不銹鋼管道預(yù)制施工方案及對策

1、-一、 Purpose 目的This statement is piled to ensure the construction quality of Bayer project pipe fabrication and meet the progress requirement.This statement is used to guide the fabrication of all Stainless Steel pipe afforded by F in Bayer MDI。為了保證工程管道預(yù)制工程的施工質(zhì)量和滿足工程進度要求，特編制本方案。 本方案用以指導(dǎo)拜耳異氰醋酸聚醚工程 MDI

2、 聯(lián)合裝置 F 承當?shù)乃胁讳P鋼材質(zhì)管道的預(yù)制施工。二、 Applicable Scope 適用圍This statement is applicable for all Stainless Steel pipe fabrication work afforded by F in Bayer MNB(V210) / WNILINE(V310).本方案適用于拜耳工程 MNB(V210)/WNILINE(V310)裝置 F 承當?shù)乃胁讳P鋼 管道預(yù)制工程的施工。三、 Reference 編制依據(jù)Technical specification and standard of this method

3、statement:本方案編制依據(jù)的施工技術(shù)規(guī)和標準為：（1） GB50235-97"construction and acceptance of industrial metal pipeproject GB50235-97 " 工業(yè)金屬管道工程施工及驗收規(guī)"（2） GB50236-98"welding project construction and acceptance specification ofsite equipment and industrial pipe"GB50236-98 " 現(xiàn)場設(shè)備工業(yè)管道焊接工程施工及驗

4、收規(guī)"（3） Bayer relevant technical document standard 拜耳的相關(guān)技術(shù)資料WN 標 準. z.-（4） 管道相關(guān)圖紙四、 Overview 工程概況1 Work scope 工作圍The scope of this project includes all Stainless Steel pipe fabrication ofMNB/ANILINE包括 MNB 、ANILINE 兩個裝置中的所有不銹鋼管道的預(yù)制。2 Major project quantity 主要工程量Stainless Steel pipe in MNB is abou

5、t 4679m (pipe diaDN15-DN600), which amounts to 70 of the whole run.MNB 裝置中不銹鋼管大約 4679 米管徑DN15-DN600 占總管道的 70Stainless Steel pipe in ANILINE is about 1900m(pipe dia DN15-DN400), which amounts to 20 of the whole run.ANILINE 裝置中不銹鋼管大約 1900 米管徑DN15-DN400占總管道的 20。五、 Technical conditions 技術(shù)條件1 Technical d

6、ocuments 技術(shù)文件1.1 Three-dimensional piping drawing used for industrialized prefabrication用于工廠化預(yù)制的管道三維圖1.2 Relative construction technical documents (working instructor, processprocedure) and management procedure相關(guān)的施工技術(shù)文件作業(yè)指導(dǎo)書、工藝規(guī)程和管理程序. z.-1.3 Construction technical clarification card施工技術(shù)交底卡1.4 Stand

7、ard for piping materials and fittings管材及配件尺寸標準2 Quality control documents質(zhì)量控制文件2.1 Materials qualification or acceptance report材料合格證或驗收報告2.2 Working procedure handover slip操作工序交接單2.3 Conformance inspection table of piping prefabrication管道預(yù)制件的符合性檢查表2.4 Tracking drawing and tracking sheet for welding

8、craters焊口跟蹤圖及跟蹤單2.5 Inspection report (RT, PT, VT)檢驗報告RT 、 PT 、VT六、不銹鋼材料的驗收及檢驗標準：1. 管道用材料，焊接用材料必須具有制造廠的合格證明書和質(zhì)量證明書，請業(yè)主協(xié)助完成此項工作。質(zhì)量證明書應(yīng)包括以下容： 產(chǎn)品標準號 材料的牌號 材料的爐罐號、批號、交貨狀態(tài)、重量和件數(shù). z.- 品種名稱、規(guī)格及質(zhì)量等級 產(chǎn)品標準中規(guī)定的各項檢驗結(jié)果 技術(shù)監(jiān)視部門的印記。2. 按設(shè)計要求核對其規(guī)格、材質(zhì)、型號。3. 外觀檢查：無裂紋、縮孔、夾渣、折迭、重皮等缺陷，所有管道壁厚均不得有負偏差。4. 法蘭、焊環(huán)及盲板密封面平整、光潔、不得有

