管道热浸镀锌施工方案.doc

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GUANGDONG LNG RECEIVING TERMINAL
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GDLNG-TT-EPC-TERMINAL-01

Document title:
METHOD STATEMENT FOR PIPING HOT-DIP GALVANIZING

管道热浸镀锌施工方案

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File Name : T653010-W07-PAI-40.81-50233_0.doc

GUANGDONG LNG RECEIVING TERMINAL

METHOD STATEMENT FOR PIPING HOT-DIP GALVANIZING

T653010-W07-PAI-40.81-50233
19-07-05

REVISION : 0

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TABLE OF CONTENTS
目 录
1. 目的 PURPOSE 5
2. 参考文件 REFERENCE DOCUMENTS 5
3. 镀锌厂家及车间概况 INTRODUCTION TO THE GALVANIZING MANUFACTURER
AND THE WORKSHOP 5
4. 工程量PROJECT QUANTITY………………………………………………………………….6
5. 组织机构和计划用工程人员ORGANIZATION AND MANPOWER SCHEDULE………………………………………………………….…………………..6
6. 主要工机具 MAIN TOOLS AND MACHINES………………………………………………7
7. 施工方案 CONSTRUCTION PROGRAM…………………….………………………..9
8. 质量保证措施QUALITY ASSURANCE MEASURES……………………………….10
9. 安全保证措施 SAFETY ASSURANCE MEASURES…………………………………13

GUANGDONG LNG RECEIVING TERMINAL

METHOD STATEMENT FOR PIPING HOT-DIP GALVANIZING

T653010-W07-PAI-40.81-50233
19-07-05

REVISION : 0

PAGE : 19 /19

1. 目的 Purpose
本方案描述了由CNI23分包的GD LNG项目合同范围内，所有需热浸镀锌的管道，其在车间的镀锌工艺和方法。
This program describes the galvanizing process and methods in workshop for all piping that need to hot-dip galvanize within the contract of GD LNG project which is subcontracted by CNI23.

2. 参考文件 Reference documents
2.1 规范Specification
- 厂商油漆规范 T653010-000-PAI-10.04-10001
Painting Specification for Vendors T653010-000-PAI-10.04-10001
- 厂站作业涂漆规范 T653010-111-PAI-10.04-10001
Plant Job Painting Specification T653010-111-PAI-10.04-10001
2.2 标准Standard
- ISO1461:1999 《钢铁制件热浸锌技术要求及实验方法》
Technical requirements and test methods for hot-dip galvanizing of steel products ISO1461:1999
- ASTM A 123 《铁制品和钢制品的锌(热浸镀锌)层的标准规范书》
ASTM A 123 STANDARD SPECIFICATION FOR ZINC (HOT-DIP GALVANIZED) COATINGS ON IRON AND STEEL PRODUCTS.
- ASTM A 153 《铁结构和钢结构的锌(热浸镀锌)层的标准规范书》
ASTM A 153 STANDARD SPECIFICATION FOR ZINC (HOTDIP GALVANIZED) COATINGS ON IRON AND STEEL
HARWARE.
- GB/T 13912-2002 《金属覆盖层叠钢铁制件热镀锌层技术要求及实验方法》
Technical requirements and test method for steel structure hot-dip galvanizing GB/T 13912-2002

3．镀锌厂家及车间概况 Introduction to the Galvanizing Manufacturer and the Workshop
3．1镀锌厂家 Galvanizing Plant
经业主和GDC批准的镀锌厂家是：惠州大亚异特钢构有限公司
Galvanizing plant approved by the Company and GDC: Huizhou Daya Irregularly-shaped Special Steel Company, ltd.
3．2车间概况 Introduction of Workshop
镀锌车间是集钢结构、管道除锈、镀锌一体的综合性生产车间，钢结构工件从除锈到镀锌、检测出货等成套的生产服务，有先进的镀锌设备和工艺，能承接各种板材、管道及其它钢结构的镀锌加工，每日能镀锌大约60吨的产品。
Galvanizing workshop is an integral production workshop for rust removal and galvanizing of steel structure and piping. It can supply sets of services from rust removal of workpiece to galvanizing, inspection and out of factory, etc. It has advanced galvanizing facilities and process, with daily production of about 60t.

4． 工程量Project Quantity
预计的需热浸镀锌的管道工作量为: 管道约2600米、各类管件约960个，总重约46吨。
Estimated work quantity of piping need to hot-dip galvanize: piping: about 2600m, various kinds of fittings: 960 pieces , total weight: 46 tons.

