工的人员认真阅读图纸，领会设计意图，并在进场施工之前，对所有施工人员一次全面系统的安全教育，通过技术交底，使施工人员对工程有较深的认识，加强施工人员的质量、安全意识。（2） 机具检查：对施工所需要的机具进行清点核实，查看施工设备、机具是否完好，各种电动机具及电焊机是否运转正常，安全可靠。检测工具是否齐全、完好，发现问题应及时更换或维修。（3） 所有的管材、管件、阀门、焊材等必须有材料质量证明书，其内容、形式必须符合相应材料制造标准的要求。（4） 所有的管材、管件、阀门、焊材等必须按规范要求进行外观检查，合格后做好合格标识；阀门应按要求进行强度及严密性试验，合格后作铅封，安全阀应按要求检验与调整开启压力，调试合格后，在技术监督局进行铅封；填写阀门试验记录及安全阀调试记录。不锈钢管道及组成件储存期间不得与碳钢接触，采取有效的隔离措施。2.4.1.2 Construction Preparation（5） Technical clarification meeting: All key employees involved in the installation shall participate in the installation meeting which is held prior to the actual installation so that they will have a thorough understanding of the project introduction, schedule, quality requirements, installation difficulty and Technical requirements. Check all persons involving certifications. All installation personnel shall study the drawings carefully. Proper training shall be conducted for all persons before entering the site. A deeper understanding shall be achieved through the technical meetings. Quality and safety shall always be kept in mind. （6） Check machines & tools: count all machines and tools involved in the installation. Check conditions of installation equipment, machines and tools. Check electrical machines and see if they are running normally and reliably. Check conditions of testing tools. Unqualified ones shall be replaced or repaired in a timely manner. （7） All pipes, pipe fittings, valves and welding materials, etc. shall bear material quality certificates, the content and form of which shall be in accordance with fabrication standard requirements for corresponding materials.（8） All pipe materials, fittings, valves and welding materials, etc. shall be visually inspected as per code requirements and be marked if qualified. Valves shall be tested for strength and air tightness as per requirements and be lead sealed if qualified. Safety valves shall be inspected and adjusted for opening pressure and shall be lead sealed if qualified. Finish valve testing records and safety valve adjusting records. Stainless steel pipes, alloy steel pipes and their components shall not come into contact with carbon steel during storage.2.4.1.3 材料检验（1） 所有的管材及管件和其它各种涉及到装置永久性存在的材料都必须有材料合格证，必要时应抽检、化验等。管件、管材、型材、阀门、螺栓、垫片、焊材的质量应符合设计文件、施工图纸的规定。并应按国标进行外观检查，不合格者严禁使用。（2） 可燃介质、高温、易爆介质管道阀门需逐个试验，其它管道阀门以每批中抽检10%，且不少于1个进行强度及严密性试验。当试验不合格时，应加倍抽查，仍不合格该批阀门不得使用。（3） 阀门壳体的试验压力取公称压力的1.5倍，试验时间10分钟，以壳体填料无渗漏为合格。密封试验以公称压力进行，以阀瓣密封面无泄露为合格。（4） 试验合格的阀门及时排尽内部积水，并吹干，密封面涂防锈油，关阀门，封闭出入口，做明标记，并填写“阀门试验记录”。（5） 管道组成件及支承件在施工过程中按业主要求妥善保管，不得混淆或损坏，其标记应明显，暂时不能安装的管材应两端封闭，不锈钢材料应特别注意不得与其它碳钢材料堆放，防金相腐蚀（渗碳）。（6） 管材、（管件）检验主要参照下述标准:GB2270-80、GB8163-87、 HGJ46-91、 HGJ20615、 GB50235-97。（7） 从业主领用的材料或乙方自采购的材料应分门别类堆放，妥善保管，发出的材料应有工程师的签字方可发放。2.4.1.3 Material Test & Inspection（1） All pipes, fittings and valves and other involved with permanent facilities of the Plant shall be provided with manufacturer quality certifications and be checked for size, type and material before use. 。