潔凈壓縮空氣管道工程施工方案

1、 China New MSD Facility-Hangzhou Project杭州默沙東制藥有限公司新生產(chǎn)基地項(xiàng)目 WMS of Clean Compressed Air System潔凈壓縮空氣工程施工方案 General工程概況 The system of clean and compressed air belongs to the work scope of Qian. The clean and compressed air was distributed from Packaging Building L2 to each single level with a total pi

2、pe length of 250m, which uses ASME BPE 316L material.本工程潔凈壓縮空氣工程屬于我司施工范圍，潔凈壓縮空氣從包裝二樓配送至各單體，管道長(zhǎng)度約250m，采用ASME BPE 316L材質(zhì)。Basis of Compilation編制依據(jù)The compilation of this WMS is as per8232-M-SPEC-15211 Compressed Air System-03 and ASME BPE standards.根據(jù)S2F 15211 壓縮空氣系統(tǒng)規(guī)范及ASME BPE標(biāo)準(zhǔn)Technical Method of Met

3、allic pipe Construction金屬管道施工技術(shù)方案 The construction of metallic pipeline must be strict accordance with relevant standards and complied with operation process procedure and cleaning measures.The construction of ASME BPE 316L pipeline shall be strictly in accordance with ASME BPE standards, meanwhile

4、it shall also comply with certain operation process flow and adopt relevant cleaning measures.對(duì)于ASME BPE 316L管路的施工必須嚴(yán)格按照ASME BPE標(biāo)準(zhǔn)進(jìn)行，同時(shí)需遵循一定操作工藝流程和保潔措施。 1. Preparation施工準(zhǔn)備Preparatory work shall be done for the construction as the followings: 施工準(zhǔn)備按以下幾個(gè)過(guò)程：² Visual check直觀檢查 Sampling: confirm that

5、 no damages on the pipes and meet the requirements. Check whether there is plastic cap.抽樣檢查，確認(rèn)無(wú)損傷并符合要求，檢查是否有塑料帽密封 Check the model, quantity and certificates.檢查型號(hào)，數(shù)量及證書 Verify the delivery list.核對(duì)送貨單 Preparation of fabrication site.加工現(xiàn)場(chǎng)的準(zhǔn)備² Acceptance and receiving shall be finished and confirme

6、d by the person responsible.驗(yàn)收及接收由負(fù)責(zé)人完成確認(rèn)² The material would be stored in specific area and classified according to the model, size and clean grade. 材料儲(chǔ)存在指定區(qū)域內(nèi)并根據(jù)型號(hào)、尺寸、潔凈級(jí)別分類保存² Prevent the material from being bent, impacted, and extruded.材料運(yùn)輸不可彎曲，撞擊，擠壓等² There shall be detailed reco

7、rd of material distribution and usage.材料取用需有詳細(xì)記錄² Site measurement and inspection of relevant equipments.現(xiàn)場(chǎng)測(cè)量，相關(guān)設(shè)備的檢查² Production of sample.樣本制作² Material fabrication: pipe cutting, chamfering, bending and precast welding. 材料預(yù)制：管道切割，面處理，彎曲及預(yù)制焊接1.1 Construction Procedure施工步驟Site weldin

8、g includes:其中現(xiàn)場(chǎng)焊接包括：² Pipe positioning, site welding and quality inspection. In order to ensure that no oxidation and change of color on the surface of every weld joint, high-purity argon shall be used and ensure that shielding time is not less than 30min. 管道定位，現(xiàn)場(chǎng)焊接，質(zhì)量檢查。為保證每一焊縫內(nèi)表面無(wú)氧化變色,必須使用高純度

9、氬氣，保證沖氣時(shí)間不小于30分鐘。² Non-welding connection: fittings and equipment connection.非焊接連接：配件、設(shè)備連接。² Post-construction treatment: pipeline inspection and pneumatic pressure test.施工后處理：管道檢查,氣壓試驗(yàn)。² Document handover: sample record, construction record and test report.文件移交：樣本記錄，施工記錄及測(cè)試報(bào)告。1.2 Flo

