某氣相二氧化硅項目管道與焊接中英文工程施工設計方案

.PAGE.某氣相二氧化硅項目的管道施工方案ConstructionMethodforPiping2.1概述General本工程是xxxxx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,質量、安全、進度三者都必須保證。CabotBlueStarChemical<Jiangxi>Co.,Ltd.4,800t/afumedsilicaprojectincludes18sections,pipematerialmanlycontains20#steel,20/PP,0Cr18Ni9,RPM,FRP,galvanizedsteelpipe<Q235-A>.Duetoconstructiontimeistight,installationworksalwayscrosscivilwork,soitisnecessarytoarrangeconstructionreasonably,toensuresafety,qualityandprogressreachedprojecttarget.2.1編制依據(jù)CompilationBasis2．1設計公司的招標圖drawingforbidissuedbyxxx.GB50235-97、GB50236-982.3主要實物工作量Majorworkquantity不銹鋼管S.Spipe150m碳鋼管C.Spipe4,900m鋁合金管Aluminumalloypipe370mFRP/PP1,670m鍍鋅管galvanizedsteelpipe2,300m閥門valves680pcs.2.4施工技術措施ConstructionMethod2.4.1管道安裝工作程序Pipinginstallationprocedure管道安裝程序示意圖pipinginstallationflow管道預制管道預制管道支架預制管道清潔度檢查管道支架安裝質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PPipingfabricateSupportfabricateCheckcleannessofpipingErectsupportQualityinspectionNDTtestingTestpressure,flushing,blowing&recoverPainting&insulationCompletion&acceptanceInspect,removerust,primecoatingMat’lentersitePipingerectionPipingfit-upPreparation施工準備技術交底：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,加強施工人員的質量、安全意識。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。所有的管材、管件、閥門、焊材等必須有材料質量證明書,其內容、形式必須符合相應材料制造標準的要求。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整開啟壓力,調試合格后,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。ConstructionPreparationTechnicalclarificationmeeting:Allkeyemployeesinvolvedintheinstallationshallparticipateintheinstallationmeetingwhichisheldpriortotheactualinstallationsothattheywillhaveathoroughunderstandingoftheprojectintroduction,schedule,qualityrequirements,installationdifficultyandTechnicalrequirements.Checkallpersonsinvolvingcertifications.Allinstallationpersonnelshallstudythedrawingscarefully.Propertrainingshallbeconductedforallpersonsbeforeenteringthesite.Adeeperunderstandingshallbeachievedthroughthetechnicalmeetings.Qualityandsafetyshallalwaysbekeptinmind.Checkmachines&tools:countallmachinesandtoolsinvolvedintheinstallation.Checkconditionsofinstallationequipment,machinesandtools.Checkelectricalmachinesandseeiftheyarerunningnormallyandreliably.Checkconditionsoftestingtools.Unqualifiedonesshallbereplacedorrepairedinatimelymanner.Allpipes,pipefittings,valvesandweldingmaterials,etc.shallbearmaterialqualitycertificates,thecontentandformofwhichshallbeinaccordancewithfabricationstandardrequirementsforcorrespondingmaterials.Allpipematerials,fittings,valvesandweldingmaterials,etc.shallbevisuallyinspectedaspercoderequirementsandbemarkedifqualified.Valvesshallbetestedforstrengthandairtightnessasperrequirementsandbeleadsealedifqualified.Safetyvalvesshallbeinspectedandadjustedforopeningpressureandshallbeleadsealedifqualified.Finishvalvetestingrecordsandsafetyvalveadjustingrecords.Stainlesssteelpipes,alloysteelpipesandtheircomponentsshallnotcomeintocontactwithcarbonsteelduringstorage.材料檢驗所有的管材及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?？扇冀橘|、高溫、易爆介質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。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。試驗合格的閥門及時排盡內部積水,并吹干,密封面涂防銹油,關閥門,封閉出入口,做明標記,并填寫"閥門試驗記錄"。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。管材、〔管件檢驗主要參照下述標準:GB2270-80、GB8163-87、HGJ46-91、HGJ20615、GB50235-97。