南海石化工艺管线施工技术方案

1、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南海石化项目苯乙烯、 环氧丙烷及丙烯乙二醇装置位于省市大亚湾区海畔.该项目由德悉尼布天辰化学工程()设计，所处地区环境干燥温度最高38.5 C,最低2.3 C,湿润温度28.1 T，空气湿度大，雨期较长。2 编制依据2.1 德悉尼布天辰化学工程()提供的工艺管道施工图；2.2 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 (SH3501-1997)；2.5 工业金属管道工程施工及验收规 (GB

2、50235-97)；2.6 现场设备、工业管道焊接工程施工及验收规 (GB50236-98)；2.7 埋地钢质管道环氧煤沥青防腐技术标准 ( SY/T0447-96) ；2.8 石油化工钢制通用阀门选用、检验及验收规 ( SH3064-94) ；2.9 石油化工设备和管道隔热技术规 ( SH30 1 0-2000) ；2.10工业设备、管道防腐蚀工程施工及验收规 ( HGJ229-9 1) ； 2.11工业设备及管道绝热工程施工及验收规 (GBJ126-89)； 2.12石油化工工程铬钼耐热钢管道焊接技术规程(SHJ520-91)；2.13电力建设施工及验收技术规(管道篇)DL5031-942

3、.14 电力建设施工及验收技术规 (火力发电厂焊接篇) DL5007-92 2.15石油化工企业设备管道表面色和标志 SH3043-1991 2.16石油化工异种钢焊接规程 SH3526-19922.17石油化工铬镍奥氏体钢、铁镍合金和镍合金管道焊接规程 SH3523-1999 2.18压力容器无损检测 (JB4730-94)；2.19 石油化工施工安全技术规程 (SH3505-99)；2.20 工程建设交工技术文件规定 (SH3503-93)；2.21 50万吨/年延迟装置施工组织设计 ；2.22压力管道安装质量保证手册 ()；2.23 压力管道安装质量程序文件 (QG/P4443.50.0

4、0-1999) ；2.24 压力管道安装工艺标准 ( QG/4441.52.00-1999 )；2.25 压力管道安装竣工技术文件规定 ()。3 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 installation, there are many pipes with inflammable, explosive and corros

5、ive medium, most of which are slurry and powder with strong corrosion. 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 specification of 304L,316L and 317L.but also some titanium pipe, alloy pipe and plast

6、ic 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，不得让设备承受管道系统的重力。There are many movable equipments in the installation, we need ensure pipe erection without stressing, and cannot impose external force on the equipments, In the pipe erection, weneed start from the equipment in

7、side, and 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，能够确保装置的长期有效地运行。The pipe welding quantities is very heavy in the projec

8、t. It needs provide a large number of qualified welders. Nowour companyhas 685 welders with certificates,which can complywith the welding requirements. Once tendered, we will send qualified welders to bear the welding task of the project, All the welders have much experience and advance technique, w

9、hich 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为提高劳动效率，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（99.99%）的气体保护管道自动焊，可以极提高劳动效率， 有效地抑制焊接接头部位的氧化，保证接头部平整、外型美观。6.3.1.4 The qua ntitiesof Process pipe erecti on is heavy, It in eludes all

10、kinds of pipeof 132k m.ln order to enhance the work efficie ncy and speed the con structi on progress, we will try our best to push pipe automatic welding and perform pipe prefabrication inmarket. There are many automatic welding machines with models in our company. In the process of pipe erect ion,

11、 the applicati on of arc protectio n automatic weldi ng mach ine with high purity of argon can improve the work efficiency, hold back the oxidization of the locati on of weld ing joint, and en sure the in side of jo int flat and on good look outside.4管道安装工程量The qua ntities of pipe erecti on类别Type材质M

12、aterial规格（mr）Specificati on质量（t）Quality数量（m）Qua ntity管材Pipi ng+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Plastic Pipe3/4 561.49706法兰Fla nge114.92配件Fitt in gs255.3阀门Valve273.21弹簧支撑Spri ngSupport ing11.88其它支

13、撑Othersupport ing157.45、管道材料检验Pipe material in specti on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管理 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管理体系以提供质量保证。The quality assura nee of pipe con structi on material is the basis of the con struct ionquality. Our companyowns a available and mature managementsystem of material

