1、工藝管線施工技術(shù)方案Construction Technique Scheme for Process Pipelines1 工程概況 我公司承建的中海殼牌石油化工有限公司南海石化項目苯乙烯、環(huán)氧丙烷及丙烯乙二醇裝置位于廣東省惠州市大亞灣區(qū)海畔.該項目由德悉尼布天辰化學工程（天津）有限公司設(shè)計，所處地區(qū)環(huán)境干燥溫度最高38.5，最低2.3，濕潤溫度28.1，空氣濕度大，雨期較長。2 編制依據(jù)2.1 德悉尼布天辰化學工程（天津）有限公司提供的工藝管道施工圖；2.2 工藝管道設(shè)計技術(shù)交底（會議紀要）；2.4石油化工劇毒、可燃介質(zhì)管道工程施工及驗收規(guī)范（SH3501-1997）；2.5工業(yè)金屬管道工

2、程施工及驗收規(guī)范（GB50235-97）；2.6現(xiàn)場設(shè)備、工業(yè)管道焊接工程施工及驗收規(guī)范（GB50236-98）；2.7埋地鋼質(zhì)管道環(huán)氧煤瀝青防腐技術(shù)標準（SY/T0447-96）；2.8石油化工鋼制通用閥門選用、檢驗及驗收規(guī)范（SH3064-94）；2.9石油化工設(shè)備和管道隔熱技術(shù)規(guī)范（SH3010-2000）；2.10工業(yè)設(shè)備、管道防腐蝕工程施工及驗收規(guī)范（HGJ229-91）；2.11工業(yè)設(shè)備及管道絕熱工程施工及驗收規(guī)范（GBJ126-89）；2.12石油化工工程鉻鉬耐熱鋼管道焊接技術(shù)規(guī)程（SHJ520-91）；2.13電力建設(shè)施工及驗收技術(shù)規(guī)范(管道篇)DL5031-942.14電力建

3、設(shè)施工及驗收技術(shù)規(guī)范（火力發(fā)電廠焊接篇）DL5007-922.15石油化工企業(yè)設(shè)備管道表面色和標志SH3043-19912.16石油化工異種鋼焊接規(guī)程SH3526-19922.17石油化工鉻鎳奧氏體鋼、鐵鎳合金和鎳合金管道焊接規(guī)程SH3523-19992.18壓力容器無損檢測（JB4730-94）；2.19石油化工施工安全技術(shù)規(guī)程（SH3505-99）；2.20工程建設(shè)交工技術(shù)文件規(guī)定（SH3503-93）；2.2150萬噸/年延遲裝置施工組織設(shè)計；2.22壓力管道安裝質(zhì)量保證手冊（QG/M4441.50.00-1999）；2.23壓力管道安裝質(zhì)量程序文件(QG/P4443.50.00-199

4、9)；2.24壓力管道安裝工藝標準（QG/4441.52.00-1999）；2.25壓力管道安裝竣工技術(shù)文件規(guī)定（QG/M4441.53.00-1999）。3 工藝配管的特點： The character of pipe erection3.1 PTA裝置中易燃，易爆及腐蝕性介質(zhì)的管道較多，且物料大多為漿料和粉料，有強烈腐蝕性，故配管材料選用要求嚴格。本裝置中大量使用超低碳不銹鋼，包括304L、316L、317L等，并有少量鈦管、海氏合金管及塑料管。IN PTA installation, there are many pipes with inflammable, explosive and

5、 corrosive 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 an

6、d plastic pipe.3.2本裝置動設(shè)備較多，必須保證無應(yīng)力配管，不得對設(shè)備施加外力。配管應(yīng)從設(shè)備開始向設(shè)備外配管，配管過程中應(yīng)及時設(shè)置管道支吊架，不得讓設(shè)備承受管道系統(tǒng)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, we need start from the equipm

7、ent inside, 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，需要投入大批量的優(yōu)秀焊工。我公司目前有壓力管道持證焊工685名，能夠保證焊接要求。如我公司中標本項目，將派出具有行業(yè)及國家級先進水平的優(yōu)秀焊工來承擔本工程的焊接任務(wù)，能夠確保裝置的長期有效地運行。 The pipe welding quantities is very heavy in the project.