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。MaterialTest&InspectionAllpipes,fittingsandvalvesandotherinvolvedwithpermanentfacilitiesofthePlantshallbeprovidedwithmanufacturerqualitycertificationsandbecheckedforsize,typeandmaterialbeforeuse.。ForInflammablemedium,hightemperatureorexplosivepipevalves,itisnecessaryfortesttobedoneonebyone;forotherpipevalves,testtobedoneby10%ofeverybatch,andatleast1pieceshallbedonewithstrengthandtightnesstest.Thetestpressureforvalvecaseshallbe1.5timesofitsnominalpressure,whichtesttimeshallbe10minutes,andnoleakfromcasestuffingisaseligible.Sealingtestpressureshallbenominalpressureofit,afternoleakfromsealfaceofvalveclack,itcanberegardedaseligible.Qualifiedvalvesshallbefreewaterintime,anddryitout,sealfaceshallbelaidwithanti-rustoil,thenturnoffvalves,closeinletandoutlet,makeidentification,andfillin"ValvesTestRecord".PipingcomponentsandsupportsshallbeingoodcustodyasperrequirementofTHEOWNER,avoidconfusionanddamage,whichmarksshallbeclear,forpipingerectedlater,whichbothendsshallbeclosed,andforstainlesssteelmaterial,attentionshallbepaidthatshallbeisolatedawayC.S.materialtopreventfromcorrosionofmetallurgicalphase<carburizing>.。test&inspectionofpipematerialandfittingsmainlyrefertofollowingcodesandstandards:GB2270-80、GB8163-87、HGJ46-91、HGJ20615、GB50235-97.Itisnecessaryformaterialtakendeliveryfromtheownerorconstructioncontractorpurchasedmaterialtobestoredingoodorder,andmaterialcannotbeissueduntilengineermakesignature.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,又保證施工質量。Pipefabricationistobeperformedindedicatedprefabricationshopsinsideofbatterylimitoftheplantsoastoimproveworkingenvironmentandensureinstallationquality.管道清潔度檢查：預制前對所需用的管道進行內部和外部的清潔程度檢查,如果內部有鐵銹、碎屑、油污等雜質,應用壓縮空氣進行清理,直到檢查合格后,才能投入使用。Pipecleannesscheck:cleannesscheckshallbeperformedforinternalandexternalofrequiredpipespriortoprefabrication,anyrust,debris,greaseorotherforeignmattersshallberemovedusingcloth,compressedair,ironwireorsandblastandshallbeinspectedbyTHEOWNERpriortouse.鋼管切割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；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；FRP/PP管、鋁合金管采用細齒鋼鋸切割.鋼管切割的質量要求是：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。切口端面斜偏差△≤外徑的1%,且不得超過3mm。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、規(guī)格、管線號,并根據(jù)施工圖紙標明所使用的位置。SteelPipeCuttingSelectmaterialinaccordancewiththeisometricdrawingprovidedbyTHEOWNER,pipesegmentnumbershouldbemarkedonthedrawing.Transplantexistingmarkingonthepipespriortocutting.Smallsizedsteelpipesshallbecutusingcuttingmachineandbebeveledusingbevelmachine;largesized<above6">carbonsteelpipethatareimpossibletobecutbycuttingmachinecanuseoxyacetyleneforcuttingandthebevelshallbeground.Stainlesssteelpipesizebelow4"willuseabrasivewheelcuttingmachine,andthoseabove6"shalluseplasma-cuttingmachine.Forfabricationonthesteelplatformintheprefabricationshop,rubbersheetsshallbelaidontheplatformforseparation.FRP/PPpipeandaluminumalloypipeshallbecutwithserratinghacksaw.Qualityrequirementsforsteelpipecutting:thecutsurfaceshallbeflatwithoutanycracks,laminations,burrs,pittingorotherdefects,ifexist,theyshallberemoved.Bevelendslopedeviation≤1%ofO.Dofpipe,andnotmorethan3mm.Forsteelpipesthatarealreadycut,usepaintormarkingpentomarkoneachpipesegmentthematerial,specificationandlinenumberforthesteelpipe,theirservicelocationsshallbemarkedonAFCdrawings.