9、毛刺及徑向溝槽，螺栓，螺母的螺紋完整，無傷痕，無毛刺等缺陷，配合良好。墊片，無折損、皺紋等缺陷。5. 經(jīng)檢驗合格的管材，應(yīng)按規(guī)格尺寸分別放置在專門設(shè)置的地方，嚴禁與鋼材混堆和直接接觸或碰傷。6. 材料負責人檢查并收集管道、管件、閥門、焊絲等所有管材的合格證及質(zhì)量保證書。7. 彎頭、異徑管、三通、法蘭、盲板及緊固件等進展檢查，其尺寸偏差應(yīng)符合現(xiàn)行標準，材質(zhì)應(yīng)符合設(shè)計要求。8. 石棉、橡膠、塑料等非金屬材料墊片應(yīng)質(zhì)地柔和，無老化變質(zhì)或分層現(xiàn)象。外表不得有折損，皺紋等缺陷。金屬墊片的加工尺寸、精度、光潔度及硬度應(yīng)符合要求，外表應(yīng)無裂紋、毛刺、凹凸槽徑向劃痕及銹斑等缺陷，包金屬及纏繞式墊片不應(yīng)有徑向劃

10、痕、松散等缺陷。9. 對驗收后的不銹鋼材料管子、管作、法蘭每批進展5%的光譜分析檢查。七、 Fabrication preparation and step 施工預(yù)制準備和步驟10. Preparation for fabrication 預(yù)制準備. z.-10.1. According to the demand of Bayer project work, Stainless Steel fabrication yard isset in (F Weiwu Road).根據(jù)拜耳要求和施工的需要分別設(shè)置兩個預(yù)制場地： 不銹鋼預(yù)制場設(shè)置 在F 衛(wèi)五路10.2. Before fabricati

11、on, pipe professional technician shall timely do the shift work ofdrawings, mark weld NO. SW-shop weld; FW-field weld. The principle of drawing shift: e*pand fabrication depth based on the convenient transportation and installation together with plan sketch, in order possibly to finish fabrication w

12、orkin fabrication shop and管道預(yù)制前，管道專業(yè)技術(shù)人員要做好圖紙轉(zhuǎn)換，標定焊口號： SW 表 示預(yù)制焊口， FW 現(xiàn)場焊口，預(yù)制分段。圖紙轉(zhuǎn)換的原則是：為了盡可 能多在預(yù)制車間完成管道的制作， 結(jié)合平面圖在考慮方便運輸與安裝的前提下，盡量擴大預(yù)制深度。10.3. Any people who join the fabrication work (helper e*cluded) must be proficienttechnician. Worker who does pipe welding must hold effective certificate being

13、 conformed to the work they conduct. These people must have received the welder training of this project and has qualified the test.凡參加管道預(yù)制作業(yè)的人員輔 助工除外必須是熟練的技術(shù)工人。參與管道焊接的工人必須持有與所從 事的作業(yè)相符且在有效期的合格證書，并經(jīng)業(yè)主焊工培訓考試合格的施工人員。10.4. Properly requisite fabrication material as per fabrication progress, received mat

14、erialmust have certificate and re-check report. The vent and hygiene shall be good in. z.-fabrication yard, equipment process ability in fabrication shop shall meet the operation requirement and have good operation performance. Tool and machinesin fabrication shop shall be plete, having special lay

15、down area and full time keeper.Equip one set of 3m3 oil-free pressor and corresponding line arrangement forin-pipe blow of pipe fabrication piece. 根據(jù)預(yù)制進度方案合理領(lǐng)用預(yù)制材 料，領(lǐng)用的材料必須具有產(chǎn)品合格證或復(fù)驗報告。 必須是經(jīng)過標色的不銹鋼管道： HB/1.4306 褐色 ； H2/1.4404 無 ； H1/1.4307/1.4306 藍色 ；HU/1.4539 桔黃色 。 預(yù)制場地應(yīng)有良好的通風狀態(tài)和衛(wèi)生環(huán)境，預(yù)制車 間的設(shè)備加工能力須滿