8、 It needs provide a large number of qualified welders. Now our company has 685 welders with certificates, which can comply with 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,

9、 which can ensure the erection in good quality in a long time.3.4 本裝置工藝配管工程量大，共有各類管道132km。為提高勞動效率，加快施工進度，我們將大力推進管道自動焊，實行管道預制工廠化、產(chǎn)品化。我公司有各種型號的自動化焊機多臺，在管道預制過程中，配以高純度氬氣（99.99%）的氣體保護管道自動焊，可以極大地提高勞動效率，有效地抑制焊接接頭部位的氧化，保證接頭內(nèi)部平整、外型美觀。.6.3.1.4 The quantities of Process pipe erection is heavy, It includes all

10、kinds of pipeof 132km.In order to enhance the work efficiency and speed the construction progress, we will try our best to push pipe automatic welding and perform pipe prefabrication in market. There are many automatic welding machines with models in our company. In the process of pipe erection, the

11、 application 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 and on good look outside.4 管道安裝工程量The quantities of pipe erection類別Type材質(zhì)Material 規(guī)格（mm）

12、Specification 質(zhì)量（t）Quality 數(shù)量（m）Quantity管材Piping +material CS 1/254 878.04 62813 SS 1/280 315.1 38850 鈦材Titanium 3/480 38.53 650 合金鋼Alloy steel 3/436 13.53 630 銅管Copper pipe 1/23/4 17.27 28403 塑料管Plastic Pipe 3/456 1.49 706 法蘭Flange 114.92 配件Fittings 255.3 閥門Valve 273.21 彈簧支撐Spring Supporting 11.88

13、其它支撐Other supporting 157.45、 管道材料檢驗Pipe material inspection管道施工材料的質(zhì)量保證是施工質(zhì)量的基礎(chǔ)。我公司具有一套成熟可行的原材料檢驗管理制度，我們將按照具體工程特點建立健全切實可行的材料檢驗管理體系以提供質(zhì)量保證。The quality assurance of pipe construction material is the basis of the construction quality. Our company owns a available and mature management system of material

14、 inspection and we will adjust it according to the actual project character for quality ensure.5.1 成立專門的檢驗小組實施統(tǒng)一的管材管件檢驗，并按照相應(yīng)標準組織檢驗。 Setting up a inspection group for pipe material and fittings check, and inspecting with relative standard.5.2 材料檢驗設(shè)有獨立的檢驗場地，并劃分出待檢區(qū)、檢驗區(qū)、合格品區(qū)和不合格品區(qū)。 Setting up a indepe

15、ndent inspection area for material examination, and divide it into waiting inspection area ,inspection area, qualified production area and unqualified production area.5.3訓練有素的檢驗人員將嚴格按照以下檢驗工藝進行檢驗： The trained person will strictly inspect material complying with the following procedure: 管材、管件接收Pipe ma

16、terial, fittings acceptance 品種、規(guī)格、數(shù)量檢查Brand ,specification and quantities inspection 外觀質(zhì)量檢查Configuration quality inspection 材質(zhì)檢查Material quality inspection 質(zhì)量驗證Erection quality inspection 產(chǎn)品標識和檢驗狀態(tài)標識Production identification and inspection in situation identification5.4管道組成件的檢驗 Piping fitting inspec

17、tion5.4.1不銹鋼管子、管件（包括螺栓、螺母），應(yīng)用光譜分析儀對材質(zhì)的主要化學成份進行復查，并作好檢驗狀態(tài)標識。 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、螺母的螺紋應(yīng)完整、無劃痕、毛刺等缺陷，并應(yīng)配合良好，無松動或卡刺現(xiàn)象。 The screw thread shall be free fro

18、m 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法蘭密封面、纏繞墊不得有徑向劃痕、松散、翹曲等缺陷，石棉墊表面應(yīng)平整光滑，不得有氣泡、分層、折皺等缺陷。 The area between flange to flange and circle pad shall be protected from scratches loose