10、w of Piping QI配管質(zhì)量檢查流程 管道焊接 否 外觀檢查 否 是安全檢查耐壓檢查泄漏檢查 否 是機(jī)能檢查移交給客戶 是1.3 General Rules of Welding 焊接總則² This specification is applicable to the welding, assembling and installation of hygiene pipes.本規(guī)范適用于衛(wèi)生管道的焊接、裝配和安裝；² This specification is applied specifically in the connection of circumfere

11、ntial butt welding head between ASME BPE stainless steel 316L pipe fittings本規(guī)范特別用于ASME BPE不銹鋼316L管件間之圓周對(duì)接焊頭之連接；² Welding in this specification shall meet ASME BPE acceptance standards.本規(guī)范中的焊接連接將需要符合ASME BPE的驗(yàn)收標(biāo)準(zhǔn)； The term maker of this specification means Qian, which is responsible for assembli

12、ng and installation of pipes. 本規(guī)范中術(shù)語(yǔ)裝配者是指啟安公司，他負(fù)責(zé)管道的裝配和安裝； “Client” means the end user or other representative. “業(yè)主”是指用戶或其代表； “Welding inspector” means the client or representative of end user, who will be responsible for inspecting the welding work of piping contractor. “焊接檢查員”是指業(yè)主或用戶代表，他將負(fù)責(zé)檢查管道承建商

13、的焊接操作。1.4 Welding specification焊接規(guī)范This specification covers the tungsten arc SS welding equipments that use automatic orbital welding machines. 本規(guī)范覆蓋用自動(dòng)軌跡焊接機(jī)的氣體鎢電弧不銹鋼焊接設(shè)備。 “Pipe” shall includes all components that require welding. “管道”應(yīng)包括所有需要焊接元件。1.5 General requirements總體要求² Operators of auto

14、matic welding machine shall take welding test to confirm their qualification. pipe material of common size of the project shall be used in the welding test.自動(dòng)焊接機(jī)的操作人員將用樣品材料做焊接測(cè)試以確認(rèn)其資格。焊接測(cè)試應(yīng)該選用項(xiàng)目常用的管材尺寸材料；² Tack welding of the module shall avoid ill effect on complete welding. 組件的定位點(diǎn)焊必須避免對(duì)完全焊接的不

15、良影響；² Tack welding shall be as light as possible to reduce internal structural change caused by overheating of the material. 定位點(diǎn)焊應(yīng)該盡可能的輕，以降低過(guò)熱而導(dǎo)致材料的內(nèi)部結(jié)構(gòu)變化；² Tack welding shall prevent penetration of the internal surface.定位點(diǎn)焊不應(yīng)焊透內(nèi)表面；² After the tack welding, inspect the alignment of th

16、e welding and the weld joint.定位點(diǎn)焊完成后，需要檢查定位焊接的對(duì)準(zhǔn)性和縫隙。1. Material 材料² The welding materials shall be complied with the technical specification of MSD.用于焊接的材料須符合甲方的技術(shù)規(guī)格；² All pipes and fittings shall be fully welded. 所有管道和配件須完全焊透；² The welding electrode shall be 2%thoriated tungsten ele

17、ctrode with square butt.采用的焊接電極為2%涂釷平頭鎢焊電極；² The welding electrode shall be replaced if any stain is found.焊接電極如有污染須更換；² The purity of argon as shielding gas inside and outside the welded pipes shall be at 99.99%. 焊接管道內(nèi)、外部保護(hù)氬氣的最低純度為99.99%；² Argon shall be injected during the welding a

18、s protective gas to prevent oxidation of the internal welding surface. Blow out all the oxygen in the welding area before the welding. 焊接過(guò)程中必須要通入氬氣進(jìn)行保護(hù)，以防止焊接的內(nèi)表面被氧化。在開(kāi)始焊接前，吹走焊接區(qū)域的所有氧氣。2. Welding Preparation 焊接準(zhǔn)備² Welding shall be prevented when the welding surface is damp. No outdoor welding sh

19、all be done in extreme hot whether, strong wind or adverse atmospheric condition, unless appropriate protective measures are adopted. 當(dāng)焊接表面潮濕時(shí)，不得進(jìn)行任何焊接。除非有適當(dāng)?shù)谋Ｗo(hù)措施，在嚴(yán)酷氣候或風(fēng)速高或不良大氣條件下不得進(jìn)行室外焊接；² It is essential that the end faces of the welding joint be clean, level and straight.焊接接頭兩端面的清潔，圓整和平直是重要