5．组织机构和计划用工程人员Organization and Manpower Schedule
5．1 组织机构 Organization

总经理 general manager

副总经理deputy general manager

质量部
quality department
仓管部
storehouse management department
工程技术部
project technical
department
专职安全员 professional safety controller

生产部 production department

质量检查员
quality inspector

物料
materials
设备
equipment
成品
finished product
工艺
process
设计
design
调度
adjustment

镀锌二班
galvanizing class 2
镀锌一班
galvanizing class 1

5．2计划用工程人员 Manpower Schedule
计划用工程的人员表Manpower Schedule Table

主要技术/管理人员Principal Technical /Management Personnel
姓　名
Name
年　龄
Age
现任职务Position
职　称
Title
工作经验(年)
Work experience（year）
李胜忠
Li Shengzhong
37
技术、质保副总
Deputy General Manager of Technology and QA
工程师
Engineer
18

李行
Li Xing
37
生产副总
Deputy General Manager of Production
工程师
Engineer
16
林红
Lin Hong
28
技术员
Technician
助理工程师Assistant engineer
8
李杰
Li Jie
32
镀锌质检
QC for Galvanizing

14
主要技术工人Principal Technical Workers
谭毫
Tan Hao
34
镀锌技术工
Galvanizing Technician

16
耿亚军
Geng Yajun
32
镀锌技术工
Galvanizing Technician

20
马春喜
Ma Chunxi
38
镀锌技术工
Galvanizing Technician

16

6． 主要工机具 Main tools and machines
6．1镀锌锅 Galvanized Boiler
6．1．1镀锌锅的主要性能 Main performances of Galvanized Boilers
长9000毫米，宽1500毫米，深2000毫米，最长可镀13米，宽1.4米,高3米。
9000mm long, 1500mm wide and 2000mm deep, maximum: 13m long, 1.4m wide and 3m high.
6．2抛丸机的主要经济技术指标 Main Economic and Technical Index of Shot Blasting Machine
6．2．1质量指标 Quality Index
工件总体质量达到ISO1461：1999标准，提高抗腐蚀能力。
General quality of the work piece reach the standard of ISO1461:1999; improve the ability of anti-corrosion.
6．2．2安全指标 Safety Index
无火灾、死亡、重伤事故，轻伤事故发生率低于1%。
No fire, death and grievous bodily harm(GBH ), and probability of slight harm shall be less than 1%.
6．2．3经济指标 Economic Index
使用效率，工人劳动强度小，环境污染轻，费用低。
High usage efficiency, low labor intensity, slight environmental contamination and low expense.
6．3镀锌锅主要工作原理Main Work Principle of Galvanized Boilers
镀锌锅主要是将锌锭熔化，构件在440度锌液中浸锌，以此将锌液附着在构件上，达到防腐作用。
To melt the zinc ingot in the galvanized boiler, and dip the structures into 440℃ zinc solution, then zinc solution will cling to the structures to achieve the aim of anti-corrosion.
6．4镀锌锅的主要经济技术指标Main Economic and Technical Index of Galvanized Boilers
6．4．1质量指数 Quality Index
由于使用的锌锭为0号锌，可达到各等级施工要求，总体达到优质工程。
Zinc ingot applied are No.0 zinc, which can achieve the construction requirements of various grades, and make it Excellent Project.
锌锭的化学成份：Zn 99.9966% ,Pb 0.0012%, Fe 0.0004%, Cd 0.0013%, Cu 0.0001%, Sn 0.0002%, Al 0.0002% 。
chemical component of zinc ingot: Zn 99.9966% ,Pb 0.0012%, Fe 0.0004%, Cd 0.0013%, Cu 0.0001%, Sn 0.0002%, Al 0.0002% .
6．4．2安全指标 Safety Index
无火灾、死亡、重伤事故，轻伤事故控制在1%以内。
No fire, death and grievous bodily harm(GBH ), and slight harm shall be controlled to 1%.
6．4．3经济指数 Economic Index
镀锌效率高、适应性强、锌膜适中、防腐性好。
High galvanizing efficiency, good adaptability, proper zinc film and good anti-corrosion performance

7．施工方案 Construction Program
7．1施工准备Construction Preparation
7．1．1技术准备 Technical Preparation
- 进行镀锌的工艺评定。
Qualification of Galvanizing Process
- 编制工艺卡，详细施工作业规章，对施工班组进行质量技术交底并作好交底记录。
Prepare process cards, and carry out quality technology talk-over for the construction teams and make the talk-over records.
- 施工人员技术培训：对各工程技术工人进行必要的有针对性的培训，经考试合格后才可上岗操作。
Training of the construction personnel: perform necessary and pertinent trainings for all engineering technicians, and these personnel can only be on post after tested qualified.
7．1．2设备、机具Equipment, Tools and Machines
- 设备经检验合格，并进行必要的维护。
The equipment are checked qualified and have necessary maintenance.
7．1．3所有施工用的检测、检验、测量仪器必须经过校验，保证其在校验有效期内。
All applied measuring and testing instrument must be checked and be guaranteed with the valid date.
7．1．4原材料进厂检验 Factory Entering Inspection for Raw Materials
- 锌锭进厂进行必要的检验，并符合最新的国家标准。
Necessary inspection shall be performed when the zinc ingot enter the factory to ensure they comply wit the latest national standard.
7． 2工艺流程Process
材料进场—— 检查——装架——检查——除油（喷砂）处理——检查——除锈处理——清水池——除锈——检查——助镀剂——检查——烘干——镀锌——冷却（钝化）——镀后检查——成品打磨——成品检查——标识——成品堆放
materials enter the site – inspection - place on rack – inspection – oil removal(blasting) – inspection – rust removal - fresh water tank – rust removal – inspection – galvanizing aid – inspection – drying – galvanizing – cooling( passivation) – inspection after galvanizing – grinding of finished products – inspection of finished products – marking – pack of finished products
7．3施工说明 Notes for Construction
7．3．1甲方材料进场与合同进行核对,准确无误后安排进行装架除锈处理。
After the materials of the Party enter the site, check it according to the contract, if it is correct carry out the rack-placing and rust removal treatment.
7．3．2对不镀锌位置进行保护家阻镀剂。
To protect the ungalvanized position with galvanizing resistance agent.
7．3．3除锈完成后加助镀剂,达到镀锌技术指标要求。
After rust removal add the galvanizing aid, so that to achieve the galvanizing technical index requirements.
7．3．4构件在锌锅中锓泡，达到防腐要求。
Dip the structures in the zinc boilers, so that to achieve the anti-corrosion requirements.
7．4文件的提供（见后附录一） Provision of Documents（see appendix 1）
- 热锓锌生产工艺流程质量控制表
Quality control table of hot dip galvanizing process
-热浸镀锌合格证书
Certificate of hot dip galvanization

