某气相二氧化硅项目管道与焊接中英文施工方案.doc

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某气相二氧化硅项目的管道施工方案
Construction Method for Piping
2.1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、 0Cr18Ni9、 RPM、 FRP, 镀锌钢管( Q235-A) 。由于施工周期短, 与土建交叉作业多, 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 material 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 编制依据 Compilation Basis
2．1 设计公司的招标图 drawing for bid issued by xxx.
2．2 GB50235-97、 GB50236-98
2.3主要实物工作量 Major work quantity
不锈钢管 S.S pipe 150m
碳钢管 C.S pipe 4,900m
铝合金管 Aluminum alloy pipe 370m
FRP/PP 1,670m
镀锌管 galvanized steel pipe 2,300m
阀门 valves 680pcs.

2.4施工技术措施 Construction Method
2.4.1 管道安装工作程序 Piping installation procedure
2.4.1.1 管道安装程序示意图 piping installation flow

管道预制
管道支架预制
管道清洁度检查
管道支架安装
质量检验
射线探伤
试压、 冲洗、 吹扫复位
油漆、 保温
交工验收
材料检验、 除锈、 涂底漆
材料进场
管道安装
管道组装
施工准备

Piping fabricate
Support fabricate
Check cleanness of piping
Erect support
Quality inspection
NDT testing
Test pressure, flushing, blowing & recover
Painting & insulation
Completion & acceptance
Inspect, remove rust, prime coating
Mat’l enter site
Piping erection
Piping fit-up
Preparation

2.4.1.2 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, 经过技术交底, 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; 阀门应按要求进行强度及严密性试验, 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） 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 requirements, 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 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. Check 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 for 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 shall 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1.5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 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 other 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 test 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, and 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 that 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 delivery 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, 这样既改进工作环境, 又保证施工质量。
Pipe fabrication is to be performed in dedicated prefabrication shops inside of battery limit of the plant so as to improve 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 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 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—乙炔切割并打磨坡口。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△≤外径的1%, 且不得超过3mm。

（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 accordance with the isometric 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 impossible 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 sheets 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 removed.
（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.

2.4.2.3 坡口加工
（1） 根据设计院提供的管道施工规范( GB50235-97) 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. 当管壁厚度为2.5~20mm时坡形式按下图。

t
>2.5~9
>9~20
α
70°+5
60°-5
b
1~2
2~3
p
1~2
2~3

c. 不等厚管子、 管件组对时, 如果内壁错边量大于1.0mm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 accordance with piping construction code (GB50235-97) supplied by design institute, bevel chamfering shall be executed as per following figure:
a. For pipe wall thickness≤2.5mm, the bevel type as following figure:

b. For pipe wall thickness≥2.5mm, and ≤20mm, the bevel type as following figure:

t
>2.5~9
>9~20
α
70°+5
60°-5
b
1~2
2~3
p
1~2
2~3

c. When fit up different thickness pipes or fittings, if offset of pipe 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δ＝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） 自由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） 自由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
±10
±1.5
法兰面与管子中心垂直度
D＜100
0.5
0.5
100≤DN≥300
1.0
1.0
DN＞300
2.0
2.0
法兰螺栓孔对称水平度
±1.6
±1.6
（4） 管支架制作
在管道预制的同时能够进行管道支架的制作。管架制作的型式结构、 材质、 加工尺寸、 制作精度应符合设计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 fabrication platform. For stainless steel assembly, δ＝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 method 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 and close spool shall be in conformity with following table requirement:
Item
Allowable deviation
Free spool
Close spool
length
±10
±1.5
Center verticality between flange and piping.
D＜100
0.5
0.5
100≤DN≥300
1.0
1.0
DN＞300
2.0
2.0
Symmetrical levelness of flange bolthole.
±1.6
±1.6

Pipe support fabrication: pipe support can 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 weld 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, 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。
（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
氩弧焊
argon arc welding
20#
J422
H08Mn2SiA
Q235A
J422

0Cr18Ni9
A102
H0Cr20Ni10Ti
AL

SALMg-X

2.4.2.5 Piping welding
（1） Welding procedure qualification, 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 humidity 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 identified 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 shall 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 accordance 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 done 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. 焊接接头错边量不应大于壁厚的10%, 且不大于2mm。
（2） 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 Welding inspection
（1） Weld visual inspection
a. No cracks, lack of fusion, porosity, slag inclusion or spatter are permitted.
b. 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 design 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