1、某氣相二氧化硅項目的管道施工方案 Construction Method for Piping2.1概述 General本工程是xxxxx有限公司新建的4800噸/年氣相二氧化硅項目，主要分為18個部分，管道的材料有20#鋼、20/PP、0Cr18Ni9、RPM、FRP，鍍鋅鋼管（Q235-A）。由于施工周期短，與土建交叉作業(yè)多，因此要合理安排施工任務，質(zhì)量、安全、進度三者都必須保證。Cabot Blue Star Chemical (Jiangxi) Co., Ltd. 4,800t/a fumed silica project includes 18 sections, pipe mate

2、rial manly contains 20#steel, 20/PP, 0Cr18Ni9, RPM, FRP, galvanized steel pipe (Q235-A). Due to construction time is tight, installation works always cross civil work, so it is necessary to arrange construction reasonably, to ensure safety, quality and progress reached project target.2.1 編制依據(jù) Compil

3、ation Basis21 設計公司的招標圖 drawing for bid issued by xxx.22 GB50235-97、GB50236-982.3主要實物工作量 Major work quantity不銹鋼管 S.S pipe 150m碳鋼管 C.S pipe 4,900m鋁合金管 Aluminum alloy pipe 370mFRP/PP 1,670m鍍鋅管 galvanized steel pipe 2,300m閥門 valves 680pcs.2.4施工技術措施 Construction Method2.4.1 管道安裝工作程序 Piping installation p

4、rocedure2.4.1.1 管道安裝程序示意圖 piping installation flow 管道預制管道支架預制管道清潔度檢查管道支架安裝質(zhì)量檢驗射線探傷試壓、沖洗、吹掃復位油漆、保溫交工驗收材料檢驗、除銹、涂底漆材料進場管道安裝管道組裝施工準備Piping fabricateSupport fabricateCheck cleanness of pipingErect supportQuality inspectionNDT testingTest pressure, flushing, blowing & recoverPainting & insulationCompletio

5、n & acceptanceInspect, remove rust, prime coatingMatl enter sitePiping erectionPiping fit-upPreparation2.4.1.2 施工準備（1） 技術交底：開工之前對所有參加施工的重點人員進行技術交底，使施工人員了解工程概況、工程工期、質(zhì)量要求、施工程序、施工難度及技術要求，明確自己在施工過程中所承擔任務的工作責任，對需持證上崗的人員進行檢查。要求參加施工的人員認真閱讀圖紙，領會設計意圖，并在進場施工之前，對所有施工人員一次全面系統(tǒng)的安全教育，通過技術交底，使施工人員對工程有較深的認識，加強施工人員的質(zhì)

6、量、安全意識。（2） 機具檢查：對施工所需要的機具進行清點核實，查看施工設備、機具是否完好，各種電動機具及電焊機是否運轉(zhuǎn)正常，安全可靠。檢測工具是否齊全、完好，發(fā)現(xiàn)問題應及時更換或維修。（3） 所有的管材、管件、閥門、焊材等必須有材料質(zhì)量證明書，其內(nèi)容、形式必須符合相應材料制造標準的要求。（4） 所有的管材、管件、閥門、焊材等必須按規(guī)范要求進行外觀檢查，合格后做好合格標識；閥門應按要求進行強度及嚴密性試驗，合格后作鉛封，安全閥應按要求檢驗與調(diào)整開啟壓力，調(diào)試合格后，在技術監(jiān)督局進行鉛封；填寫閥門試驗記錄及安全閥調(diào)試記錄。不銹鋼管道及組成件儲存期間不得與碳鋼接觸，采取有效的隔離措施。2.4.1.

7、2 Construction Preparation（5） Technical 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 re

8、quirements, installation difficulty and Technical requirements. Check all persons involving certifications. All installation personnel shall study the drawings carefully. Proper training shall be conducted for all persons before entering the site. A deeper understanding shall be achieved through the

9、 technical meetings. Quality and safety 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. Ch

10、eck conditions of testing tools. Unqualified 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 accordance with fabrication standard requirements f

11、or corresponding materials.（8） All pipe 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 sh

12、all be inspected and adjusted for opening pressure and shall be lead sealed if qualified. Finish valve testing records and safety valve adjusting records. Stainless steel pipes, alloy steel pipes and their components shall not come into contact with carbon steel during storage.2.4.1.3 材料檢驗（1） 所有的管材及

