PTA二期管道预制方案

1、ZhuHai PTA No.2 ProjectContractor Job No.Method StatementContractor Doc. No.MS-PTA2-PIPE-001Piping Fabrication workRev. 0Page 21 of 26Zhuhai PTA No. 2 Project珠海PTA二期项目 管道预制施工方案Piping Fabrication Method Statement会 签 Signature 批准 Approved by Pan Shaoming 审核 Reviewed by Gan Lin 编制 Prepared by Tang Benl

2、inTJune 20, 2006二零零六年六月二十日 目 录1. 工程概述 General2. 编制依据 References3. 施工工艺程序、施工方法Construction Procedure and Methods4. 劳动力需用计划及技能要求 Manpower Plan and Skill Requirements 5. 施工机具、计量器具及施工手段用料计划Construction Equipment and Tools, Dispensing Mechanism and Construction Materials Plan 6. 附JHA Attachment: JHA ：1.

3、工程概况珠海PTA二期工程工艺管道的预制由我单位施工。本工程管道材质较多，其中需要预制的金属管道有碳钢（20#），低温钢（A333-6），不锈钢（00CR19NI10,316L，317L）,，合金钢；管道的壁厚大约在219mm之间，为保证管道预制工作优质、安全的进行，特编制此施工方案。1. GeneralMany pipe materials shall be used in this project including pre-fabricated metal pipe, such as carbon steel pipe (20#), low temperature steel pipe

4、(A333 Gr.6), stainless steel pipe (00Cr19Ni10, 316L, 317L) etc.， alloy and all pipes schedule are 219mm.This procedure is compiled to ensure the quality of works and to safely expedite construction progress.2. 编制依据：2.1 焊工产品记录质量控制计划 QP800901 2.2 焊接检查质量控制计划 QP8009022.3 工业金属管道施工及验收规范 GB50235-97 Code of

5、 construction and acceptance specification of industry metal piping GB50235-972.4 现场设备、工业管道焊接工程施工及验收规范 GB50236-98Construction and acceptance specification for field welding of equipment and industry steel piping GB50236-983. 施工工艺程序:管道除锈防腐材料验收施工准备单线图标注技术交底方案编制 焊口预热（如果需要）管段焊接管段组对、标识坡口加工管道下料及标记移植 外观及尺寸

6、检查合金钢热处理和硬度检验管段封闭、出厂无损检测不锈钢焊口酸洗 3. Construction sequence:Execution Plan Compiling Technical ReviewingIsometric Marking Construction PreparationRust and Painting of pipingSpool fit-up and MarkPiping Cutting and Mark TransplantingBevel Machining合金钢预热Preheat Spool WeldingHeat treatmentHardness testInsp

7、ect Appearance and DimensionSS Joint PicklingSpool Sealing and Ex-factoryNon-destructive TestSpool Sealing and Ex-factory4.施工方法、技术措施：4.1.1施工技术准备施工前工程技术人员必须认真阅读设计图纸及有关的规范标准，并结合现场情况编制施工方案（对于有特殊施工要求的管道将另行编制施工（技术措施）方案）和施工计划，并作好对班组的技术交底。4. Construction method and technical measures：4.1 Construction prepa

8、ration 4.1.1 Technical preparation Prior to construction, all technical staff shall carefully study construction drawing and relative codes and specifications, explain to construction groups. Prepare construction procedure. For piping with particular requirement, the correlative procedure shall be p

9、repared separately.4.1.2管道预制厂的布置根据工程要求设立管道预制厂。管道焊接中的大部分工作量将在预制厂内进行。预制厂内应布置有行车，吊车，汽车，电焊机放置区，氧气瓶放置区，乙炔瓶放置区，切割机（包括等离子）放置区，原材料堆放区，半成品堆放区，组对及焊接工作区，焊条保管及烘烤库等。所有工机具，电器均应检查合格后才能使用。工艺管道的预制深度将根据图纸要求进行。4.1.2 Pipe prefabrication shop layout Pipe prefabrication shop shall be built according to work volume and te

10、chnical requirement. Majority of pipe prefabrication shall be done in shop. Gantry crane, crane, car, welding machine laying area, oxygen bottle storage area, acetylene bottle storage area, cutting machine (including plasma cutting machine) laying area, raw material storage area, semi-finished produ

11、ct storage area, different type pipe fitting and welding area, electrode storage house and drying house etc. shall be included in prefabrication shop. All equipment, tools, electrical apparatus etc. must be approved prior to putting into use. Joints that need prefabrication shall be done according t