（2） For Inflammable medium, high temperature or explosive pipe valves, it is necessary for test to be done one by one; for other pipe valves, test to be done by 10% of every batch, and at least 1 piece shall be done with strength and tightness test. （3） The test pressure for valve case shall be 1.5 times of its nominal pressure, which test time shall be 10 minutes, and no leak from case stuffing is as eligible. Sealing test pressure shall be nominal pressure of it, after no leak from seal face of valve clack, it can be regarded as eligible. （4） Qualified valves shall be free water in time, and dry it out, seal face shall be laid with anti-rust oil, then turn off valves, close inlet and outlet, make identification, and fill in “Valves Test Record”. （5） Piping components and supports shall be in good custody as per requirement of THE OWNER, avoid confusion and damage, which marks shall be clear, for piping erected later, which both ends shall be closed, and for stainless steel material, attention shall be paid that shall be isolated away C.S. material to prevent from corrosion of metallurgical phase (carburizing). 。（6） test & inspection of pipe material and fittings mainly refer to following codes and standards:GB2270-80、GB8163-87、 HGJ46-91、 HGJ20615、 GB50235-97.（7） It is necessary for material taken delivery from the owner or construction contractor purchased material to be stored in good order, and material cannot be issued until engineer make signature. 2.4.2 管道预制管道预制拟定在施工临设规定的管道预制厂的专门的预制平台上进行，这样既改善工作环境，又保证施工质量。Pipe fabrication is to be performed in dedicated prefabrication shops inside of battery limit of the plant so as to improve working environment and ensure installation quality. 2.4.2.1 管道清洁度检查：预制前对所需用的管道进行内部和外部的清洁程度检查，如果内部有铁锈、碎屑、油污等杂质，应用压缩空气进行清理，直到检查合格后，才能投入使用。Pipe cleanness check: cleanness check shall be performed for internal and external of required pipes prior to prefabrication, any rust, debris, grease or other foreign matters shall be removed using cloth, compressed air, iron wire or sandblast and shall be inspected by THE OWNER prior to use. 2.4.2.2 钢管切割（1） 按提供的管道布置图进行选材下料，并在图上标识管段号。管子下料之前，应将管道上原有标记进行移植；（2） 小口径钢管采用切割机切割，然后用坡口机坡口；大口径碳钢管（6以上）用切割机无法切割时，可采用氧乙炔切割并打磨坡口。不锈钢管4以下采用砂轮切割机切割，6以上不锈钢管道采用等离子切割机切割。在管道预制车间的钢平台上操作时，应用橡胶板铺设在平台上进行隔离；（3） FRP/PP管、铝合金管采用细齿钢锯切割.（4） 钢管切割的质量要求是：切口表面应平整，不得有裂纹、重皮、毛刺、凹凸等缺陷，如有应予以清除。（5） 切口端面斜偏差外径的1%，且不得超过3mm。（6） 切割之后的钢管应及时在每一个管段上用油漆或记号笔标明钢管的材质、规格、管线号，并根据施工图纸标明所使用的位置。2.4.2.2 Steel Pipe Cutting （1） Select material in accordance with the isometric drawing provided by THE OWNER, pipe segment number should be marked on the drawing. Transplant existing marking on the pipes prior to cutting. （2） Small sized steel pipes shall be cut using cutting machine and be beveled using bevel machine; large sized (above 6”) carbon steel pipe that are impossible to be cut by cutting machine can use oxy acetylene for cutting and the bevel shall be ground. Stainless steel pipe size below 4” will use abrasive wheel cutting machine, and those above 6” shall use plasma-cutting machine. For fabrication on the steel platform in the prefabrication shop, rubber sheets shall be laid on the platform for separation. （3） FRP/PP pipe and aluminum alloy pipe shall be cut with serrating hacksaw. （4） Quality requirements for steel pipe cutting: the cut surface shall be flat without any cracks, laminations, burrs, pitting or other defects, if exist, they shall be removed. （5） Bevel end slope deviation 1% of O.D of pipe, and not more than 3mm. （6） For steel pipes that are already cut, use paint or marking pen to mark on each pipe segment the material, specification and line number for the steel pipe, their service locations shall be marked on AFC drawings. 