20、的；² The processing method of metals shall ensure that the welding surface is smooth, free of scratch and other harmful abnormity.金屬加工方法應(yīng)確保焊接端表面光滑，無(wú)劃痕或其它有害的不規(guī)則形狀；² It is suggestive that +GF+ or equivalent equipments be used in the cutting and final treatment.建議采用+GF+或同類設(shè)備來(lái)處理切割和最終處理；² T

21、he cutting shall be level and straight, and pipe deformation or damage shall be prevented. Abrasive dust or burr on the end face of pipe shall be cleaned and removed. 切割必須平直和不會(huì)造成管件變形或損壞。切割的管件端面必須清潔以除去磨屑；² No carbon steel cutting tools can be used under any circumstance.碳鋼切割工具在任何情況下都不得使用；²

22、Tools for the treatment, assembling and installation of welding end face, shall be inspected before using, to confirm whether it is approved or rustless alloy steel, and whether it is clean, free of grease and residual of other dirt. 用于焊接端面的處理、裝配和安裝工具，在使用前須檢查是否是沒(méi)有生銹的認(rèn)可合金鋼，清潔無(wú)油脂，和無(wú)其它污染殘留物；² No s

23、ulfenyl cutting oil shall be used, unless all residual grease has been thoroughly cleaned inside and outside the pipe fittings before the welding.不得使用硫基切割油，除非在焊接前管件的內(nèi)外表面都被徹底清除所有殘留油漬；² Welding equipment setting is required to be done with the welding inspector.需與焊接檢查員一起設(shè)定焊接設(shè)備；² This inspect

24、or shall, sign the welding log with his signature and the date after checking whether all the settings conform with the main program.此檢查員將檢查所有設(shè)置是否符合主程序。他將簽署焊接日志和注明日期；² Every welder shall take a welding test before the work everyday. The welding sample shall be tagged and forward to the welding

25、inspector. Each automatic welding machine shall be subject to test.每天開(kāi)始時(shí)，每個(gè)操作人員要作焊接測(cè)試。這些焊樣將編號(hào)，并呈交給焊接檢查員。每臺(tái)自動(dòng)焊接機(jī)都需做測(cè)試。3. Warm-up temperature預(yù)熱溫度² Warming up is not needed if the temperature of welding materials is not lower than 10ºC 在焊接材料的溫度不得低于10ºC。一般來(lái)說(shuō)，不需要預(yù)熱。4. power supply供電²

26、The electric current shall be in conformity with corresponding welding form.電流應(yīng)與注明在相應(yīng)的焊接表相符。5. Welding procedure焊接程序² Welding procedures such as welding sequence, setting of welding procedure and position of welding electrode shall be also in conformity with corresponding welding form. 焊接工藝，如焊接

27、次序，焊接程序設(shè)置，焊極位置等，都將與相應(yīng)的焊接表相符。6. Procedure of automatic welding自動(dòng)焊接程序² All main programs have specified parameters for the welding of pipe and fittings with different diameters or sizes.所有主程序都規(guī)定了不同尺寸管件焊接的一組參數(shù)；² The welding procedure of automatic pipe welding system shall comply with the proc

28、edure made by welder and the inspector.自動(dòng)管道焊接系統(tǒng)的焊接程序都須符合焊接操作員與檢查員一起制定的程序；² Approved welding procedure shall be used for both formal and test welding.正式和測(cè)試焊接需采用已認(rèn)可的焊接程序；² Welding sample shall be numbered in order(such as T1, T2). The welding sample shall have complete traceability and shall

29、 subject to inspection by independent institution. 焊接樣品必須按順序編號(hào)(如T1，T2等)。焊接樣品，具備完全的可追朔性，將備獨(dú)立機(jī)構(gòu)檢驗(yàn)；² All samples on site everyday shall be left to the client during the whole construction phase.在整個(gè)施工階段，所有每天的現(xiàn)場(chǎng)樣品將留予業(yè)主；² The calibration of automatic pipe welding system shall be comply with the

30、procedure made by welder and the inspector.自動(dòng)管道焊接系統(tǒng)的校正都須符合焊接操作員與檢查員一起制定的程序。7. Document 文檔² Qian is responsible for providing all reports of welding record of this system. The reports shall be filled in completely which should includes at least:啟安將提供此系統(tǒng)所有焊接記錄報(bào)告。此焊接記錄報(bào)告表格，必須完全填寫，最少包含： System name