13、管件和其它各種涉及到裝置永久性存在的材料都必須有材料合格證，必要時應抽檢、化驗等。管件、管材、型材、閥門、螺栓、墊片、焊材的質(zhì)量應符合設計文件、施工圖紙的規(guī)定。并應按國標進行外觀檢查，不合格者嚴禁使用。（2） 可燃介質(zhì)、高溫、易爆介質(zhì)管道閥門需逐個試驗，其它管道閥門以每批中抽檢10%，且不少于1個進行強度及嚴密性試驗。當試驗不合格時，應加倍抽查，仍不合格該批閥門不得使用。（3） 閥門殼體的試驗壓力取公稱壓力的1.5倍，試驗時間10分鐘，以殼體填料無滲漏為合格。密封試驗以公稱壓力進行，以閥瓣密封面無泄露為合格。（4） 試驗合格的閥門及時排盡內(nèi)部積水，并吹干，密封面涂防銹油，關閥門，封閉出入口，做

14、明標記，并填寫“閥門試驗記錄”。（5） 管道組成件及支承件在施工過程中按業(yè)主要求妥善保管，不得混淆或損壞，其標記應明顯，暫時不能安裝的管材應兩端封閉，不銹鋼材料應特別注意不得與其它碳鋼材料堆放，防金相腐蝕（滲碳）。（6） 管材、（管件）檢驗主要參照下述標準:GB2270-80、GB8163-87、 HGJ46-91、 HGJ20615、 GB50235-97。（7） 從業(yè)主領用的材料或乙方自采購的材料應分門別類堆放，妥善保管，發(fā)出的材料應有工程師的簽字方可發(fā)放。2.4.1.3 Material Test & Inspection（1） All pipes, fittings and valve

15、s and other involved with permanent 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 ot

16、her pipe valves, test to be done 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 te

17、st pressure shall be nominal pressure 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, a

18、nd fill in “Valves Test Record”. （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 t

19、hat shall be isolated away C.S. material 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 deliv

20、ery from the owner or construction contractor purchased material to be stored in good order, and material cannot be issued until engineer make signature. 2.4.2 管道預制管道預制擬定在施工臨設規(guī)定的管道預制廠的專門的預制平臺上進行，這樣既改善工作環(huán)境，又保證施工質(zhì)量。Pipe fabrication is to be performed in dedicated prefabrication shops inside of battery

21、 limit of the plant so as to improve working environment and ensure installation quality. 2.4.2.1 管道清潔度檢查：預制前對所需用的管道進行內(nèi)部和外部的清潔程度檢查，如果內(nèi)部有鐵銹、碎屑、油污等雜質(zhì)，應用壓縮空氣進行清理，直到檢查合格后，才能投入使用。Pipe cleanness check: cleanness check shall be performed for internal and external of required pipes prior to prefabrication,

22、any rust, debris, grease or other foreign matters shall be removed using cloth, compressed air, iron wire or sandblast and shall be inspected by THE OWNER prior to use. 2.4.2.2 鋼管切割（1） 按提供的管道布置圖進行選材下料，并在圖上標識管段號。管子下料之前，應將管道上原有標記進行移植；（2） 小口徑鋼管采用切割機切割，然后用坡口機坡口；大口徑碳鋼管（6以上）用切割機無法切割時，可采用氧乙炔切割并打磨坡口。不銹鋼管4以下

23、采用砂輪切割機切割，6以上不銹鋼管道采用等離子切割機切割。在管道預制車間的鋼平臺上操作時，應用橡膠板鋪設在平臺上進行隔離；（3） FRP/PP管、鋁合金管采用細齒鋼鋸切割.（4） 鋼管切割的質(zhì)量要求是：切口表面應平整，不得有裂紋、重皮、毛刺、凹凸等缺陷，如有應予以清除。（5） 切口端面斜偏差外徑的1%，且不得超過3mm。（6） 切割之后的鋼管應及時在每一個管段上用油漆或記號筆標明鋼管的材質(zhì)、規(guī)格、管線號，并根據(jù)施工圖紙標明所使用的位置。2.4.2.2 Steel Pipe Cutting （1） Select material in accordance with the isometric

24、drawing provided by THE OWNER, pipe 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 impossib

25、le to be cut by cutting machine can 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 s

26、heets shall be laid on the platform for separation. （3） FRP/PP pipe and aluminum alloy pipe shall be cut with serrating hacksaw. （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 re

27、moved. （5） Bevel end slope deviation 1% of O.D of pipe, and not more than 3mm. （6） For steel pipes that are already cut, use paint or marking pen to mark on each pipe segment the material, specification and line number for the steel pipe, their service locations shall be marked on AFC drawings. 2.4.