16、足預(yù)制的操作要求，并具有良好的操作性能。預(yù)制 車間的工機具應(yīng)齊全，并有專門的堆放場所和進展專人管理。 預(yù)制場地需 要隔離的地方，用橡膠皮或石棉板做好隔離準備。配制一臺 3m3 無油空壓 機及相應(yīng)的管線布置，用于管道預(yù)制件的管吹掃。2 Fabrication step (see Appendi*1) 施工預(yù)制步驟material requisition and check 領(lǐng)料、核對材料 ID transfer of pipe 管. z.子標識移植 sizelineation 劃線標注尺寸baiting and cutting 下料切割Pipe ID transfer 管子標識移植Steelem

17、bly and welding 組對、焊接Groove treatment 坡口加工weld ID 焊縫標識aStainlessVisualInspection 目視檢查NDT inspection NDT 檢查spools clean 管段清潔 spool ID 管段標識 seal and storage 封口保護、堆放儲存2.1 Batching 配料Full-time material person shallbe in charge of batching, in principle, batching ofpiping fittings shall be pleted as isom

18、etric a*is drawing, all requisited material must be-marked for batching and construction.配 料 應(yīng) 由 專 職 材 料 員 負 責 ，原 則 上 按 等 軸 圖進 展 管 配 件 配 料 ，所有領(lǐng)用的材料必須進展標識后， 方可領(lǐng)出配料施工。2.1.1 Batching work shall be made according to prefabrication weekly plan and material delivery as per isometric a*is drawing.配料工作應(yīng)根據(jù)預(yù)制

19、周方案和材 料到貨情況按等軸圖進展配制。2.1.2 Special bo* can be used separately for storage as each isometric a*is drawing.It is also allowable to batch in several drawings or tens of drawings;furthermore, batched material schedule shall be pasted on the bo*.可按每等軸圖用專用箱子 分開配放， 也可幾或幾十圖紙開在一起配好， 并在箱子上貼上配好的材料清單。2.1.3 When

20、prefabrication personnel requires (of specially delivery), requisitionpersons shall recheck according to material schedule and sign it for confirmation. One list shall be in two copies; requisition person and material person keep eachone copy.預(yù)制人員領(lǐng)用或?qū)Ｋ蜁r，領(lǐng)用者應(yīng)按材料清單進展復(fù)查并在清單上簽 字確認，清單一式兩份，領(lǐng)用者和材料員各保管一份。2.

21、2 Bating and cutting 下料切割2.2.1 Spool field bating and cutting shall be done after reviewing spool isometric,the major reviewing point:管段現(xiàn)場下料切割前應(yīng)首先對管段單線圖進展審核，主要Drawing number, line number, spool number and material is as per design ornot. 圖號、管線號、管段號及材質(zhì)是否與設(shè)計相符；. z.-Spool segment and reserved weld for

22、field installation of each isometrica*ial drawing is reasonable or not, and field resurvey for spool fabrication size shall be necessarily conducted. Accurately calculate when confirming baiting size of each spool, mainly considering about difference between fabrication spool size and baiting spool

23、size, baiting spool size shall deduct theoretical size of elbow, tee and reducer, as well as regulated weld assembly gap; and thickness of flange and gasket, as well as theoretical size of other fittings (such as valve, filter; etc). confirm practical size of fabrication baiting after measuring in o

24、rder to increase the measuring accuracy. 每一等軸圖的管段分段、現(xiàn)場安裝預(yù)留口是否合理，并應(yīng) 對管段預(yù)制尺寸進展必要的現(xiàn)場復(fù)測。在確認每一段下料尺寸時， 應(yīng)準確計算，主要考慮預(yù)制段尺寸和下料段尺寸之間的差異，下料 段尺寸應(yīng)去除彎頭、三通、大小頭等管配件的理論尺寸以及規(guī)規(guī)定 的焊口組對間隙；法蘭、墊片的厚度以及其它配件如閥門、過濾 器等的理論尺寸。以提高測量準確度，測量后確定預(yù)制下料的實際尺寸。2.2.2 Original mark shall be transferred before cutting pipes, pipe materialwithou