19、ning, 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閥門檢驗 Valve inspection5.4.4.1閥門試驗、檢驗前，專門成立閥門檢驗、試驗小組，其成員應(yīng)由施工班組、相關(guān)技術(shù)人員和質(zhì)量檢查人員組成。同時必須進行專門的技術(shù)交底，并配置相應(yīng)的工裝設(shè)備。 We will set up a valve check and test group before valve i

20、nspection, which include construction team, relative technique personnel, quality inspector. Meanwhile We will transfer necessary technique information and assemble proper work equipment.5.4.4.2閥門檢驗、試驗程序見圖3-1。 The valve inspection and test procedure see drawing 3-15.4.4.3閥門試驗應(yīng)從每批中抽查10%，且不少于1個，進行殼體壓力

21、試驗和密封性試驗。當不合格時，應(yīng)再抽查20%抽查，仍然不合格時，該批閥門不得使用。 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 case it is not qualified, another 20% of it shall be rechecked. If unqualified again, the valves cannot be used. 5.4.4.4閥門

22、的殼體壓力性試驗和密封性試驗必須用潔凈水進行。不銹鋼閥門試驗用水的氯離子含量不得超過25ppm. Clean water should be used in the valve shell pressure and densification test .The content of chlorine used in stainless steel valve should not overpass 25ppm5.4.4.5閥門的殼體試驗壓力應(yīng)為公稱壓力的1.5倍；試驗時間不得少于5min，以殼體、填料無滲漏為合格。Valves shell tested pressure should be

23、1.5 times of nominal pressure , and the test should last 5 minutes, It will be qualified in the case of shell and packing be free from leakage.圖3-1 閥門檢驗、試驗工藝流程圖 Drawing 3-1 Valve Inspection and Test Flow Plan閥門外觀質(zhì)量檢查valve configuration quality inspection質(zhì)量證明文件核查、確認Review and Confirmation of Qualific

24、ation Documentqiquuqq成立閥門檢驗、試驗小組Setting Up valve inspection and test group嚴密性試驗Pressure test強度試驗intensity test 不合格unqualified檢驗、試驗狀態(tài)標識Inspection ,test situation identification工裝設(shè)計制作檢驗場地準備Process assembly design and fabrication inspection yard preparation yard 編制技術(shù)措施并進行技術(shù)交底Prepared Technique and Tran

25、sfer it 不合格品處置Nonqualified production disposal合格交付安裝Erection available合格5.4.4.6除止回閥、節(jié)流閥外，閥門的密封試驗宜以公稱壓力進行，以閥瓣密封面不泄漏為合格。Except back and throttling valves, valve qualified inspection shall be determined by nominal pressure and no leakage in the densification area of valve petal.5.4.4.7公稱壓力小于1MPa，且公稱直徑大

26、于等于600的閘閥，殼體壓力試驗宜在系統(tǒng)試驗時，按系統(tǒng)的試驗壓力進行試驗，閘板密封試驗可采用色印等方法進行檢驗，接合面上色印應(yīng)連續(xù)。 As for the gate valve with nominal diameter more than 600 and nominal pressure less than 1Mpa, When doing the shell pressure test, It is better to examine according to the system testing pressure. Slide plate may use the color papers

27、 for testing and the continuation area should be continued. 5.4.4.8合金鋼閥門的殼體材質(zhì)必須逐件進行快速光譜分析，不合格時該批閥門不得使用。 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試驗合格的閥門，應(yīng)及時排凈內(nèi)部積水、吹干密封面

28、上應(yīng)涂防銹油，關(guān)閉閥門，封閉出入口。 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安全閥按設(shè)計文件規(guī)定的定壓值進行調(diào)試，允許偏差為3%。調(diào)試介質(zhì)：管道內(nèi)介質(zhì)為氣體時，優(yōu)先酇用氮氣調(diào)試；管道內(nèi)介質(zhì)為液體時，應(yīng)使用液體調(diào)試。調(diào)

