南海石化工艺管线施工技术方案

1、南海石化工艺管线施工技术方案Construction Technique Scheme for Process Pipelines1 工程概况 我公司承建的中海壳牌石油化工有限公司南海石化项目苯乙烯、 环氧丙 烷及丙烯乙二醇装置位于广东省惠州市大亚湾区海畔 .该项目由德悉尼布天辰 化学工程(天津)有限公司设计，所处地区环境干燥温度最高385C，最低2.3 C,潮湿温度28.1C，空气湿度大，雨期较长。2.12.22 编制依据 德悉尼布天辰化学工程(天津)有限公司提供的工艺管道施工图； 工艺管道设计技术交底(会议纪要) ；2.4石油化工剧毒、可燃介质管道工程施工及验收规范 (SH3501-199

2、7)；2.52.62.72.82.92.102.112.12工业金属管道工程施工及验收规范 (GB50235-97)； 现场设备、工业管道焊接工程施工及验收规范(GB50236-98)；埋地钢质管道环氧煤沥青防腐技术标准 ( SY/T0447-96)； 石油化工钢制通用阀门选用、检验及验收规范( SH3064-94) ；石油化工设备和管道隔热技术规范 (SH3010-2000)； 工业设备、管道防腐蚀工程施工及验收规范 工业设备及管道绝热工程施工及验收规范 石油化工工程铬钼耐热钢管道焊接技术规程( HGJ229-91)；GBJ126-89)；( SHJ520-91)；2.132.142.152

3、.162.17电力建设施工及验收技术规范 (管道篇 )DL5031-94 电力建设施工及验收技术规范 (火力发电厂焊接篇) DL5007-92 石油化工企业设备管道表面色和标志 SH3043-1991 石油化工异种钢焊接规程 SH3526-1992 石油化工铬镍奥氏体钢、铁镍合金和镍合金管道焊接规程 SH3523-19992.18压力容器无损检测(JB4730-94);2.192.202.212.222.232.24石油化工施工安全技术规程 (SH3505-99)； 工程建设交工技术文件规定 (SH3503-93)；50 万吨 /年延迟装置施工组织设计 ； 压力管道安装质量保证手册 (QG/M

4、4441.50.00-1999)； 压力管道安装质量程序文件 (QG/P4443.50.00-1999)； 压力管道安装工艺标准 (QG/4441.52.00-1999)； 压力管道安装竣工技术文件规定 ( QG/M4441.53.00-1999)。2.253 工艺配管的特点：The character of pipe erection3.1 PTA 装置中易燃，易爆及腐蚀性介质的管道较多，且物料大多为浆料 和粉料，有强烈腐蚀性，故配管材料选用要求严格。 本装置中大量使用超低碳不锈钢， 包括 304L、316L、317L 等，并有少量钛管、海氏合金管及塑料管。IN PTA installati

5、on, there are many pipes with inflammable, explosive a nd corrosive medium, most of which are slurry and powder with strong corr osion. Therefore the required material of pipe erection is very strict. In this installation, we not only use a lot of low carbon stainless steel with specific ation of 30

6、4L,316L and 317L.but also some titanium pipe, alloy pipe and pl astic pipe.3.2 本装置动设备较多，必须保证无应力配管，不得对设备施加外力。配 管应从设备开始向设备外配管， 配管过程中应及时设置管道支吊架， 不得让设 备承担管道系统的重力。There are many movable equipments in the installation, we need ensur e pipe erection without stressing, and cannot impose external force on th

7、e e quipments, In the pipe erection, we need start from the equipment inside, an d then the outside of the equipments. We need set up the pipe rack in time to avoid the gravity from the pipe system.3.3 本工程管道焊接量大，需要投入大批量的优秀焊工。我公司目前有压 力管道持证焊工 685 名，能够保证焊接要求。 如我公司中标本项目， 将派出具 有行业及国家级先进水平的优秀焊工来承担本工程的焊接任务

8、， 能够确保装置 的长期有效地运行。The pipe welding quantities is very heavy in the project. It needs prov ide a large number of qualified welders. Now our company has 685 welders with certificates, which can comply with the welding requirements. Once te ndered, we will send qualified welders to bear the welding tas

9、k of the proje ct, All the welders have much experience and advance technique, which can ensure the erection in good quality in a long time.3.4本装置工艺配管工程量大，共有各类管道132km。为提升劳动效率，加快施工进度，我们将大力推进管道自动焊，实行管道预制工厂化、产品化。 我公司有各种型号的自动化焊机多台， 在管道预制过程中， 配以高纯度氩气 （9 9.99%）的气体爱护管道自动焊，能够极大地提升劳动效率，有效地抑制焊接 接头部位的氧化，保证接头内部