14、 inspection and we will adjust it according to the actual project 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。Settingup a inspectiongroup for pipe material and fittings check, andin spect ing with relative sta ndard.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。Sett ingup a in depe nd

15、ent in specti on area for material exam in ati on, and divide itinto wait ing in specti on area ,in spect ion area, qualifiedproduct ion area and unq ualifiedproduct ion 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 strictly inspect material complying with the followingprocedure: 管材、管件接收P

16、ipe 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 identification and inspection in situation identification5.4 管道组成件的检验Piping fittin

17、g 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主要化学成份进行复查， 并作好检验状态标识。Stainless piping and fittings (including bolts and screw nuts) shall be rechecked chemical combinations by spectrum analyzer, and located in inspection situation.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 b

18、e 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，石棉垫表面应平整光滑，不得 有气泡、分层、折皱等缺陷。The area between flange to flange and circle pad shall be protected from scra

19、tches 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、相关技术人员和质量检查人员组成。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 bef

20、ore valve in specti on, which in elude con struct ion team, relative tech nique pers onn el, quality in spector. Mea nwhile We will tran sfer n ecessary tech nique in formati on and assemble proper work equipme nt. 5.442阀门检验、试验程序见图3-1 oThe valve in spect ion and test procedure see draw ing 3-1阀门试验应从

21、每批中抽查10%且不少于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%由查，仍然不合格时，该批阀门不得使用。10% of valves shall be take for in specti on from each batch of it. And no less than 1 piece to shell pressure and densification test. In case it is not qualified, another 20% of it shall be rechecked. If unqualified again, the valves ca

22、nnot be used.不锈钢阀门试验用水的氯离子阀门的壳体压力性试验和密封性试验必须用洁净水进行。含量不得超过25ppm.Cleanwater should be used in the valve shellpressure and densificationtest .The content of chlorine used in stainless steel valveshould not overpass 25ppm阀门的壳体试验压力应为公称压力的1.5倍；试验时间不得少于5min,以壳体、填料无渗漏为合格。Valves shell tested pressure shouldb

23、e 1.5 times of nominal pressure , and the test shouldlast 5 minutes, It will be qualifiedin the case of shell and packing be free from leakage.图3-1阀门检验、试验工艺流程图Drawi ng 3-1 Valve In spect ion and Test Flow Pla n质量证明文件核查、确认阀门外观质量检查 valve con figurati on quality in spect ionReview and Con firmati on of

24、成立阀门检验、试验小组Qualificati on Docume ntSetti ng Up valvein specti on and test group严密性试验Pressure test强度试验inten sity test检验、试验状态标识不合格 unqualified工装设计制作检验场地准备 Process assembly desig n andfabricati onin spect ionyardpreparation yard编制技术措施并进行技术交底Prepared Tech nique andTran sfer itInspection ,test situationi

25、de ntificati on不合格品处置Nonq ualified product ion disposal合格交付安装Erect ion available除止回阀、节流阀外，阀门的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 determined by nominal pressure and no leakage in the den sificati on area of valve petal.5.447公称压力小于1MPa且公称直径大

26、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，闸板密封试验可采用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 nominal pressure less than 1Mpa, Whendoing the shell pressure test, It is better to examine according to the system test ing pressure. Slide plate may use the color paper

27、s for test ing and the continu ati on area should be con ti nued.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 valves are forbidden to using. 5.4.4.9 试验合格的阀门，应及时排净部积水、吹干密封面上应

28、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 valve should be closed .The egress and ingress 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， 允许偏差为± 3%。调试介质： 管道介质为气 体时，优先酇用氮气调试；管道介质为液体时，应使

29、用液体调试。调压时的压力应稳定，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 document regulations and +/-3% deviation is permitted. We will use different mediums as follows according to the specified

30、 conditions: Using nitrogen first in case of air in the piping . Using liquid in case of liquid in the piping. The pressure should be stable whenadjusting and every safety valve should be opened and closed three times. The up and down pressure should be clear without internal and external leakage. B

31、ecause the pressure deviation between 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 permitted and the labels can be made on safety valve ingress and egress for visual check.5.5 质量检验人员均对检验过程做出详实