29、壓時的壓力應(yīng)穩(wěn)定，每個安全閥啟閉次數(shù)為3次。要求起跳壓力明顯，無前漏、后漏現(xiàn)象。由于安全閥進出口壓差較大，不進行殼體壓力試驗，密封試驗時，壓力小于定壓值，不得泄漏，可在安全閥出口貼紙進行目測。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 conditions

30、: Using nitrogen first 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 clear without internal and external leakage. Because the

31、 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 質(zhì)量檢驗人員均對檢驗過程做出詳實的檢驗記錄，以備隨時

32、查證。 Quality inspector shall make detailed inspection record for verifying anytime.5.6 裝置區(qū)工藝管道材料經(jīng)檢查合格后，均將做出不同色標加以標識。防止施工過程用錯材料，并方便檢查人員監(jiān)查確認。各種管道配件在易于辨認處做出兩處標識，各種管材、型材均做出通長標識。After checked qualified ,the piping material shall be identified with different color tags ,which can avoid mistake of material

33、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 管道的預制加工 Piping prefabrication and processing 6.1為了減少現(xiàn)場預制帶來的技術(shù)管理、材料管理、設(shè)備管

34、理的工作負擔，搞好文明施工，開辟第二現(xiàn)場，設(shè)置管道預制場地，進行管道的工廠化、產(chǎn)品化的預制加工，而后再在現(xiàn)場進行安裝。管道預制加工廠設(shè)有軌道式天車、車床、搖臂鉆床、剪板機、坡口加工機、自動焊機等施工機具。We have track crown blocks, lathes, beam drills, plate shears ,groove processing machine and automatic welding machines in the piping prefabrication yard to avoid field work bearing such as techniqu

35、e management ,material management and 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 jobsite 6.2 預制前仔細核對單線圖與平面圖，核對基礎(chǔ)、設(shè)備、管架、預埋件、預留孔是否正確，對于最后封閉的管段應(yīng)考慮組焊位置和調(diào)節(jié)裕量。Before prefabricat

36、ion, We will check the isolated drawings and plans carefully , align the foundations ,equipments, pipe 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 closed last.6.3 管道預制應(yīng)按單線圖

37、規(guī)定的數(shù)量、規(guī)格、材質(zhì)選配管道組成件，預制過程中的每一道工序均應(yīng)核對管子的標記，并做好標記的移植，做到用料正確、尺寸準確、標識明顯。 In piping prefabrication progress, We will purchase piping fittings according to the specification, quantities and material quality formed in isolated drawings. We will check the piping tags in every steps and make changed tags in go

38、od consequence for using correct material and size and making clear tags.6.4 鋼材的切割及管道坡口的加工應(yīng)采用以下方法：鍍鋅鋼管和公稱直徑50的碳鋼管，采用機械切割，公稱直徑大于DN50的碳鋼管采用氧乙炔焰法切割；不銹鋼管應(yīng)用機械或等離子的方法切割，304L、316L和317L材質(zhì)的鋼管用砂輪切割或修磨時，應(yīng)有專用砂輪片。管子切口表面應(yīng)平整、無裂紋、重皮、毛刺、凸凹、縮口、熔渣、氧化物、鐵屑等。 Steel material cutting and piping groove process should use me

39、thods as follows; For galvanized steel tubes and carbon steel tubes with nominal diameter 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 ,For steel tubes wit

40、h 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 預制好的管段，按單元或區(qū)域擺放整齊，以便于運輸和安裝。管道施焊時，按規(guī)定的焊

41、接工藝執(zhí)行。管道焊接、無損檢測工作完成后，應(yīng)在預制廠內(nèi)除銹、噴砂和防腐，但焊口兩側(cè)各100mm的范圍內(nèi)不允許涂漆，焊工鋼印號、管道編號以及管線號不允許涂漆，待系統(tǒng)水壓試驗合格后再進行防腐涂漆。為保證焊接質(zhì)量，工藝管道焊接均采用氬電聯(lián)焊的工藝進行。Prefabricated piping section shall be laid in order to transportation and erection. We will weld complying with regulated welding process. After piping welding and non-destructi