12、o construction drawings.,4.2材料验收：4.2.1管子的检验a. 全部管子应进行外观检查, 其表面应无裂纹, 结疤, 麻点, 夹杂物, 折皱, 重皮, 划痕, 严重锈蚀等缺陷 4.2 Material Acceptance 4.2.1 Inspection of piping a. Visual inspection shall be conducted for all pipes, and the surface of pipe shall be free defects such as cracks, scars, pitting, foreign substan

13、ce, cockle, nick, serious corruption etc.b. 对于合金钢钢管，应进行材料成份光谱分析鉴定，应符合有关材料标准的规定。抽查数量如下：数量少于或等于5根，全部需作光谱分析，数量在6-200间抽查5%，不少于5根，数量大于200根抽查3%，不少于10根。c. 到货管子的标记，代号，识别色带应清晰可见，并和说明书一致。c. Marking, code, and identification color shall be clear and be consistent with the manual. d. 对有耐晶间腐蚀要求的不锈钢管，质量证明文件上应注明晶间

14、腐蚀试验结果并符合设计文件要求。当设计文件有低温冲击韧性要求时，钢管产品质量证明书中应有此项合格数据。d. All stainless steel pipe shall have required certificate and test report.4.2.2管件检验a. 按同规格，同型号，同材质的管件抽取10%，但不得少于2件，检查管件的内，外表面，应无严重锈蚀，裂纹，砂眼，分层，破损，变形等缺陷。4.2.2 Pipe fittings acceptancea .Random inspection shall be conducted for different type and spe

15、cification fittings, and portion should be 10% or at least 2 pieces. Inspected fittings shall be free of defects such as ruse corruption, cracks, sand holes, damage, deformation etc. b. 检查管件的外径，壁厚，长度，圆度，法兰密封尺寸，螺孔直径和中心距，焊端，透镜垫弧度等尺寸，检查高压管件密封面的粗糙度，其抽查数量可按同规格，同材质5%10%，但不得少于2件。b. Check the sizes of diame

16、ter, wall thickness, length, round, flange seal surface, diameter of bolts holes and centerlines, welding ends, radian of eye glass washers etc. check seal surface roughness of high pressure fitting. Volume to be checked shall be 5%-10% for material of each type and specification. if 5%-10% is less

17、than 2 pieces, then at least two pieces have to be checked.c. 管件的标记，代号，识别色带应清晰可见.c .Tags, codes, color mark of pipes shall be very clear.4.2.3焊接材料的检验a. 核查焊接材料的标准牌号，商品牌号和规格等标识，应符合设计文件的要求。4.2.3 检验 of welding material aStandard, brand and specification of welding material shall comply with specificatio

18、n.b. 对封闭包装的焊条，应按同牌号，同规格盒数的2%进行检查，简易包装的焊条应逐盒检查，应无受潮，锈蚀，药皮剥落和规格不符等缺陷。bElectrodes in sealed package, 2% packages shall be inspected randomly for each branch, electrodes without sealed package shall be checked package by package. Electrode shall be free of damp, rust, damage, and misspecification etc.4.

19、3材料入库存放及出库管理:由于本工程工艺管道材质多样，为防止用错用混，应严格按照如下要求进行.4.3 Material storage, handle and issueThere are various type of piping materials. For ensuring these materials can be used correctly, material to be controlled according to following procedure:4.3.1按管道单线图分批从仓库领取管道材料。在领取管道材料时，应根据管件上的色标或金属牌来辨别管件材质，并在运输中不要

20、混堆。4.3.1. Receive material by ISO drawings separately from warehouse. During transportation, pipes shall be piled by different code marking.4.3.2在预制厂设立管件库，管件库内应设立货架，货架上的管件应按材质，规格分类摆放，并挂标示牌，注明规格、材质与壁厚或压力等级。4.3.2 Warehouse with rack to be prepared in prefabrication shop. Pipe fittings stored on rack s

21、hall be separated by style, specification and tagged. Relative information such as type, specification, wall thickness and pressure grade etc. shall be indicated on the tag clearly.4.3.3 小于或等于2的管件，阀门及螺栓螺母，垫片应上货架，大于2“的管件，阀门应堆放在木板上。4.3.3 Fittings, valves, bolts, nuts, washers that diameter is equal or

22、 less than 2” shall be stored on racks in warehouse. Fittings and valves that diameter are lager than 2” shall be put on the wood plate.4.3.4各类钢管应按材质，按规格及壁厚分类摆放，并挂标示牌，注明材质、规格及壁厚。所有钢管都应用木块垫起。两端口的封闭盖不要移开。4.3.4 All steel pipes shall be stored by type, specification, wall thickness on dunnage separately