32、的检验记录，以备随时查证。Quality inspector shall makedetailed inspection record for verifying 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 different color tags ,which can avoid mistake

33、 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 materialand shape steel.6 管道的预制加工Piping prefabrication and processing6.1 为了减少现场预制带来的技术

34、管理、材料管理、设备管理的工作负担，搞好文明施工，开辟 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。 Wehave track crown blocks, lathes, beamdrills, plate shears ,groove processing machine and automatic welding machines in the piping prefabrication yard to avoid field work bearing

35、 such as technique management,material managementand equipment management, make housekeeping ,develop the second site, set up piping prefabrication yard ,make piping prefabrication process in the market and then erect in the jobsite6.2 预制前仔细核对单线图与平面图，核对基础、设备、管架、预埋件、预留孔是否正确，对于 最后封闭的管段应考虑组焊位置和调节裕量。Bef

36、ore prefabrication, We will check the isolated drawings and plans carefully , align the foundations ,equipments, pi < pe frames embedded parts and preformed holes in correct, and consider the welding position and adjust the size under the actual construction condition to the piping sections close

37、d 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 tothe specification, quantities and material quality formed in isolated drawings. Wewill check the piping tags in every steps and makec

38、hanged tags in good consequence for 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用以下方法：镀锌钢管和公称直径w50的碳钢管，采用机械切割，公称直径大于DN50的碳钢管采用氧乙炔焰法切割；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 应平整、无裂纹、重皮、毛刺、凸凹、缩口、熔渣、氧化物、铁屑等。Steel material cutting and piping groove pro

39、cess should use methods as follows;For galvanized steel tubes and carbon steel tubes with nominal diameterw 50 using mechanical cutting .For carbon steel tubes with nominal diameter less than DN50 using oxygen acetylene cutting ,For stainless steel tubes using applied mechanical or plasma cutting ,F

40、or steel tubes with specification of 304L,314L and 317L using abrasive wheel cutting or another alternative using special emery plate to grind. Tube cutting should be flat and smooth and no cracking, sand crust, fins ,uneven open track ,melted residue ,scrap and oxidization.6.5 预制好的管段，按单元或区域摆放整齐，以便于

41、运输和安装。管道施焊时，按规定的焊接 工艺执行。管道焊接、无损检测工作完成后， ? 应在预制厂除锈、喷砂和防腐，但焊口两侧各 100mm勺围不允许涂漆，焊工钢印号、管道编号以及管线号不允许涂漆，待系统水压试验合格后 再进行防腐涂漆。为保证焊接质量，工艺管道焊接均采用氩电联焊的工艺进行。Prefabricated piping section shall be laid in order to transportation and erection. We will weld complying with regulated welding process. After piping weldi

42、ng and non-destructive test. The derusting, blasting and anti-rotting steps should be done in the prefabrication yard. But 100mm away form two sides of welding joints and welder'ssign, piping number and pipeline number are not permit to paint, it should be done after system water pressure test q

43、ualified. In order to ensure welding quality, all the process piping use argon continuation welding .6.6 预制完成勺管段进行管线号、预制管段号标识，并用人工或压缩风将管膛清除干净，用塑料 布封闭管口分门别类摆放。不锈钢和碳钢在切割和存放时，严格区分开。Wemakeidentification tags for pipeline number and prefabricationpiping section numberwhich are completed the prefabricatio

44、n, clean piping inside by hand and pressure wind, Classify and lay down them with piping mouth closed by plastic cloth. When cutting and storing ,stainless steel and carbon steel should be divided strictly.7 管道焊接Piping weldingPTA装置焊接工程中，工艺管道母材的不锈钢比例在60%以上，且有钛一类特殊材质的管道，焊接难度大、 工艺标准要求高是该工程勺主要特点。 焊接质量直接

45、决定整个安装工程勺质量， 因此，我们应从焊接材料、焊接工艺、施焊过程、焊接检验诸方面对焊接质量进行严格控制，确保 每个焊接环节都处于受控状态。In PTAassembly welding process, Because there is 60%of stainless steel in process piping parent material and piping has the especial titanium, the main character oftheproject is the difficult welding and high requirements of proc