42、ve 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 welders sign, piping number and pipeline number are not permit to paint, it should be done after system water pressure test qualified. In order to en

43、sure welding quality, all the process piping use argon continuation welding .6.6 預制完成的管段進行管線號、預制管段號標識，并用人工或壓縮風將管膛內(nèi)清除干凈，用塑料布封閉管口分門別類擺放。不銹鋼和碳鋼在切割和存放時，嚴格區(qū)分開。We make identification tags for pipeline number and prefabrication piping section number which are completed the prefabrication, clean piping insi

44、de 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裝置焊接工程中，工藝管道母材的不銹鋼比例在60以上，且有鈦一類特殊材質(zhì)的管道，焊接難度大、工藝標準要求高是該工程的主要特點。焊接質(zhì)量直接決定整個安裝工程的質(zhì)量，因此，我們應(yīng)從焊接材

45、料、焊接工藝、施焊過程、焊接檢驗諸方面對焊接質(zhì)量進行嚴格控制，確保每個焊接環(huán)節(jié)都處于受控狀態(tài)。In PTA assembly welding process, Because there is 60% of stainless steel in process piping parent material and piping has the especial titanium, the main character of the project is the difficult welding and high requirements of process standard. Weldin

46、g 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.焊材型號和規(guī)格選用應(yīng)嚴格執(zhí)行焊接工藝評定。焊前檢查、修正接縫的間隙、錯邊量等；焊接作業(yè)期間，注意自然環(huán)境對焊接作業(yè)的影響，焊后檢查焊縫表面質(zhì)量、角變形，及時

47、作出質(zhì)量評定，并按要求進行無損檢測，及時填寫焊接施工記錄。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. We will notice welding operation effects by native envi

48、ronment, 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 焊工應(yīng)在合格的焊接項目內(nèi)從事管道的焊接，

49、且在有效期內(nèi)。 Welders shall work on piping welding in acceptable welding project and in available period.7.1.2 焊材應(yīng)有產(chǎn)品合格證明書，并經(jīng)復驗合格。 Welding material should have qualified production certificates and acceptable after checking again.7.1.3 焊條應(yīng)按說明書或焊接作業(yè)指導書的要求進行烘干，并在施焊過程中，使用保溫筒保持焊條干燥。 Welding rod shall be dried

50、 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藝卡（焊接作業(yè)指導書）施焊。焊接工藝卡應(yīng)按與之相對應(yīng)鋼材的焊接工藝評定進行編制，并按程序進行審批。 Welders do their job with welding technique card,. Which will be prepared and reviewed by equivalent stee

51、l welding process qualification and procedure. equivalent steel welding process qualification and procedure. 7.1.5 當出現(xiàn)下列情況如沒有防護措施時，應(yīng)停止焊接工作： Welding operation must be stop in case following problem happened without protecta. 手工電弧焊時，風速8m/s，氬弧焊時，風速2m/s；The wind velocity is8m/s in SMAW, the wind velocit

52、y is 2m/s in arc welding.b. 相對濕度90%；Relative moisture is 90%c. 下雨；Raining7.1.6 焊接完畢后，及時在焊縫兩側(cè)50mm范圍內(nèi)打上焊工鋼印號，不銹鋼鋼管不做鋼印標識，但是應(yīng)在管道單線圖上標注清楚。 Welders stamps NO. shall be made in the 50mm range away from welding joints in time, Rebar marks will not be done in stainless steel tubes, but it should be indicate

53、d in piping isolated drawings.7.2 焊接材料的選擇 Welding Material Alternative焊接材料選用表 5-1List for Welding Material Alternative 序 號No. 管 道 材 料Piping material 焊 絲Welding wire 焊 條Welding rod 備 注Remarks1API5L GR BER105-2E7016-15 2ANSI 304ER308E308-16 3 ANSI 304LER308LE308L-16 4 ANSI 316ER316E316-16 5 ANSI 316LER316LE316L-16 6ANSI 317LER317LE317L-16 7C276ERNiCrMo-4EniCrMo-4 8