23、 and tagged, Relative information such as type, specification, wall thickness etc. shall be indicated on the tag clearly. The seal cap at each end shall remain.4.3.5 发放和使用过程中要做好标识码和色带移植。4.3.5 all pipe shall have marking and color code during issuing and using.4.3.6材料的保管发放要定专人负责，做好材料的登记台帐、发放台帐，在施工过程中

24、做好材料的销核、库存、缺件的统计工作。4.3.6. A man shall be assigned for material storage and issuing, builds and maintains material receiving record, issuing record. During construction, he builds and maintains the statistic record of material issued, remained in warehouse, and missing etc.4.3.7 对于不锈钢管件堆放时应不得与碳钢直接接触。

25、4.3.7 Stainless steel pipe can not contact with carbon steel pipe during storage.4.3.8 焊条库内不同的焊接材料要分类摆放，室内应保持干燥。4.3.8 Different kinds of electrodes shall be stored separately in electrode warehouse and keep dry condition.4.3.9 不同材质的钢管在预制时应分区域隔离预制或在同一区域内将所有结束预制的材料移开再开始进行下一种材质的预制。4.3.9 Different categ

26、ory steel pipe cannot be prefabricated in same place at the same time4.3.10 在预制时，应先核对一下材质和壁厚后才开始进行下料。4.3.10 Prior to cutting during pipe prefabrication, material category and wall thickness must be checked.4.3.11 在管道喷砂之前和管道预制过程中，要做好标识码和色带移植（管子和管件内外壁）。在安装和喷砂防腐间应一次移交一种材质。4.3.11. Prior to blasting and

27、during pipe prefabrication, code marking and color belts of pipes must be kept or re-marked for every piece of pipe and pipe fitting (external wall or internal wall). During the transform of pipe fabrication, blasting, and painting, only one category of pipes can be handled one time.4.5管道预制:4.5.1管道预

28、制前应先在单线图上将焊口号，管段号标注好经业主批准。自由管段和封闭管段的选择应合理，所有自由管段都应加上100mm的安装调整余量。自由管段和封闭管段的加工尺寸允许偏差见下表：项 目允许偏差（mm）自由管段封闭管段长 度101.5法兰面与管子中心垂直度DN1000.50.5100DN3001.01.0DN3002.02.0法兰螺栓孔对称水平度1.61.64.5.2管道切割下料：a. 管道应按管段图进行预制，所用材料的数量、规格、材质等应符合设计图纸要求，在根据图纸下料前，应核对管子的标记（规格、材质、等级），确认无误后，方可开始切割下料（管道下料前应先从无标记端开始），做到用料正确、尺寸准确、标

29、识移植正确。废料也应做好标记的移植。对法兰和管道口要加以保护，只有在加工或检查时才可以打开，完成后将其复原。b.管道的切割应根据管材的直径、壁厚、材质及现场设备情况确定切割办法，通常采用下列方法：a不锈钢管宜采用砂轮机或等离子切割。aStainless pipe to be cut with lathe or sand wheel machine or plasma sand wheel machine.b Dg100以下的中、低压碳钢管、合金钢管宜采用砂轮机切割。b Dg100 or below middle pressure, low pressure carbon steel pipe

30、and alloy steel pipe to be cut with sand wheel machine or lathe.c Dg100以上的中、低压碳钢管和合金钢管宜采用氧乙炔切割。cMiddle pressure or low pressure carbon steel or alloy steel pipe that is larger than Dg 100 to be cut with Oxygen-Acetylene flame. For low alloy steel, after flame cutting, approximately 2mm of material s

31、hall be removed from the cut surface by grinding.d 切割后的管子应用锉刀或砂轮磨光机清除管子切口内、外的毛刺、铁屑和焊瘤。切口端面倾斜偏差不大于管子外径的1%，且不超过3mm。d Cut pipe shall trim the burrs of end, remove iron scrapes and oxidation. The slope tolerance at the cut end shall be less than 1% of pipe outer diameter, and be less than 3mm. e 支管安装：在主

32、管上开孔应尽量在预制厂内进行，采用气割或等离子切割时要沿线切割。主管上的开孔要符合支管直径的要求，不得随意开小。孔开好后要用砂轮或锉刀仔细清理。组对支管时要严格控制好支管与主管的角度，符合设计要求。e Branches installation: Opens on main pipe should be cut in shop as possible with gas or plasma cutting machine along marked line. The holes shall be suitable for the diameter of braches and cannot be