46、ess standard. Welding quality determine the overall erection project quality. we will control the welding material, welding process, welding operation ,welding inspection and so on to ensure welding quality and every welding steps in control.焊材型号和规格选用应严格执行焊接工艺评定。焊前检查、修正接缝的间隙、错边量等；焊 接作业期间，注意自然环境对焊接作业

47、的影响，焊后检查焊缝表面质量、角变形，及时作出质量 评定，并按要求进行无损检测，及时填写焊接施工记录。The utilization of the welding models and specification shall be strictly complied with welding process qualification such as checking before welding and correcting the distance in continued joints and misalignment. Wewill notice welding operation e

48、ffects by native environment, check welding joints surface quality and twisted angels after welding ,make quality qualification in time ,execute non-destructive inspection with requirements and make record of welding construction in time.7. 1 焊接施工一般要求General requirement of welding construction7.1.1

49、焊工应在合格的焊接项目从事管道的焊接，且在有效期。Welders shall work on piping welding in acceptable welding project and in available period.7.1.2 焊材应有产品合格证明书，并经复验合格。Welding material should have qualified production certificates and acceptable after checking again.7.1.3 焊条应按说明书或焊接作业指导书的要求进行烘干，并在施焊过程中，使用保温筒保持焊 条干燥。Welding ro

50、d shall be dried by instruments and guide book of welding operation. Insulation tank shall be used for electrode drying in welding operation.6.3.5.1.4 焊工按指定的焊接工艺卡（焊接作业指导书）施焊。焊接工艺卡应按与之相 对应钢材的焊接工艺评定进行编制，并按程序进行审批Welders do their job with welding technique card,. Which will be prepared and reviewedby eq

51、uivale nt steel weld ing process qualificati on and procedure.equivale nt steelwelding process qualification and procedure.当出现下列情况如没有防护措施时，应停止焊接工作：Weldingoperation must be stop in case following problem happened without protecta. 手工电弧焊时，风速8m/s，氩弧焊时，风速2m/s；The wind velocity is > 8m/s in SMAW, the

52、wi nd velocity is> 2m/s in arc weldi ng.b. 相对湿度90%Relative moisture is > 90%c. 下雨；Rai ning焊接完毕后，及时在焊缝两侧50mr围打上焊工钢印号，不锈钢钢管不做钢印标识，但是应 在管道单线图上标注清楚。Welder ' s stamps NO. shall be made in the 50mm range away from welding joints in time, Rebar marks will not be done in sta ini ess steel tubes, b

53、ut it should be in dicated in pip ing isolated draw in gs.7.2 焊接材料的选择Weldi ng Material Alternative焊接材料选用表5-1List for Weldi ng Material Alternative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 316ER316E316-16

54、5ANSI 316LER316LE316L-166ANSI 317LER317LE317L-167C276ERNiCrMo-4En iCrMo-48TI 1ERTi-17.3奥氏体不锈钢管道焊接Stai nl ess pipi ng weldi ng奥氏体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 comply with follow ing regulati on:焊接坡口形式和尺寸Weldi ng Groove Type and Size 5-2序号NO.厚度S(mm)Thi

55、ck ness坡口类型GrooveType坡口形式Groove Type坡口尺寸Groove size备注Remarks间隙b(mm)Dista nc钝边P(mm坡口角度a ( ° )Groove123I型坡口Type I groove勿I-4-£1e0 1.5厂angle单面焊Si ngleWeld ng23.6 8V型坡口V typeGrooveci4020265 ± 5单面焊Si ngleweldi ng奥氏体不锈钢管道焊口组对质量应符合以下要求:Stainlesspiping welding mouth to mouth should comply fol

56、lowingrequirements:管口应做到壁平齐，其错边量不应超过壁厚的10%且应w 0.5mmTheinside wall of piping mouth shall be flat and smooth, the misalignment shall not be more than 10% of wall thickness, and should be less than or equivalent to 0.5mm 7.322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1015mm 围的氧化层应清理干净，清理围应无裂纹、夹层等缺陷。Welding gr

57、oove should cleaned by abrasive wheel ,Groove should 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 cracking and double layers.7.3.3 奥氏体不锈钢焊接时，应采用小规、短电弧、快速焊和窄焊道工艺进行焊接，并应控制层间温度不得超过150C，必要时，应采取强制冷却措施。In stainless steel welding operations, We will weld with process such as small specification, s