31、系統(tǒng)名稱 Weld joint number焊接號(hào) Name of the welder焊接工姓名 Equipment no.設(shè)備編號(hào) Welding date焊接日期 No. of welding procedure焊接程序編號(hào) Signature of operators(if any, the inspector)焊接操作工(如有，還加上檢查員)簽名² Record of automatic welding shall be printed by the equipment and there shall be weld joint number in the welding

32、report.設(shè)備將打印相應(yīng)自動(dòng)焊接記錄。在此焊接記錄中要有焊接編號(hào)。² Welding map (with corresponding groove, size and length, and all weld joint numbers marked on it) shall be used and updated throughout the construction period and a completion drawing shall be generated when the project is completed.焊接圖 (標(biāo)示相應(yīng)的坡度，尺寸和長(zhǎng)度，所有焊點(diǎn)編號(hào)

33、)將在整個(gè)施工期間使用并且更新，在工程完成生成竣工圖。² Each weld joint shall be numbered in a progressive manner, all weld joints shall be marked in the welding map and welding report.每個(gè)焊點(diǎn)以累進(jìn)方式編號(hào)。所有焊點(diǎn)標(biāo)示在焊接圖和焊接報(bào)告中。8. 內(nèi)窺檢查 Endoscopic inspection² When required by specific terms or provision of the contract, endoscopic

34、 inspection shall be done under the terms or provision thereof, and time delay shall be taken into consideration therefore. 當(dāng)相應(yīng)的條例或合同規(guī)格要求時(shí)，內(nèi)窺檢查將在符合條例或合同規(guī)格下進(jìn)行。須考慮到因此而造成的時(shí)間延誤。² 評(píng)定標(biāo)準(zhǔn) AWS D18.1:1999 Specification for welding of austenitic stainless steel tube and pipe systems in sanitary (hygienic)

35、 applications 衛(wèi)生潔具用奧氏體不銹鋼管和管道的焊接規(guī)范1-4是可以接受的 From 1 to 4,it is acceptable.Discolouration / Oxidation變色和氧化Amount of oxygen in ppm in the backing gas per sampleNo. 1 10No. 3 50No. 5 200No. 7 1 000No. 9 12 500No. 2 25No. 4 100No. 6 500No. 8 5 000No. 10 25 0009. Daily welding test piece每日焊接樣品² Equip

36、ment welding procedure shall be used for daily welding samples, which shall be numbered in order (such as T1, T2). All these samples shall be submitted to the client throughout the construction period on a regular basis.每日焊接樣品應(yīng)采用設(shè)備焊接程序。這些樣品必須按順序編號(hào)(如T1，T2等)。所有這些焊接樣品將在整個(gè)施工期間提供給業(yè)主；² The results of

37、 daily samples shall be recorded in the fully-filled test report of automatic welding equipment.每日樣品結(jié)果必須收集在完全填寫的自動(dòng)焊接設(shè)備測(cè)試報(bào)告中。1.6 Assembly and Installation裝配和安裝1. Receiving, Storage and Disposal of Pipe Materials管件材料接收儲(chǔ)存和現(xiàn)場(chǎng)處理² Pipe materials shall be confirmed and inspected by relevant personnel.

38、管件材料需由專人確認(rèn)和檢驗(yàn)；² The storage of pipe materials and the preassembled fittings shall free of contamination by grease, damp and other substance. pipe materials and the preassembled fittings shall be appropriately handled to avoid any possible deformation, scratching and other tangible damage. 管材和預(yù)裝

39、配件的存放應(yīng)注意不會(huì)被油脂，潮濕或其它物質(zhì)污染；管材和預(yù)裝配件應(yīng)處理得當(dāng)，以避免變形，刮傷或任何有形損傷；² All SS materials shall be separately inspected and stored with other construction materials. Storage area shall be indoor with protective measures against corrosive environment and temperature variation.所有不銹鋼材料應(yīng)與其它施工材料分開(kāi)檢查和儲(chǔ)存。儲(chǔ)存區(qū)必須在建筑物內(nèi)，并且有