33、 smaller. Holes shall be cleaned with sand wheel or file carefully. The angle between main pipe and branch shall be controlled to comply with requirement of design.4.5.3 坡口型式及加工要求:4.5.3 Bevel type and fabrication requirement:a.不锈钢管道宜用砂轮机打磨，对于厚度超过12mm的采用车床或坡口加工机加工, 碳钢管道可用氧、乙炔焰气割加工，但必须用磨光机磨去影响焊接质量的表面层

34、（一般为2毫米），并打磨平整。用于切割或打磨管子的砂轮机不能碳钢，不锈钢混用。a Bevels of stainless steel pipe to be made mechanically and grinded with sand wheel machine, for pipes that thickness lager than 12mm, bevels to be made with lathe or bevel making machine. Bevels of carbon steel pipe, bevels to be made with oxygen-acetylene fl

35、ame, and grind surface with grinding machine to remove substance that may affect the welding quality in the future (generally 2mm) and leveled. Cutting machine and sand wheel machine can not be used both or carbon steel pipe and stainless pipe.b. 管子壁厚不大于3mm时，采用I型坡口.b. While the wall thickness is equ

36、al or less than 3mm, I type bevel to be fabricated.c.管子壁厚大于3mm时，采用V型坡口。如下图示： 302.501.60.8mm3.20.8mm(管道壁厚22mm) c. While the wall thickness is over 3mm, V type bevel to be fabricated as the sketch below 4.5.4管道组对:a. 壁厚相同的管道组成件组对时，应保证内壁平齐，错边量不得超过壁厚的10%，且不大于1.6mm。4.5.4 Fit-up of piping :a . When the spo

37、ols with the same wall thickness are fit up, the inside wall shall be level and at same length, the staggered size shall not exceed 10% wall thickness of piping and not be more than 1.6mm.b. 管子对口时在距接口中心200mm处测量平直度：当管子公称直径小于100mm时，允许偏差为1mm；当管子公称直径100mm时，允许偏差为2mm，但全长允许偏差均为10mm。b When the spools are fi

38、t up, measure the levelness 200mm away from the joints center. If the nominal piping diameter is less than 100mm, the allowable tolerance is within 1mm, if the nominal piping diameter is more than or equal to 100mm, the tolerance is within 2mm, but the tolerance in full length is within 10mm.c. 管道上支

39、管开孔和仪表取源部件的开孔和焊接应尽量在管道预制厂进行。开孔形式和焊接形式按照设计图纸进行。d. 为保证管道组对质量及方便施焊，管道组对时，应根据管径及其壁厚在组对平台（地面）或小型组对活动支架上进行（组对支架现场用型钢制作），并使用合适和足够多的夹具和卡具。d. When the spools are fit up, measure the levelness 200mm away from the joints center. If the nominal piping diameter is less than 100mm, the allowable tolerance is with

40、in 1mm, if the nominal piping diameter is more than or equal to 100mm, the tolerance is within 2mm, but the tolerance in full length is within 10mm.e. 当管段按图纸预制好后，应存放在规定的区域内，管段的两端应及时封闭，管段应分区域，分材质分类摆放。所有的管段下面均应垫上木块。e. Fabricated spools shall be stored in specified area, and both end shall be capped. S

41、pools shall be stored on dunnage by material category and belonging area. 4.6管道焊接:4.6.1工艺管道材质有:20#、00CR19NI10、316L、317L，其焊接工艺应严格执行PQR规定进行，焊接材料选用见下表所示（00CR19NI10小直径管采用GTAW（自熔焊）。母材类别母材牌号SMAWGTAWGMAWSAW碳 钢20#J427H08MnSi2A_低温碳钢A333GR.6E5018-1TGS-N1_不锈钢316LA022H00Cr20Ni14Mo3_不锈钢317LE317L-17ER317L-4.6.2焊接

42、人员和焊接环境要求:a. 承担本工程管道焊接的焊工必须经现场培训考取相应焊接资格证，且应在本人合格证规定范围内施焊。4.6.2 Welders and welding equipment a. Welders engaging in piping welding must be trained and qualified in field, and welding as per the scope specified in the qualification certificates.b. 在焊接中应按照WPS和PQR要求实施焊接。b. All welders shall master wel