28、2.3 坡口加工（1） 根據(jù)設計院提供的管道施工規(guī)范（GB50235-97）中的技術要求，坡口加工應按下列圖表進行：a. 管壁厚度小于等于2.5mm坡口形式按下圖b. 當管壁厚度為2.520mm時坡形式按下圖。t2.5992070+560-5b1223p1223c. 不等厚管子、管件組對時，如果內(nèi)壁錯邊量大于1.0mm或外壁錯過量大于2mm時按下圖形式進行修整。2.4.2.3 Bevel chamfering（2） In accordance with piping construction code (GB50235-97) supplied by design institute, bev

29、el chamfering shall be executed as per following figure: a. For pipe wall thickness2.5mm, the bevel type as following figure: b. For pipe wall thickness2.5mm, and 20mm, the bevel type as following figure:t2.5992070+560-5b1223p1223c. When fit up different thickness pipes or fittings, if offset of pip

30、e inside is over 1.0mm, or offset of pipe outside is upper 2mm, repair shall be done as following figure: 2.4.2.4 管道的組對（1） 管道預制的組對工作，在管道加工平臺上進行，組對不銹鋼管時平臺上應鋪設3mm的橡膠板，同碳鋼板進行隔離。不得用碳鋼器皿打擊不銹鋼管。管道組對允許偏差按管道允許偏差進行檢查，其檢驗方法是用角尺、鋼板尺、鋼卷尺測量。（2） 自由管段和封閉管段選配應合理，封閉管段應按現(xiàn)場實測后的安裝長度加工。（3） 自由管段和封閉管段的加工尺寸允許偏差應符合下表規(guī)定：項 目允

31、 許 偏 差自 由 管 段封 閉 管 段長度101.5法蘭面與管子中心垂直度D1000.50.5100DN3001.01.0DN3002.02.0法蘭螺栓孔對稱水平度1.61.6（4） 管支架制作在管道預制的同時可以進行管道支架的制作。管架制作的型式結(jié)構、材質(zhì)、加工尺寸、制作精度應符合設計院提供的管支架標準的要求，外觀應平整美觀，焊接應牢固，無漏焊、欠焊、裂紋等缺陷，焊接表面應光潔，無飛濺物，焊接變形應予以矯正，制作好的管支架應及時進行防銹處理，并作出標記。2.4.2.4 Piping fit-up（1） pipe assembly shall be done on the pipe fabr

32、ication platform. For stainless steel assembly, 3mm rubber sheets shall be furnished on the platform for separation against carbon steel plate. Carbon steel tools are not allowed to strike stainless steel pipes. Assembly tolerance shall be checked against allowable pipe tolerance. The inspection met

33、hod involves measurement with Angle Square, steel plate ruler and steel tape. （2） It shall be reasonable for Selection and arrangement of free spool and close spool, construction for close spool shall be as per installation length measured at site. （3） Allowable process size deviation for free spool

34、 and close spool shall be in conformity with following table requirement: Item Allowable deviationFree spoolClose spoollength101.5Center verticality between flange and piping. D1000.50.5100DN3001.01.0DN3002.02.0Symmetrical levelness of flange bolthole. 1.61.6Pipe support fabrication: pipe support ca

35、n be fabricated as the pipes are prefabricated. The supports shall 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 we

36、ld or cracks. The welding surface shall be smooth without any spatters. 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，應具備焊接工藝評定、焊工合格考試并取證、焊接工藝卡、焊接材料根據(jù)焊接母材作相應的選定。（2