40、防護(hù)任何腐蝕性環(huán)境和溫度變化的措施；² Access shall be strictly restricted in case of material loss or damage. Only when needed in the construction can material be withdrawn.通道應(yīng)嚴(yán)格限制以確保材料不會(huì)受損傷和丟失。只有在施工需要時(shí)才能從儲(chǔ)存區(qū)提取材料。2. Classification 分類² All material shall be classified according to specification and appropria

41、tely stored and disposed.所有材料將按規(guī)格進(jìn)行分類，并且適當(dāng)儲(chǔ)存和處理以便于辨認(rèn)。3. Assembly 裝配² The assembling shall be in accordance with the requirements of this specification and current detailed installation requirements (drawings etc.) 裝配應(yīng)按照此規(guī)格的要求和已有的詳細(xì)安裝要求(圖紙或其它)進(jìn)行。4. pipe layout, cutting and assembling布管、切割和裝配

42、78; The pipe fittings shall be cut precisely according to the size on the drawing to meet site requirement.管件應(yīng)按圖紙上的尺寸精確切割以適應(yīng)現(xiàn)場(chǎng)情況；² The burr on end face of pipes to be welded shall be removed, the cutting face shall be level and the chamfer shall be free of cutting arc. Terminal treatment tools

43、shall be used in the treatment of end face of pipe edge and burr. The tolerance of pipe shall the consistent with that of the fittings to ensure welding linearity. 所有待焊接的管件端面需清理毛刺，并且切割面應(yīng)平直，邊角無(wú)切割圓弧。管件邊緣的端面處理和清理毛刺應(yīng)使用終端處理工具，并且其公差與配件一致以確保適當(dāng)?shù)暮附泳€性；² Inspect the pipe end after the cutting to ensure th

44、at it is level and straight. 檢查切割管件終端，以確保其平直；² When removing burr, internal polishing that damage the inner and outer diameter or the pipe shall be prevented.清除毛刺應(yīng)避免破壞內(nèi)外徑，或損傷管件的內(nèi)拋光；² Abrasive dust accumulated at the end of the pipe and fittings shall be cleaned and removed.在管件端口積聚的磨屑必須擦拭干凈

45、；² All pipe and fittings of the pipeline shall refrain from excessive elasticity or assembled under stress.所有安裝在管線上的管件不應(yīng)受過(guò)分彈力和受力下裝配；² Heating and bending the pipe to achieve linearity is not allowable.不允許通過(guò)管件加熱和彎曲以達(dá)到線性整齊。5. Acceptance of Welding Procedure and Qualification焊接程序和資格認(rèn)可² A

46、ll welders shall be qualified with 6 months of working experience and their operation on the site shall be subject to qualified test by LL. 所有焊工應(yīng)得到LL考試合格確認(rèn)后，方可進(jìn)入現(xiàn)場(chǎng)施工；² Welding procedure shall be submitted to the welding inspector for review and approval before the commencement of welding.在開(kāi)始焊接前

47、，焊接程序應(yīng)提交給焊接檢查員核準(zhǔn)。6. Installation 安裝² All pipe and fittings of the pipeline shall refrain from excessive elasticity or assembled under stress. No cutting or weakening bracket with shall be used in the installation of pipework. 所有組裝管件應(yīng)在不受過(guò)分彈力和受力下裝配。不允許有切割或弱化的支撐物作管道安裝；² Installation of pipe a

48、nd fittings shall be able freely expand and contract, so that it wont damage the connectors and bracket.所有管件安裝應(yīng)可以自由膨脹和收縮，而不至于損壞連接和支撐；² All pipes shall have appropriate gradient (0.5%, max 1%.) to ensure complete drainage. 所有管道必須有適當(dāng)?shù)钠露?0.5%最大1%)以確保完全排水。7. Welding 焊接接口² All welding shall be

49、prepared and done in accordance with this specification and requirements stated hereinabove.所有焊接應(yīng)按照本規(guī)格前文所述的要求進(jìn)行準(zhǔn)備和裝配。8. Package joint快裝接口 ² No screw joint shall be used.不得使用螺紋接口。9. Bracket and conduit installation 支撐和穿管² The bracket of pipe shall be designed, assembled and installed accord