10、平坦、外型美观。 .6.3.1.4 The quantities of Process pipe erection is heavy, It includes all kinds of pipeof 132km.In order to enhance the work efficiency and speed the constru ction progress, we will try our best to push pipe automatic welding and perf orm pipe prefabrication in market. There are many autom

11、atic welding machi nes with models in our company. In the process of pipe erection, the applic ation of arc protection automatic welding machine with high purity of argon can improve the work efficiency, hold back the oxidization of the location of welding joint, and ensure the inside of joint flat

12、and on good look outsid e.4 管道安装工程量The qua ntities of pipe erecti on类别Type材质Material规格（mmSp ecificati on质量（t）Quality数量（m）Qua ntity管材Piping+materialC . S1/2 54878.0462813S . S1/2 80315.138850钛材Tita nium3/4 8038.53650合金钢Alloy steel3/4 3613.53630铜管Copper pipe1/2 3/417.2728403塑料管P lastic Pipe3/4 561.497

13、06法兰Fla nge114.92配件Fitt in gs255.3阀门Valve273.21弹簧支撑SpringSupporting11.88其它支撑Othersupporting157.45、管道材料检验Pipe material inspection 管道施工材料的质量保证是施工质量的基础。 我公司具有一套成熟可行的 原材料检验治理制度， 我们将按照具体工程特点建立健全切实可行的材料检验 治理体系以提供质量保证。The quality assurance of pipe construction material is the basis of the c onstruction qua

14、lity. Our company owns a available and mature management s ystem of material inspection and we will adjust it according to the actual pr oject character for quality ensure.5.1 成立专门的检验小组实施统一的管材管件检验， 并按照相应标准组织 检验。Setting up a inspection group for pipe material and fittings che ck, and inspecting with

15、relative standard.5.2 材料检验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。Setting up a independent inspection area for material examination, and divide it into waiting inspection area ,inspection area, qualified producti on area and unqualified production area.5.3 训练有素的检验人员将严格按照以下检验工艺进行检验：The trained person will

16、strictly inspect material complying with t he following procedure:管材、管件接收Pipe material, fittings acceptance 品种、规格、数量检查Brand ,specification and quantities inspection 外观质量检查Configuration quality inspection 材质检查Material quality inspection 质量验证Erection quality inspection 产品标识和检验状态标识Production identifica

17、tion and inspection in situation identification5.4 管道组成件的检验Piping fitting inspection5.4.1 不锈钢管子、管件（包括螺栓、螺母） ，应用光谱分析仪对材质的要 紧化学成份进行复查，并作好检验状态标识。Stainless piping and fittings (including bolts and screw nuts) sha ll be rechecked chemical combinations by spectrum analyzer, and located in inspection situa

18、tion.5.4.2 螺栓、螺母的螺纹应完整、无划痕、毛刺等缺陷，并应配合良好， 无松动或卡刺现象。The screw thread shall be free from defects such as deformities, scratches and irregular of distance between thread to thread, and shall be in good quality without loosening and jamming .5.4.3 法兰密封面、缠绕垫不得有径向划痕、松散、翘曲等缺陷，石棉垫 表面应平坦光滑，不得有气泡、分层、折皱等缺陷。The

19、area between flange to flange and circle pad shall be protected from scratches loosening, twisting and so on. The surface of asbestos shall be flat and smooth , and be free from bubbles ,multi-layers ,crease and so on.5.4.4 阀门检验Valve inspection5.4.4.1阀门试验、检验前，专门成立阀门检验、试验小组，其成员应由施 工班组、有关技术人员和质量检查人员组成

20、。同时必须进行专门的技术交底， 并配置相应的工装设备。We will set up a valve check and test group before valve inspection, which include construction team, relative technique personnel, quality ins pector. Meanwhile We will transfer necessary technique information and ass emble proper work equipment.5.4.4.2 阀门检验、试验程序见图 3-1。Th

21、e valve inspection and test procedure see drawing 3-1 5.4.4.3阀门试验应从每批中抽查 10%，且许多于 1 个，进行壳体压力试验 和密封性试验。 当不合格时， 应再抽查 20%抽查，仍旧不合格时， 该批阀门不 得使用。10% of valves shall be take for inspection from each batch of it. And no less than 1 piece to shell pressure and densification test. In cas e it is not qualified

22、, another 20% of it shall be rechecked. If unqualified ag ain, the valves cannot be used.5.4.4.4 阀门的壳体压力性试验和密封性试验必须用洁净水进行。不锈钢 阀门试验用水的氯离子含量不得超过 25ppm.Clean water should be used in the valve shell pressure and de nsification test .The content of chlorine used in stainless steel valve should not overpa