43、ding method, familiar with the technical requirement and quality control criteria. They shall have applicable certificates during welding as per the requirements of WPS and PQR.c. 管道施焊时，焊接环境不能满足下述条件时，应采用铁皮棚或布棚遮挡，或制作可移动式小型焊接防护棚等措施，方可施焊：a 风速：氩弧焊2m/s, 手工电弧焊8m/s；d 施焊电弧1米范围内的相对湿度90%。c. If the circumstanc

44、e condition can not meet the requirement below, welding work shall be sheltered by steel sheet shelter, canvas shelter or movable small welding protective shelter:a Wind velocity: arc-argon welding 2m/s, manual arc-electrical welding Relative humidity 管道施焊前，应组织施焊人员进行详细的施焊施工技术交底。1 Prior to welding of

45、 piping, welders shall be informed of the detailed welding techniques or receive a welding technical training or exam if necessary.2 管道组对焊口的坡口型式和尺寸要求按WPS执行。管道施焊前，应对管口组对质量进行检查确认。2 Bevel type and size shall comply with WPS. Before welding, the assembling quality shall be checked and confirmed.3 管道焊口组对

46、应做到内壁平齐，错边量不超过壁厚的10%，且1.6mm；3 The assembling joint shall be flat inside. The undercut shall be no more than 10% of the wall thickness and not exceed 1.6mm.4 焊接坡口经砂轮打磨，坡口整齐光洁，坡口表面的油污、锈蚀和坡口两侧各10-15mm范围内的氧化层清理干净，清理范围内无裂纹、夹层等缺陷。4 Bevel shall be cleaned by means of grinding wheel so as to keep it smooth.

47、 Any oil contamination , rust and oxides within the area 10-15mm from the joint shall be cleaned. There shall be no such defects such as cracks and crackles within this area.5为确保焊缝没有残留胶、灰尘等污染物，在进行焊接前应由CFCS QC检查员对不锈钢管道内部检查。4.6.5定位焊(点焊):4.6.5 Tack welding ( spot welding)1 管道焊口组对定位焊，应选用正式施焊相同的焊材，定位焊的工艺

48、要求与正式焊接工艺要求相同，定位焊须由持证合格焊工进行。1 Material and welding procedure applied for tack welding of piping shall be same with that used in formal welding. Tack welding operation shall be performed only by certificated welders.2 定位焊的焊缝高度要求为焊件厚度的70%以下，且6mm；定位焊的焊缝长度为10-30mm，定位焊点数为2-5点。2 The height of tack welding

49、 joint shall be less than 70% of the welding object and be no more than 6mm, tack welding shall be performed at 25 spots, each seam shall 1030mm.3 管口组对点固完成后，方可进行正式焊接。3 Upon qualification after checking of the tack welding, formal full welding can proceed.4.6.6焊接工艺:4.6.6 Welding procedure1 管道焊接时，严禁在被

50、焊工件（母材）表面引燃电弧、试验电流；施焊过程中，注意接头和收弧的质量，收弧时将溶池填满，多层焊的焊接接头错开。1 Ignition of electrical arc and test current on welded piece (base metal) are prohibited during welding piping. Attention should be given to joint and weld-end. Fully fill the fuse pit when ending welding, and the joints of multi-layer welding

51、 should be staggered。2 氩气纯度应不小于99.99%。，不合格的氩气不能使用。2 Purity of argon gas shall not less than 99.99%, unqualified argon gas can not be used in formal welding.3 管道焊接完成后，及时清理和检查焊缝表面；所有经检查合格的焊缝都应标上合格标识。4不锈钢管道焊接要求:4Welding requirement of stainless steel pipinga、 为保证管口背面焊接成型质量和管道内清洁度，不锈钢管道焊接全部采用氩弧焊打底（GTAW）

52、。b、 焊接时，对于较短管段采用整体充氩，充氩时管子两端进行封堵，焊口处用医用胶布密封，随焊接随揭开;对于长管段，采取局部充氩的方法进行充氩保护。 b During welding of prefabricated piping, short spools shall be fully filled with argon. Both ends of spool shall be blocked, and welding joints shall be sealed with medically-used fabric tape, which will be uncovered as the w

53、elding goes on. Long spools shall be protected by means of locally filling of argon. c、 焊接时管内应提前充氩气，排净空气，并保持微弱正压和呈现流动状态。熄弧后，焊丝不得立即暴露在大气中，应在焊缝脱离保护时取出。CDuring welding, fusing end of welding wire shall be always under the protection on argon. Argon shall be filled prior to welding keep argon flows our at a uniform speed from the bevel. After arc extinguished, welding wire can not ex