25、t mark or with blurry mark shall not be used.管子切割前應(yīng)移植原有標記， 沒有標記或標記模糊不清的管材不得使用。2.2.3 Pipe cutting generally adopts mechanical method, any following machine can be adopted accordingto situation: 管子切割必須應(yīng)采用機械方法， 根據(jù)情況可 采用以下任何一種機械：. z.- Pipe lathe 管子車床 Band saw machine 帶鋸床 Abrasion wheel cuttingmachine 不銹

26、鋼專用砂輪切割機和砂輪片2.2.4 Stainless steel pipe also can be cut by plasma cutting machine. 不銹鋼管也可以用等離子切割機進展切割。2.2.5 When stainless steel pipe is cut by abrasion wheel cutting machine or grinded by abrasive disk, must use alumina substrate, and abrasion sheet which has cut or grinded stainless steel cannot be

27、 used to cut or grind stainless steel pipe. 不銹鋼 管用砂輪切割機切割或用砂輪打磨時， 必須用氧化鋁基的砂輪片， 且切割或打磨過碳素鋼的砂輪片不能用來切割或打磨不銹鋼管。2.2.6 Pipe cut shall be as per the following requirement: 管子切口質(zhì)量應(yīng)符合以下要求： Cut surface shall be smooth, free of crack, double skin, burr, concave andconve*, contracted opening, sinter, o*ide, sla

28、g or other defects or debris.切 口外表平整，無裂紋、重皮、毛刺、凹凸、縮口、熔渣、氧化物、 鐵屑等。 Tilting error of cut end face shall not be 1% bigger than e*ternal diameterof pipes, and no more than 3mm.切口端面傾斜偏差不應(yīng)大于管子外徑的 1，且不超過 3mm 。 如執(zhí)行的標準不同時，按相應(yīng)標準執(zhí)行2.3 Groove Processing 坡口加工2.3.1 Groove shall be processed after marking and cutt

29、ing on pipe (material) byconstruction personnel according to fabrication isometric drawing shifted by. z.-technical person. Beveled spool shall be put on process bench (fabrication shop) forgroovegrinding. 施工人員依據(jù)技術(shù)人員已轉(zhuǎn)化的預(yù)制單線圖紙對管道素材 進展劃線、 切割下料后進展坡口加工。 坡口加工的管段應(yīng)放置在加 工臺上預(yù)制車間進展坡口打磨；2.3.2 Groove type and

30、size of pipe and fitting shall be conformed to requirement of corresponding to drawing and design document, when there is no demand ondesign, confirm as per item ofGB50235-97 Appendi*B.管子、管件的坡口型式和尺寸應(yīng)符合相應(yīng)的圖紙和設(shè)計文件的要求，當設(shè)計無規(guī)定時，按 GB50235-97 規(guī)附錄 B 第條規(guī)定確定。Processing of piping slope is monly adopting mechan

31、ical method, for e*ample, after slope is processed in a way of heat processing,o*ide skin, sinter and surface layer that will have effect on the quality of joints at slope shall be removed, and the place that is conve* or concave shall be ground and leveled.Stainless steel shall be cut or grinded by

32、 special abrasion sheet, and cannot be mi*ed with carbon steel abrasion sheet.管道坡口加工一般采用機械方法， 不銹鋼管道的坡口加工可采用坡口機加工 或等離子切割加工方法。 采用等離子切割方法加工坡口后， 必須除去坡口外 表的氧化皮、 熔渣及影響焊接質(zhì)量的外表層， 并應(yīng)將管子端面的凹凸不平處打磨平整。 不銹鋼切割或打磨時應(yīng)使用專用砂輪片， 不得與碳鋼砂輪片混用。 No matter which method is used, after slope opening is processed, oil, water, r

33、ust andother debris shall be cleaned無論用哪一種方法， 坡口加工完畢后， 均應(yīng)去除油圬、 水份、 鐵銹等雜物。2.4 Weld assembly 焊口組對. z.-2.4.1 Assembly 組對 When assembling, clean groove and its internal and e*ternal surface as perthe followingtable: 組對時，對坡口及其外外表應(yīng)按下表要求清理干凈：Pipe material管道材質(zhì)CS 碳素鋼SS 不銹鋼AS 合金鋼Aluminum or A-alloy鋁及鋁合金Copper