23、ss 25ppm5.4.4.5阀门的壳体试验压力应为公称压力的 1.5 倍；试验时刻不得少于 5 min，以壳体、填料无渗漏为合格。Valves shell tested pressure should be 1.5 times of nominal pressure , a nd the test should last 5 minutes, It will be qualified in the case of shell a nd packing be free from leakage.图 3-1 阀门检验、试验工艺流程图Drawing 3-1 Valve Inspection and

24、 Test Flow Planprep arati on yard不合格品处置Nonq ualified p roduct ion dis posal交付安装Erect ion available5.446除止回阀、节流阀外，阀门合格密封试验宜以公称压力进行，以阀瓣 密封面不泄漏为合格。Except back and throttling valves, valve qualified inspection shall be det ermined by nominal pressure and no leakage in the densification area of val ve p

25、etal.5.447公称压力小于1MPa,且公称直径大于等于600的闸阀，壳体压力 试验宜在系统试验时，按系统的试验压力进行试验，闸板密封试验可采纳色印 等方法进行检验，接合面上色印应连续。As for the gate valve with nominal diameter more than 600 and nom inal pressure less than 1Mpa, When doing the shell pressure test, It is better to exam ine accord ing to the system test ing p ressure. Sli

26、de p late may use th e color papers for testing and the continuation area should be continued.544.8合金钢阀门的壳体材质必须逐件进行快速光谱分析，不合格时该 批阀门不得使用。The shell material of alloy steel valve should be analyzed one by one by high speed spectra. If unqualified valves in it, this batch of val ves are forbidde n to us

27、ing.5.4.4.9试验合格的阀门，应及时排净内部积水、吹干密封面上应涂防锈油， 关闭阀门，封闭出入口。Internal water in the valve acceptable should be drained in time and density area should be dried and coated with rust preventive oil. The valv e should be closed .The egress and in gress should be closed.5.4.4.10安全阀按设计文件规定的定压值进行调试，承诺偏差为士 3%。调试介质：

28、管道内介质为气体时，优先酇用氮气调试；管道内介质为液体时，应 使用液体调试。调压时的压力应稳固，每个安全阀启闭次数为3次。要求起跳 压力明显，无前漏、后漏现象。由于安全阀进出口压差较大，不进行壳体压力 试验，密封试验时，压力小于定压值，不得泄漏，可在安全阀出口贴纸进行目 测。Constant pressure of safety valves should be adjusted according to the d ocument regulations and +/-3% deviation is permitted. We will use different mediums as fo

29、llows according to the specified conditions: Using nitrogen firs t in case of air in the piping . Using liquid in case of liquid in the piping.The pressure should be stable when adjusting and every safety valve should be opened and closed three times. The up and down pressure should be cle ar withou

30、t internal and external leakage. Because the pressure deviation betw een safety valves ingress and egress is relative far ,the pressure is less than its constant pressure in density test .in this condition, the leakage is not per mitted and the labels can be made on safety valve ingress and egress f

31、or vi sual check.5.5 质量检验人员均对检验过程做出详实的检验记录，以备随时查证。 Quality inspector shall make detailed inspection record for ver ifying anytime.5.6 装置区工艺管道材料经检查合格后，均将做出不同色标加以标识。防 止施工过程用错材料， 并方便检查人员监查确认。 各种管道配件在易于辨认处 做出两处标识，各种管材、型材均做出通长标识。After checked qualified ,the piping material shall be identified with diffe

32、rent color tags ,which can avoid mistake of material utilization and make a convenience for supervisor checking and assurance.Two tags shall be made on the clear area of every kind of piping fittings and general tags shall be made on every kind of tube material and shape steel.6 管道的预制加工Piping prefab

33、rication and processing6.1 为了减少现场预制带来的技术治理、 材料治理、设备治理的工作负担， 搞好文明施工，开创第二现场，设置管道预制场地，进行管道的工厂化、产品 化的预制加工， 而后再在现场进行安装。 管道预制加工厂设有轨道式天车、 车 床、摇臂钻床、剪板机、坡口加工机、自动焊机等施工机具。We have track crown blocks, lathes, beam drills, plate shears ,groove pr ocessing machine and automatic welding machines in the piping prefa

34、bricatio n yard to avoid field work bearing such as technique management ,material management and equipment management, make housekeeping ,develop the se cond site, set up piping prefabrication yard ,make piping prefabrication proc ess in the market and then erect in the jobsite6.2 预制前认真核对单线图与平面图，核对

35、基础、设备、管架、预埋件、 预留孔是否正确，关于最后封闭的管段应考虑组焊位置和调剂裕量。Before prefabrication, We will check the isolated drawings and plans car efully , align the foundations ,equipments, pi pe frames embedded parts an d preformed holes in correct, and consider the welding position and adjust t he size under the actual constr