2.4.2.3 坡口加工（1） 根据设计院提供的管道施工规范（GB50235-97）中的技术要求，坡口加工应按下列图表进行：a. 管壁厚度小于等于2.5mm坡口形式按下图b. 当管壁厚度为2.520mm时坡形式按下图。t2.5992070+560-5b1223p1223c. 不等厚管子、管件组对时，如果内壁错边量大于1.0mm或外壁错过量大于2mm时按下图形式进行修整。2.4.2.3 Bevel chamfering（2） In accordance with piping construction code (GB50235-97) supplied by design institute, bevel chamfering shall be executed as per following figure: a. For pipe wall thickness2.5mm, the bevel type as following figure: b. For pipe wall thickness2.5mm, and 20mm, the bevel type as following figure:t2.5992070+560-5b1223p1223c. When fit up different thickness pipes or fittings, if offset of pipe inside is over 1.0mm, or offset of pipe outside is upper 2mm, repair shall be done as following figure: 2.4.2.4 管道的组对（1） 管道预制的组对工作，在管道加工平台上进行，组对不锈钢管时平台上应铺设3mm的橡胶板，同碳钢板进行隔离。不得用碳钢器皿打击不锈钢管。管道组对允许偏差按管道允许偏差进行检查，其检验方法是用角尺、钢板尺、钢卷尺测量。（2） 自由管段和封闭管段选配应合理，封闭管段应按现场实测后的安装长度加工。（3） 自由管段和封闭管段的加工尺寸允许偏差应符合下表规定：项 目允 许 偏 差自 由 管 段封 闭 管 段长度101.5法兰面与管子中心垂直度D1000.50.5100DN3001.01.0DN3002.02.0法兰螺栓孔对称水平度1.61.6（4） 管支架制作在管道预制的同时可以进行管道支架的制作。管架制作的型式结构、材质、加工尺寸、制作精度应符合设计院提供的管支架标准的要求，外观应平整美观，焊接应牢固，无漏焊、欠焊、裂纹等缺陷，焊接表面应光洁，无飞溅物，焊接变形应予以矫正，制作好的管支架应及时进行防锈处理，并作出标记。2.4.2.4 Piping fit-up（1） pipe assembly shall be done on the pipe fabrication platform. For stainless steel assembly, 3mm rubber sheets shall be furnished on the platform for separation against carbon steel plate. Carbon steel tools are not allowed to strike stainless steel pipes. Assembly tolerance shall be checked against allowable pipe tolerance. The inspection method involves measurement with Angle Square, steel plate ruler and steel tape. （2） It shall be reasonable for Selection and arrangement of free spool and close spool, construction for close spool shall be as per installation length measured at site. （3） Allowable process size deviation for free spool and close spool shall be in conformity with following table requirement: Item Allowable deviationFree spoolClose spoollength101.5Center verticality between flange and piping. D1000.50.5100DN3001.01.0DN3002.02.0Symmetrical levelness of flange bolthole. 1.61.6Pipe support fabrication: pipe support can be fabricated as the pipes are prefabricated. The supports shall be fabricated such that their form, material, dimension, accuracy meet requirements in the pipe support standard provided by CO. The surface shall be flat. The welding shall be fixed without defects like missing weld, insufficient weld or cracks. The welding surface shall be smooth without any spatters. Any welding distortion shall be corrected. Rust-proofing treatment shall be performed for fabricated supports in a timely manner, and shall be properly marked.2.4.2.5 管道焊接（1） 在管道焊接之前，应具备焊接工艺评定、焊工合格考试并取证、焊接工艺卡、焊接材料根据焊接母材作相应的选定。