50、ing to parameter and details of the drawing. 管件的支撐應(yīng)按管件支撐圖紙上的參數(shù)和細(xì)節(jié)設(shè)計(jì)、裝配和安裝；² Stainless steel pipe and fittings shall be installed under the recommendations of the vendor. 不銹鋼管件的安裝按制造商的建議進(jìn)行；² Installation of hanger and bracket shall be economical and meanwhile meet requirements of drawings a

51、nd specifications.吊架和支撐的安裝應(yīng)盡量的經(jīng)濟(jì)，并符合支撐圖紙或規(guī)格上的描述；² The gradient of pipe bracket shall be in accordance with that required in the drawings.管道的支撐應(yīng)符合管道圖紙上要求的坡度；² The installed pipes shall at least meet specification of inspection and test.所有裝配的管道應(yīng)最少符合檢查，檢驗(yàn)和測(cè)試要求規(guī)格。1.7 Inspection 檢查1. Scope范圍

52、78; Inspection list of the welding log will be used in verifying major information, preparation and quality inspection.焊接日志檢查清單將用于查核主要信息，準(zhǔn)備和質(zhì)量要求；² Welding inspector shall inspect welding records, setting, endoscopic inspection and visual check of the contractors in accordance with welding requi

53、rements. This work can be done at any time as it is agreed and understood by both parties. 焊接檢查員按照焊接要求，檢視分包商的焊接記錄、檢查和設(shè)置、內(nèi)窺檢查，以及目檢。在雙方同意并理解相應(yīng)的時(shí)間延誤下，此工作須在任何時(shí)間進(jìn)行；² The welding inspector or his representative shall visually check all weld joints.焊接檢查員或其指定代表應(yīng)目檢所有焊接。2. Fittings and welding No.配件和焊接編號(hào)

54、² Each weld shall be numbered in the diagram.每個(gè)焊接應(yīng)在其立體圖中編號(hào)；² The inspector shall keep the inspection list, which shall be used for distinguishing for actual welding spots.檢查員應(yīng)保留焊接檢查清單，而且實(shí)際的焊點(diǎn)以此編號(hào)辨別；² Record of each welding spot shall includes all items deserved.每個(gè)焊點(diǎn)的記錄應(yīng)包括所有相關(guān)的條目。Weldi

55、ng preparation焊接準(zhǔn)備The welding inspector shall decide whether to make the following inspection and confirmation.焊接檢查員決定是否進(jìn)行下列檢查/確認(rèn)。² Confirmation of pipe section管道截面確認(rèn) Length of pipe shall be marked in the pipe drawing according to relevant requirements.管道的長(zhǎng)度按要求在管道圖紙中標(biāo)示； Clean all possible sundr

56、ies in the pipe end generated during the cutting.要去掉管道端口切割產(chǎn)生的任何可能之污物； Tools shall be prevented from being contaminated by carbon steel.工具不得被碳鋼所污染； Confirm the roundness tolerance of pipe確認(rèn)管道圓度公差。² Cleanness清潔確認(rèn) Approved ethanol shall be used for the cleaning of fittings. 用酒精清潔配件。 The cleaned an

57、d readily-prepared pipe end shall refrain from touching skin before the welding.在焊接前，已清潔和準(zhǔn)備好的端口不得接觸皮膚。 There shall be no visible foreign matters in the end of the pipe and components, including fiber from the cloth.在部件的端口不得有可目見(jiàn)的異物，此包括清潔布的纖維。 The tungsten electrode shall be clean and free of contamin

58、ation.鎢焊極必須清潔和無(wú)污染。² Joint preparation接口準(zhǔn)備 Thickness of gap between the ends of welding components shall be measured with feeler gauge焊接組件端口間隙用厚度塞尺測(cè)量，不得超過(guò)0.25 mm。 The tungsten electrode shall be placed in the center of the welding spot.鎢焊極應(yīng)置于焊點(diǎn)中央。² Setting of welding machine焊機(jī)設(shè)置 The setting of parameter shall take reference from relevant welding forms in the welding procedure.參數(shù)的設(shè)置應(yīng)按焊接程序中相應(yīng)的焊接表進(jìn)行。 Positioning of gas source確認(rèn)氣源就位。3. welding inspection焊接檢驗(yàn)Each welding sample and all erection welding shall be inspected by visually checking the pipe inter