34、 and copperalloy 銅及銅合金Titanium 鈦Clean range清理圍10502050Cleaning material 清 Cleaning method理物 清理方法Oil, paint and rust Manual or machine油、油漆鐵銹等 手工或機械Useorganicdissolvent toremove oil, usechemical orOil and o*ide film mechanical油、氧化膜 method to removeo*ide film.用有機溶劑除油，用化學方法或機械方法除氧化膜 Use gasket material

35、to isolate the bench and support used for stainless steelassembly. 對于不銹鋼管組對用的臺架、支承架等，應(yīng)用襯墊材料 進展隔離。. z.- After assembling, shall keep pipe straight. 組對后，應(yīng)保持管子的平直。 As for the thin wall pipe easily deforming during welding, use special clampto fi* it duringassembly. 對于焊接時易產(chǎn)生變形的簿壁管，組對時應(yīng)使用專用夾具進展固定。 During

36、 weld assembling, inner wall shall be smooth , unfitness of inner wallshall not be beyond 10% of wall thickness and not more than 2mm.焊口組 對時，應(yīng)做到壁平齊，壁錯邊量不宜超過壁厚的 10%，且不大于 2mm。 During assembling pipe ponent with uneven wall thickness, repair as peritem .b and then assemble. 不等厚管道組成件組對時，應(yīng)按.b 條要求進展修整后再進展

37、組對。 Further check whether there is scratch on sealing surface of flange or notduring assembly, if there is scratch that shall influence flange sealing, this flange shallnot beused. 法蘭時應(yīng)進一步檢查法蘭的密封面有無徑向 劃痕，如果發(fā)現(xiàn)有影響法蘭密封的劃痕，該法蘭不得使用。 If the flange is connected with valve, ensure site installation of valve

38、 is asper the design requirement during assembly. 如果是連接閥門的法蘭， 在組對時要保證閥門在現(xiàn)場安裝時符合設(shè)計要求。 Put pad under the butt-welded pipe to ensure it is firm, in order to avoidthe deformation during welding, strong force shall not be used for assembly duringconnecting pipe. 管子對口后應(yīng)墊置結(jié)實，防止焊接過程中產(chǎn) 生變形，管道連接時不得強力組對。 All a

39、ssembled welding joint size shall ply with the requirement of design. z.-documentordrawing. 所有組對好的焊接接頭尺寸應(yīng)滿足設(shè)計文件或圖紙的要求。2.4.2 Welding 焊接Operation requirement during the whole welding(including pipe welding, non-destruction inspection, weld repair; etc) see pipe welding method statement of pipe fabrica

40、tion plant. 整個焊接過程包括管道焊接、無 損檢測、焊口返修等工序的操作和要求詳見管道預(yù)制廠管道焊接 方案和焊接工藝卡。2.5 Superficial treatment of stainless steel pipe weld 不銹鋼管道焊縫的外表處理2.5.1 If there is requirement in design document regulation or implementation standard, superficial treatment shall be used for all stainless steel pipe weld, removeo*i

41、dizing layer until the base metal color shall be e*posed. 如設(shè)計文件的規(guī)定或執(zhí)行的標準有要求， 應(yīng)對所有的不銹鋼管焊縫的外外表進展處理， 去除外 表氧化層，到達金屬母材本色。2.5.2 Generally use pickling cream (mordant) to wash it, also shall use othermethods to brush it, like stainless steel wire, the concrete operation shall be as percorrespondingstandard

42、. 處理方法一般采用酸洗膏 酸洗液進展酸洗， 涂液 4 小時后在焊口處用不銹鋼鋼絲刷進展刷擦，具體操作應(yīng)執(zhí)行相應(yīng)的標準。2.6 Mark on pipe fabrication piece 管道預(yù)制件的標記2.6.1 Mark all pipe fabrication piece according to spool NO on isometric. 對所有. z.-管道預(yù)制件進展標記，按等軸圖上的管段編號進展。2.6.2 use mark pen or pain to mark Welder ID (welder NO or weld NO)焊工標識 焊工號及焊口號應(yīng)采用記號筆或油漆進展。