37、） 焊工應根據(jù)焊接工程師所提供的工藝卡進行施焊，不允許在雨天、霧天、相對濕度超過90%，風速超過8m/s除非采取相應的保護措施。（3） 焊條根據(jù)要求，由專門烘烤工實施干燥，不同烘干溫度的焊條不得在同一烘箱中烘烤，不同牌號的焊條應作出相應的標記。沒有用完的焊條應及時回收，超過烘烤次數(shù)的焊條應禁止使用。焊工必須使用正規(guī)焊條筒領用焊條。（4） 在點焊之前，應仔細檢查坡口、表面、并進行相應的清理，管內(nèi)無雜物，焊接坡口端50mm以內(nèi)的表面應打磨干凈，呈現(xiàn)金屬光澤，方可點焊。（5） 管道對接焊口的組對應做到內(nèi)壁平齊，內(nèi)壁錯邊量不宜超過壁厚的10%，且不大于2mm，不等壁管道施工時，應注意修整。（6） 當焊

38、接完成時，在管道軸測圖上標注焊口號，焊工號。（7） 預制完成的管線，管口端應用管帽（塑料）封堵，防止臟物進入。（8） 本工程各鋼種選用的焊絲、焊條如下：Weld rod & wire (applied in this project) as follows鋼 號steel No.手弧焊焊條manual welding rod氬弧焊argon arc welding20#J422H08Mn2SiAQ235AJ4220Cr18Ni9A102H0Cr20Ni10TiALSALMg-X2.4.2.5 Piping welding（1） Welding procedure qualification,

39、welder qualification examination, welding process card and welding material (choice as per base metal)shall be conducted 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 hu

40、midity exceeds 90%, or when wind speed exceeds 8m/s. （3） Welding 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 identifie

41、d with different color marking or other types of marking at the 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 sh

42、all check assembly conditions prior to tack welding. The bevel angle, butt clearance 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 ac

43、cordance with the corresponding welding procedure sheet. Slag and 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 do

44、ne accordingly on the single-line diagram. （7） Fabricated pipeline shall have their ends covered with pipe caps (plastic) to protect ingress of foreign matters.2.4.2.6 焊接檢查（1） 焊縫外觀檢查a. 不允許有裂紋、未溶合、氣孔、夾渣、飛濺存在；b. 咬邊度0.5mm，焊縫兩側(cè)咬邊總長不大于該焊縫全長的105，且不應大于100mm；c. 焊縫表面不得低于母材表面，焊縫余高應符合GB50236-98提供的焊接規(guī)范要求；d. 焊接接

45、頭錯邊量不應大于壁厚的10%，且不大于2mm。（2） 焊縫質(zhì)量：管道焊縫質(zhì)量檢查按設計院提供管道施工規(guī)范（GB50235-97）中的有關焊縫檢查的標準進行。（3） 焊接合格的焊縫應及時填寫管道焊接記錄，記錄應整潔、準確、工整、對不合格片應嚴格進行返修，然后用原方法作射線無損檢測，檢查合格的焊口應在單線圖或焊接記錄上作出相應的標識。2.4.2.6 Welding inspection（1） Weld visual inspectiona. No cracks, lack of fusion, porosity, slag inclusion or spatter are permitted.b.

46、 Undercut shall be less than 0.5mm, total undercut length on both sides of the weld shall not be larger than 10% of total weld length, and shall not be larger than 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 de

47、sign institute; d. Weld joint unfitness shall not exceed 10% of wall thickness, 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

48、in pipe welding records for qualified welds and enter proper qualification data 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 accord

49、ingly marked on the single-line diagram or welding record. 2.4.3 管道安裝前應具備的條件2.4.3.1 與管道安裝的土建或鋼結(jié)構工程已檢驗合格，滿足安裝要求，并辦理好交接手續(xù)；2.4.3.2 與管道連接的設備已找正合格，固定完畢；2.4.3.3 管道內(nèi)部清潔度已檢查合格，對管內(nèi)有特殊要求的管線其質(zhì)量應符合設計文件的要求；2.4.3.4 設計需要修改的位置及管道上的開孔應在安裝之前完成。2.4.3 Conditions before installation2.4.3.1 Civil or structure works assoc

50、iated with pipe installation have been completed and inspected to be satisfactory 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 requiremen