（2） 焊工应根据焊接工程师所提供的工艺卡进行施焊，不允许在雨天、雾天、相对湿度超过90%，风速超过8m/s除非采取相应的保护措施。（3） 焊条根据要求，由专门烘烤工实施干燥，不同烘干温度的焊条不得在同一烘箱中烘烤，不同牌号的焊条应作出相应的标记。没有用完的焊条应及时回收，超过烘烤次数的焊条应禁止使用。焊工必须使用正规焊条筒领用焊条。（4） 在点焊之前，应仔细检查坡口、表面、并进行相应的清理，管内无杂物，焊接坡口端50mm以内的表面应打磨干净，呈现金属光泽，方可点焊。（5） 管道对接焊口的组对应做到内壁平齐，内壁错边量不宜超过壁厚的10%，且不大于2mm，不等壁管道施工时，应注意修整。（6） 当焊接完成时，在管道轴测图上标注焊口号，焊工号。（7） 预制完成的管线，管口端应用管帽（塑料）封堵，防止脏物进入。（8） 本工程各钢种选用的焊丝、焊条如下：Weld rod & wire (applied in this project) as follows钢 号steel No.手弧焊焊条manual welding rod氩弧焊argon arc welding20#J422H08Mn2SiAQ235AJ4220Cr18Ni9A102H0Cr20Ni10TiALSALMg-X2.4.2.5 Piping welding（1） Welding procedure qualification, welder qualification examination, welding process card and welding material (choice as per base metal)shall be conducted prior to pipe welding. （2） Welders shall comply with welding process card issued by engineer to execute welding work. No welding is permitted in raining, foggy weather, or when humidity exceeds 90%, or when wind speed exceeds 8m/s. （3） Welding electrodes shall be dried as per requirement (skilled person will be in charge of welding electrode drying work, strict electrode issuing record system shall be carried out). Meanwhile, different brands of electrodes shall be identified with different color marking or other types of marking at the electrode ends. Wrong electrode will directly affect weld quality. Therefore, welders shall request for electrodes with electrode request sheets issued by the installation technician, and shall use formal electrode dryer. （4） Welders shall check assembly conditions prior to tack welding. The bevel angle, butt clearance and internal wall unfitness shall be as per welding procedure sheet. The surface within 50mm of the welding bevel end shall be ground till sound metal prior to tack welding. （5） Pipe welding procedure shall be in accordance with the corresponding welding procedure sheet. Slag and spatter shall be removed immediately after welding. The weld surface shall be cleaned and visually inspected. （6） When welding is finished, mark the welder No., crater No., welding date on the corresponding crater. Marking shall be done accordingly on the single-line diagram. （7） Fabricated pipeline shall have their ends covered with pipe caps (plastic) to protect ingress of foreign matters.2.4.2.6 焊接检查（1） 焊缝外观检查a. 不允许有裂纹、未溶合、气孔、夹渣、飞溅存在；b. 咬边度0.5mm，焊缝两侧咬边总长不大于该焊缝全长的105，且不应大于100mm；c. 焊缝表面不得低于母材表面，焊缝余高应符合GB50236-98提供的焊接规范要求；d. 焊接接头错边量不应大于壁厚的10%，且不大于2mm。（2） 焊缝质量：管道焊缝质量检查按设计院提供管道施工规范（GB50235-97）中的有关焊缝检查的标准进行。（3） 焊接合格的焊缝应及时填写管道焊接记录，记录应整洁、准确、工整、对不合格片应严格进行返修，然后用原方法作射线无损检测，检查合格的焊口应在单线图或焊接记录上作出相应的标识。2.4.2.6 Welding inspection（1） Weld visual inspectiona. No cracks, lack of fusion, porosity, slag inclusion or spatter are permitted.b. Undercut shall be less than 0.5mm, total undercut length on both sides of the weld shall not be larger than 10% of total weld length, and shall not be larger than 100mm; c. The weld surface shall not be lower than that of base metal, excess weld metal shall be as per code requirement provided by design institute; d. Weld joint unfitness shall not exceed 10% of wall thickness, and shall not be larger than 2mm.