8．质量保证措施Quality Assurance Measures
8．1质量方针 Quality Policy
“重视质量, 创优品牌，服务顾客，持续改进”
Stress quality, create nameplate, serve customer and improve continuously.
8．2质量目标 Quality Objective
本厂的质量目标：一次交验合格率大于等于98%，出厂合格率100%。
Quality objective of the factory: acceptable rate of those submitted for test in one time: equal or larger than 98%, protective acceptance rate: 100%.
向客户承诺管道镀锌防腐工程全部过程将严格按该方案的各项规定进行施工，操作。向客户提供满足生产和合同要求的优良产品。
We guarantee to the customers that the piping galvanizing and anti-corrosion projects are all constructed strictly according to the provisions of this program. We will provide to the customers excellent products which meet the production and contract requirements.
8．3质量控制原则 Quality Control Principle
- 由公司下属的质量安全责任人执行质量控制职能。
Carry out the quality control function by the quality safety responsibility personnel affiliated to the company.
- 质量控制活动应严格执行质量标准设计文件及相关工作程序的要求。
Quality control activities shall strictly comply with the requirements of quality standard design document and relative work procedure.
- 对从事质检活动的人员进行执行培训，考核并进行资格评定，以确保质检人员的素质。
Train for the personnel who take charge the quality inspection activities, and qualify them to ensure the quality of QC personnel.
- 执行质量否决权制度。
Implement quality veto right system.
- 加强班组长及一线人员的质量意识教育。
Strengthen the quality consciousness education for the team leaders and the key personnel.
8． 4质量控制要点 Key Points of Quality Control
8．4．1一般要求 General Requirements
- 人员资格,首先要验证操作人员的资格是否符合有关程序的规定,同时也要验证操作人员的合格证是否有效。
Personnel qualification: first check whether the personnel certification comply with the provisions of relative procedures. And check whether the personnel certificate is valid.
- 设备、工机具：应验证所使用的设备、工机具是实施该项操作的程序所规定的设备、工机具，并验证这些设备、工机具是按要求检定，保养合格处于完好状态。
Equipment, tools and machines: make sure that the equipment, tools and machines applied are the required ones for construction, and verify that these equipment are inspected and in good status.
- 材料：验证所使用的材料符合相关程序和设计要求。
Materials: confirm that the materials applied comply with relative procedures and design requirements.
- 环境条件：需要注意执行作业场所的环境条件是否符合有关程序的要求。
Environmental conditions: pay attention whether the environmental conditions conform to relative procedure requirements.
8．4．2物项接收的质量控制 Quality Control of Items Acceptance
- 物项质量证明文件的检查，质量证明文件是否齐备，质量证明文件内容是否正确，质量证明文件所盖的量，物项质量是否符合要求。
Inspection of items certification documents, whether these documents complete or not, their contents are correct or not, relative work quantity and items quality conform to the requirements.
- 物项的标识：标识的方法符合规定要求，标识的内容符合规定要求，标识的位置符合规定要求，标识的可溯性。
Identification of items: the identification method shall comply with the requirements, its contents and positions shall comply with the requirements, traceability of marks.
- 物项的数量：应包括随带附件的数量。
Quantity of items: shall include the quantity of the accessories
- 物项的目视检查：表面和实体损伤、规格、型号、尺寸、方位的符合性，防护罩和封印，及采购文件中要求的其它检查。
- Visual inspection for items: Surface and body damage, specification, model, size and conformity of orientation, protection cover and stamp, and other inspection required in the procurement documents.
- 复验：有要求对物项进行复验（化学性能、物理性能等）。
Re-inspection: re-inspection for items(chemical performance, physical performance, etc)
- 状态标识：物项接收检查要由质检员加以状态标识，状态标识可分为三类：不合格品（不符合项）、待验、合格品、可交付使用。
Status identification: after item acceptance inspection the ins