某气相二氧化硅项目管道与焊接中英文施工方案

1、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、0Cr18Ni9s RPM、FRP,镀锌钢管(Q235-A)。由于施工周期短，与土建交义作业多，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 ma

2、terial manly contains 20#steel, 20/PP, 0Cr18Ni9, RPM, FRP, galvanized steel pipe (Q235-A). Due to construct!on time is tight, installation works always cross civil work, so it is n ecessary to arrange con struction reas on ably, to ensure safety, quality and progress reached project target.2.1 编制依据

3、Compilation Basis2. 1 设讣公司的招标图 drawing for bid issued by xxx.2. 2 GB50235-97、GB50236-982.3主要实物工作量Major work quantity不锈钢管S.S pipe150m碳钢管 C.S pipe4,900m铝合金管 Aluminum alloy pipe370mFRP/PP 1,670m镀锌管 galvanized steel pipe 2,300m阀门 valves680pcs.2.4 施工技术措施 Construction Method2.4.1 管道安装工作程序 Piping installat

4、ion procedure2.4.1.1 管道安装程序示意图 piping installation flow2.4.1.2 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

5、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；阀门应按要求进行強度及严密性试验，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) Technica

6、l 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 an

7、d Technical requirements. Check all persons involving certifications. All installation personnel shall study the drawings carefully. Proper training shall be con ducted for all pers ons before entering the site. A deeper understanding shall be achieved through the technical meetings. Quality and saf

8、ety 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. Unqua

9、lified 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 accordanee with fabrication standard requirements for corresponding materials (8) All pipe

10、 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 openin

11、g pressure and shall be lead sealed if qualified Finish valve testi ng records and safety valve adjusti ng records Stain less steel pipes, alloy steel pipes and their comp orients shall not come into contact with carb on steel duri ng 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

12、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15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

13、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 pe

14、rmanent 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 d

15、one 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 p

16、ressure 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”.(

17、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. ma

18、terial 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

19、con tractor purchased material to be stored in good order, and material cannot be issued until engineer make signature2.4.2 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 fabricatio n is to be performed in dedicated prefabricati on shops in side of battery limit of the plant so as to imp

20、rove 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 othe

21、r foreign matters shall be removed using cloth, compressed air, iron wire or sandblast and shall be inspected by THE OWNER prior to use2.4.2.2 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，可采用氧一乙烘切割并打磨坡口。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

22、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aS外径的1%,且不得超过3mrm（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 accordanee with the isometric drawing provided by THE OWNER, p

23、ipe 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 ca

24、n 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 platfor

25、m for separation.(3) FRP/PP pipe and aluminum alloy pipe shall be cut with serratinghacksaw.(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 angle square(6) For steel pipes

26、 that are alrea dy cut, segment the material,(5) Bevel end slope deviations 1% of O.D of pipe, and not more than 3mm.use paint or marking pen to mark on 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)

27、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.当管壁耳度为2.5-20mm时坡形式按下图。t2.5-99-20a70+560-5b1-22-3P1-223ac. 不等厚管子、管件组对时，如果内壁错边量大于10mm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 accordanee with piping construction code (GB50235-97) supplied by design institute, bevel chamfering shall be executed a

28、s per following figure:a. For pipe wall thicknessS2.5mm, the bevel type as following figure:_01 nmb. For pipe wall thickness2.5mm, and 2.5-99-20a70+560-5b1-223p1-223c. Whe n fit up differe nt thick ness pipes or fitti ngs, if offset of pipe in side is over 1.0mm, or offset of pipe outside is upper 2

29、mm, 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6-3mm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）自山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）自山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D1000.50.51003001.01.0DN3002.0

30、2.0法兰螺栓孔对称水平度1.621.6（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、制作精度应符合设讣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 fabricati on platform. For stain less steel assembly, 6=3mm rubber sh

31、eets shall be furnished on the platform for separation against carb on steel plate Carb on steel tools are not allowed to strike stainless steel pipes Assembly toleranee shall be checked against allowable pipe toleranee. The inspection method involves measurement with Angle Square, steel plate ruler

32、 and steel tape.(2) It shall be reas on able for Selecti on and arran geme nt of free spool and closespool, 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 tabl

33、e requirement:ItemAllowable deviationFree spoolClose spoollength101.5Center verticality between flange and piping.D1000.50.51003001.01.0DN3002.02.0Symmetrical levelness of flange bolthole.1.61.6Pipe support fabrication: pipe support can be fabricated as the pipes are prefabricated. The supports shal

34、l 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 spa

35、tters. 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。（

36、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

37、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氮弧焊argon arc welding20#J422H08Mn2SiAQ235AJ4220Cr18Ni9A102H0Cr20Ni10TiALSALMg-X2.4.2.5 Piping welding(1) Weldi ng procedure qualificati on, welder qualificati on exami nation, welding process card and wel

38、ding material (choice as per base metal)shall be con ducted 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) Weldin

39、g 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

40、 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 a

41、ngle, butt clearanee 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 accordanee with the corresponding welding procedure sheet. Slag and

42、 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 s

43、hall 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.(2)焊接接头错边量不应大于壁厚的10%,且不大于2mm =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

44、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(1)Welding inspection Weld visual inspectiona.b.No cracks, lack of fusion, porosity, slag inclusion or spatter are permitted Undercut shall be less than 0.5mm, total undercut length on both sides

45、of the weld shall not be larger than 10% of total weld length, and shall not be larger tha n 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 thickn

46、ess, 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 dat

47、a 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 2.4.32.4.3.1管道安装前应具备

48、的条件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；2.4.3.22.4.3.3与管道连接的设备已找正合格，固定完毕；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询完成。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

49、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 do

50、cuments;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200C的管

51、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 化钮油脂、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.

52、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DN1003L%。,垠大 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

53、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

54、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

55、.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 Flang

56、e 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 not more than 2mm.2.4.4.3 For piping which temperature under 200C, Teflon tape is applicable for the thread joint sealing material.2.4.4.4 The

57、flange sealing faces shall be smooth, any damaged face shall be repaired or replaced; during bolting, the flange face shall maintain axiality and parallelism to ensure even force on the gaskets.2.4.4.5 When piping installation on outdoor or in ambient corrosion environment, bolts & nuts shall be smeared with supramol