36、uction condition to the piping sections closed last.6.3 管道预制应按单线图规定的数量、规格、材质选配管道组成件，预制 过程中的每一道工序均应核对管子的标记， 并做好标记的移植， 做到用料正确、 尺寸准确、标识明显。In piping prefabrication progress, We will purchase piping fittings according to the specification, quantities and material quality formed in isolat ed drawings. We

37、will check the piping tags in every steps and make change d tags in good consequencefor using correct material and size and making clear tags.6.4 钢材的切割及管道坡口的加工应采纳以下方法： 镀锌钢管和公称直径 50的碳钢管，采纳机械切割，公称直径大于DN50的碳钢管采纳氧乙炔焰 法切割；不锈钢管应用机械或等离子的方法切割，304L、316L和317L材质 的钢管用砂轮切割或修磨时， 应有专用砂轮片。 管子切口表面应平坦、 无裂纹、 重皮、毛刺、凸凹、

38、缩口、熔渣、氧化物、铁屑等。Steel material cutting and piping groove process should use methods as follows;For galvanized steel tubes and carbon steel tubes with nominal diamete r 8m/s in SMAW, the wind velocity is 2m/s in arc welding.相对湿度 90%;Relative moisture is 90%雨；Raining7.1.6 焊接完毕后，及时在焊缝两侧 50mm 范畴内打上焊工钢印号，不

39、锈 钢钢管不做钢印标识，然而应在管道单线图上标注清晰。Welder s stamps NO. shall be made in the 50mm range awa y from welding joints in time, Rebar marks will not be done in stainiess st eel tubes, but it should be in dicated in piping isolated draw in gs.7.2焊接材料的选择Welding Material AlternativeList for Welding Material Alternat

40、ive焊接材料选用表 5-1序号管道材料焊丝焊条备注No.Piping materialWeldi ng wireWeldi ng rodRemarks1API5L GR BER105-2E7016-152ANSI 304ER308E308-163ANSI 304LER308LE308L-164ANSI 316ER316E316-165ANSI 316LER316LE316 L-166ANSI 317LER317LE317 L-167C276ERNiCrMo-4En iCrMo-48TI 1ERTi-17.3奥氏体不锈钢管道焊接Sta in less piping weldi ng731奥氏体

41、不锈钢焊接坡口形式和尺寸应符合下表的规定:The groove spec and size of sta ini ess steel tubes should complywith following regulation:焊接坡口形式和尺寸Weldi ng Groove Type and Size 5-2732奥氏体不锈钢管道焊口组对质量应符合以下要求:Stainiess piping welding mouth to mouth should comply following requirements:7.3.2.1管口应做到内壁平齐，其错边量不应超过壁厚的10%，且应W 0.5mm;Th

42、e in side wall of piping mouth shall be flat and smooth, the misalignment shall not be more than 10% of wall thickness, and should be less tha n or equivale nt to 0.5mm7.3.2.2焊接坡口应经砂轮打磨，坡口应整齐光洁，坡口表面的油污、锈蚀 和坡口两侧各10 15mm范畴内的氧化层应清理洁净，清理范畴内应无裂纹、 夹层等缺陷。Welding groove should cleaned by abrasive wheel ,Gro

43、ove shoul d be flat and smooth, The oil ,rusting and oxidization of groove surface should cleaned very well. In clean range should have no defects such as cracki ng and double layers.7.3.3奥氏体不锈钢焊接时，应采纳小规范、短电弧、快速焊和窄焊道工艺进行焊接，并应操纵层间温度不得超过 150C，必要时，应采取强制冷却措 施。In stainless steel welding operations, We wi

44、ll weld with process suc h as small specification, short arc, and high speed welding and narrow weldi ng. And will control the interpass temperature less than 150.If necessarywe will use cooling measures in force.随焊接随掀开； 安装 采取局部充氩的方法 待坡口处有氩气平均7.3.4为保证管口背面焊接成型质量，奥氏体不锈钢管道焊接全部采纳氩 弧焊打底。打底焊接时，管道内应充氩爱护。 预

45、制管口焊接时应采纳整体充氩， 充氩时管子两端应进行封堵， 焊口处应用医用胶布密封， 管口焊接时， 应在焊口组对前， 在焊口内部放置易溶纸， 进行充氩爱护。 充氩时， 应将管口内部的空气置换洁净， 流出时方可进行焊接。 氩弧焊打底焊接后， 应及时进行打底焊缝的检查， 确认 打底焊缝合格后方可进行次层焊道的焊接，以防产生打底焊接缺陷。In order to ensure the welding shape quality of pipe mouth backing, Al l stainless tubes welding should use argon arc welding to make

46、a bottom, When making the bottom. Argon should be filled the tubes. We should fill argon when prefabricated tubes mouth welding, it should be done in the con dition of two tube mouths are closed. The welding area should sealed with hospital adhesive tape and opened with welding progress. When erecting t he tubes w