（2） Weld quality: pipe weld quality inspection shall proceed as per relative weld inspection requirements in the pipe installation code (GB50235-97) provided by design institute.（3） Fill in pipe welding records for qualified welds and enter proper qualification data into the computer. The record shall be tight, accurate and clean. Unqualified product shall be repaired and radiographed by the original method, and shall follow code (H-331) requirement. Qualified crater shall be accordingly marked on the single-line diagram or welding record. 2.4.3 管道安装前应具备的条件2.4.3.1 与管道安装的土建或钢结构工程已检验合格，满足安装要求，并办理好交接手续；2.4.3.2 与管道连接的设备已找正合格，固定完毕；2.4.3.3 管道内部清洁度已检查合格，对管内有特殊要求的管线其质量应符合设计文件的要求；2.4.3.4 设计需要修改的位置及管道上的开孔应在安装之前完成。2.4.3 Conditions before installation2.4.3.1 Civil or structure works associated with pipe installation have been completed and inspected to be satisfactory for pipe installation. Proper handover has been done;2.4.3.2 Equipment to be connected with the pipes are aligned and fitted;2.4.3.3 The pipe internal cleanness has been inspected. For pipelines with special requirements for their internal, their quality shall be as per requirements in the design documents;2.4.3.4 Location modifications required by design and opening on the pipe shall be completed prior to pipe installation.2.4.4 钢制管道安装2.4.4.1 管道安装时，应检查法兰密封面及密封垫片，不得有影响密封性能的划痕、斑点等缺陷。2.4.4.2 法兰连接应与管道同心，并应保证螺栓自由穿入。法兰螺栓应跨中安装。法兰间应保持平行，其偏差不得大于法兰外径的1.5%，且不得大于2mm，不得用强紧螺栓的方法消除歪斜。2.4.4.3 工作温度低于200的管道，其螺纹接头密封材料宜选用聚四氟乙烯带。拧紧螺纹时，不得将密封材料挤入管内。2.4.4.4 法兰连接应使用同一规格的螺栓，安装方向应一致。螺栓紧固后与法兰紧帖，不得有楔缝。需加垫圈时，每个螺栓不应超过一个。紧固后的螺栓与螺母宜齐平。2.4.4.5 当管道安装处于露天或处于大气腐蚀环境时，螺栓、螺母应涂以二硫化钼油脂、石墨机油或石墨粉。建设单位另有要求时，按建设单位要求进行。2.4.4.6 管子对口时应在距接口中收200mm处测量平直度（见下图）。当管子公称直径小于100mm时，允许偏差为1mm，当管子公称直径大于100mm时，允许偏差为2mm。全长允许偏差10mm。2.4.4.7 管道对口平直度（1） 管道连接时，不得用强力对口、加偏垫或加多层垫等方法来消除接口端面的空隙、偏隙、错口或不同心等缺陷。（2） 支管与主管连接时，当工艺要求按介质流向倾斜，倾斜度按设计规定。2.4.4.8 管道安装允许偏差应符合下表规定：（单位：mm）项 目允 许 偏 差坐标架空及地沟室外25室内15标高架空及地沟室外20室内15水平管道平直度DN1002L,最大50DN1003L,最大80立管铅垂度5L,最大30成排管道间距15交叉管的外壁或绝热层间距202.4.4.9 膨胀节安装时，按设计要求进行予拉伸，允许偏差10mm，拉前将固定管托焊接牢固。2.4.4.10 阀门安装（1） 阀门安装前，应检查填料，其压盖螺栓应留有调节余量。（2） 阀门安装前，应按设计文件核对其型号，并应按介质流向确定其安装方向。（3） 当阀门与管道以法兰或螺纹连接时，阀门应在关闭状态下安装。（4） 水平管道上的阀门，其手柄方向宜安装在上半周范围内，阀门操作和机构应灵活，指示准确。2.4.4.11 支架安装（1） 管道安装时，应及时固定，高调整支架。支架位置应准确，安装应平整牢固，与管子接触应紧密。（2） 有热位移的管道，导向支架或滑动支架的滑动面应洁净平整；不得有歪斜和卡涩现象。其安装位置应从支撑面中心位置向位移反方向偏移，偏移量应为位移量的1/2，或符合设计规定，绝热层不妨碍其位移。（3） 固定支架应严格按设计规定执行；在一直管线上不得有两个以上固定支架。（4） 管道安装时不宜使用临时管架，当使用临时管架时，支架不得与正式管架位置冲突；并应有明显标记。在管线安装完毕应予拆除。（5） 管道安装完毕后，应按设计文件规定逐个核查支架形式和位置。a 活动架的位移方向及导向性能应符合设计规定。b 管托不得脱落。c 固定支架牢固可靠。2.4.4.12 伴热管安装（1） 伴热管应与主管平行安装，多个伴热管在主管圆周上的分布按设计要求布置。（2） 不允许将伴热管直接点焊到主管上，伴热管的固定按设计要求进行。（3） 伴热管的其他安装同主管的要求相同（包括伴热管的压力试验吹扫）。2.4.4 Steel Pipe installation2.4.4.1 For pipes connected to static equipment, no additional stress is allowed with flanged connection. The equipment openings shall be covered with sheet steel or asbestos rubber plate for separation;2.4.4.2 Flange connection shall keep concentric with piping; ensure bolts can be free into holes. Flange bolts shall be set at striding to center method. Parallel shall be kept between flanges, which deviation shall be not more than 1.5% of O.D of flange, and n