51、ts for their internal, their quality shall be as per requirements in the design documents;2.4.3.4 Location modifications required by design and opening on the pipe shall be completed prior to pipe installation.2.4.4 鋼制管道安裝2.4.4.1 管道安裝時，應檢查法蘭密封面及密封墊片，不得有影響密封性能的劃痕、斑點等缺陷。2.4.4.2 法蘭連接應與管道同心，并應保證螺栓自由穿入。法

52、蘭螺栓應跨中安裝。法蘭間應保持平行，其偏差不得大于法蘭外徑的1.5%，且不得大于2mm，不得用強緊螺栓的方法消除歪斜。2.4.4.3 工作溫度低于200的管道，其螺紋接頭密封材料宜選用聚四氟乙烯帶。擰緊螺紋時，不得將密封材料擠入管內(nèi)。2.4.4.4 法蘭連接應使用同一規(guī)格的螺栓，安裝方向應一致。螺栓緊固后與法蘭緊帖，不得有楔縫。需加墊圈時，每個螺栓不應超過一個。緊固后的螺栓與螺母宜齊平。2.4.4.5 當管道安裝處于露天或處于大氣腐蝕環(huán)境時，螺栓、螺母應涂以二硫化鉬油脂、石墨機油或石墨粉。建設單位另有要求時，按建設單位要求進行。2.4.4.6 管子對口時應在距接口中收200mm處測量平直度（見

53、下圖）。當管子公稱直徑小于100mm時，允許偏差為1mm，當管子公稱直徑大于100mm時，允許偏差為2mm。全長允許偏差10mm。2.4.4.7 管道對口平直度（1） 管道連接時，不得用強力對口、加偏墊或加多層墊等方法來消除接口端面的空隙、偏隙、錯口或不同心等缺陷。（2） 支管與主管連接時，當工藝要求按介質(zhì)流向傾斜，傾斜度按設計規(guī)定。2.4.4.8 管道安裝允許偏差應符合下表規(guī)定：（單位：mm）項 目允 許 偏 差坐標架空及地溝室外25室內(nèi)15標高架空及地溝室外20室內(nèi)15水平管道平直度DN1002L,最大50DN1003L,最大80立管鉛垂度5L,最大30成排管道間距15交叉管的外壁或絕熱層

54、間距202.4.4.9 膨脹節(jié)安裝時，按設計要求進行予拉伸，允許偏差10mm，拉前將固定管托焊接牢固。2.4.4.10 閥門安裝（1） 閥門安裝前，應檢查填料，其壓蓋螺栓應留有調(diào)節(jié)余量。（2） 閥門安裝前，應按設計文件核對其型號，并應按介質(zhì)流向確定其安裝方向。（3） 當閥門與管道以法蘭或螺紋連接時，閥門應在關閉狀態(tài)下安裝。（4） 水平管道上的閥門，其手柄方向宜安裝在上半周范圍內(nèi)，閥門操作和機構應靈活，指示準確。2.4.4.11 支架安裝（1） 管道安裝時，應及時固定，高調(diào)整支架。支架位置應準確，安裝應平整牢固，與管子接觸應緊密。（2） 有熱位移的管道，導向支架或滑動支架的滑動面應潔凈平整；不得

55、有歪斜和卡澀現(xiàn)象。其安裝位置應從支撐面中心位置向位移反方向偏移，偏移量應為位移量的1/2，或符合設計規(guī)定，絕熱層不妨礙其位移。（3） 固定支架應嚴格按設計規(guī)定執(zhí)行；在一直管線上不得有兩個以上固定支架。（4） 管道安裝時不宜使用臨時管架，當使用臨時管架時，支架不得與正式管架位置沖突；并應有明顯標記。在管線安裝完畢應予拆除。（5） 管道安裝完畢后，應按設計文件規(guī)定逐個核查支架形式和位置。a 活動架的位移方向及導向性能應符合設計規(guī)定。b 管托不得脫落。c 固定支架牢固可靠。2.4.4.12 伴熱管安裝（1） 伴熱管應與主管平行安裝，多個伴熱管在主管圓周上的分布按設計要求布置。（2） 不允許將伴熱管直

56、接點焊到主管上，伴熱管的固定按設計要求進行。（3） 伴熱管的其他安裝同主管的要求相同（包括伴熱管的壓力試驗吹掃）。2.4.4 Steel Pipe installation2.4.4.1 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. Flange bolts shall be set at striding to center method. Parallel shall be kept between flanges,