43、注意：油漆必須和底漆一樣 cl-mmp2.6.3 Mark shall be clear and remain for a long time at least when this spool is finished installation 標記應(yīng)清晰， 且能保持較長時間。 至少應(yīng)保持到該管段安 裝完畢。2.7 Cleanness of pipe fabrication piece 管道預(yù)制件清潔度Cleanness inspection shall be conducted on fabricated spool, there is no foreign matter inside pip

44、e, such as welding slag, oil, rubble, if there is debris,use scrub or air blow to clean them. 對于預(yù)制好的管段進展清潔度檢查，管不得有焊渣、油跡、石子等外來物，如有雜物，應(yīng)用擦洗或 壓空吹掃的方法來進展去除， 去除后立刻進展管口的包裝保護，防止異 物再次進入。2.8 Conformity inspection of fabrication piece 預(yù)制件的符合性檢查 Conformity inspection (as per proportion)is conducted to pipe fabr

45、ication piece according to design document requirement, main content is as follows: 應(yīng)根據(jù)設(shè)計文件要求，對管道預(yù)制件進展符合性檢查按比例 ，主 要容如下：2.8.1 Ensure the material specification, type and material is correct. 確認使用材料的規(guī)格、型號、材質(zhì)正確無誤。2.8.2 Ensure pipe fabrication spool size is conformed to drawing requirement. 確. z.-認管道預(yù)制段

46、的尺寸符合圖紙要求。2.8.3 Ensureweld appearance quality and non destruction inspection is conformed to design documentrequirement. 確認焊縫的外觀質(zhì)量和無損檢驗滿足設(shè)計文 件要求。2.8.4 Fill in conformity inspection record of pipe fabrication piece(seeattachment 2) 填寫好管道預(yù)制件符合性檢查記錄見附錄 2Note: conformity inspection record of fabrication

47、 piece is confirmed and filled in by QC personnel. 說明：預(yù)制件的符合性檢查記錄由 QC 人員 負責檢查確認填寫。2.9 Pack for pipe fabrication piece 管道預(yù)制件的包裝保護2.9.1 Use polyethylene cap to seal for pipe end of small bore pipe fabrication piece. Ifpipe cap is loosening, use adhesive tape to fi* on pipe. 對于小口徑的管道預(yù)制 件的管端用聚乙烯管帽進展封口，如

48、管帽較松時，可用膠粘帶固定在管子上。2.9.2 Use clean white glabrous cloth or polyethylene plastic cloth to pack and use adhesive tape to fi* for pipe end of big bore pipe fabrication piece. 對于大口徑 的管道預(yù)制件的管端用清潔的無毛白布或聚乙烯塑料布包扎并用膠粘帶固 定。2.9.3 Flange surface generally use adhesive plate to pack, use nylon (galvanized iron wi

49、re) to bind and fi* through the hole pre-drilled on flange bolt and cover plate. 法蘭面一般用膠合板進展包裝， 包裝方法可用尼龍繩 鍍鋅鐵絲 通過法蘭 螺栓孔和蓋板上預(yù)先鉆好的孔綁扎固定。2.9.4 If there is additional requirement for design, use polyethylene film to pack. z.-the whole stainless steel fabrication piece. 如果設(shè)計另有要求，對整個不銹鋼預(yù)制件用聚乙烯薄膜包裹起來。2.9.5

50、 對檢查合格以及包裝保護好的預(yù)制件按照指定的地點存放。存放的原 則是先裝置后系統(tǒng)再管線。2.9.6 對檢查合格以及包裝保護好的預(yù)制件及時輸機進展有效管理，保持預(yù) 制件的可追溯性。八、 Safety and technique measure (JHA Appendi* 3)平安技術(shù)措施JHA 分析附錄 3 All workers entering fabrication shop must wear uniform work clothes, helmetand crash-proofshoes. 進入預(yù)制現(xiàn)場的所有作業(yè)人員必需穿公司統(tǒng)一工 作服，戴好平安帽，穿防砸勞保鞋。 No smoking in construction area and site office area, smokers shall go toindicatedp