坡口加工根據(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：管壁厚度小于等于2.5mm坡口形式按下圖當管壁厚度為2.5~20mm時坡形式按下圖。t>2.5~9>9~20α70°+560°-5b1~22~3p1~22~3不等厚管子、管件組對時,如果內壁錯邊量大于1.0mm或外壁錯過量大于2mm時按下圖形式進行修整。BevelchamferingInaccordancewithpipingconstructioncode<GB50235-97>suppliedbydesigninstitute,bevelchamferingshallbeexecutedasperfollowingfigure:Forpipewallthickness≤2.5mm,thebeveltypeasfollowingfigure:Forpipewallthickness≥2.5mm,and≤20mm,thebeveltypeasfollowingfigure:t>2.5~9>9~20α70°+560°-5b1~22~3p1~22~3Whenfitupdifferentthicknesspipesorfittings,ifoffsetofpipeinsideisover1.0mm,oroffsetofpipeoutsideisupper2mm,repairshallbedoneasfollowingfigure:管道的組對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δ＝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。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。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：項目允許偏差自由管段封閉管段長度±10±1.5法蘭面與管子中心垂直度D＜1000.50.5100≤DN≥3001.01.0DN＞3002.02.0法蘭螺栓孔對稱水平度±1.6±1.6管支架制作在管道預制的同時可以進行管道支架的制作。管架制作的型式結構、材質、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。Pipingfit-uppipeassemblyshallbedoneonthepipefabricationplatform.Forstainlesssteelassembly,δ＝3mmrubbersheetsshallbefurnishedontheplatformforseparationagainstcarbonsteelplate.Carbonsteeltoolsarenotallowedtostrikestainlesssteelpipes.Assemblytoleranceshallbecheckedagainstallowablepipetolerance.TheinspectionmethodinvolvesmeasurementwithAngleSquare,steelplaterulerandsteeltape.ItshallbereasonableforSelectionandarrangementoffreespoolandclosespool,constructionforclosespoolshallbeasperinstallationlengthmeasuredatsite.Allowableprocesssizedeviationforfreespoolandclosespoolshallbeinconformitywithfollowingtablerequirement:ItemAllowabledeviationFreespoolClosespoollength±10±1.5Centerverticalitybetweenflangeandpiping.D＜1000.50.5100≤DN≥3001.01.0DN＞3002.02.0Symmetricallevelnessofflangebolthole.±1.6±1.6Pipesupportfabrication:pipesupportcanbefabricatedasthepipesareprefabricated.Thesupportsshallbefabricatedsuchthattheirform,material,dimension,accuracymeetrequirementsinthepipesupportstandardprovidedbyCO.Thesurfaceshallbeflat.Theweldingshallbefixedwithoutdefectslikemissingweld,insufficientweldorcracks.Theweldingsurfaceshallbesmoothwithoutanyspatters.Anyweldingdistortionshallbecorrected.Rust-proofingtreatmentshallbeperformedforfabricatedsupportsinatimelymanner,andshallbeproperlymarked.管道焊接在管道焊接之前,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。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。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。在點焊之前,應仔細檢查坡口、表面、并進行相應的清理,管內無雜物,焊接坡口端50mm以內的表面應打磨干凈,呈現(xiàn)金屬光澤,方可點焊。管道對接焊口的組對應做到內壁平齊,內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。當焊接完成時,在管道軸測圖上標注焊口號,焊工號。預制完成的管線,管口端應用管帽〔塑料封堵,防止臟物進入。本工程各鋼種選用的焊絲、焊條如下：Weldrod&wire<appliedinthisproject>asfollows鋼號steelNo.手弧焊焊條manualweldingrod氬弧焊argonarcwelding20#J422H08Mn2SiAQ235AJ4220Cr18Ni9A102H0Cr20Ni10TiALSALMg-XPipingweldingWeldingprocedurequalification,welderqualificationexamination,weldingprocesscardandweldingmaterial<choiceasperbasemetal>shallbeconductedpriortopipewelding.Weldersshallcomplywithweldingprocesscardissuedbyengineertoexecuteweldingwork.Noweldingispermittedinraining,foggyweather,orwhenhumidityexceeds90%,orwhenwindspeedexceeds8m/s.Weldingelectrodesshallbedriedasperrequirement<skilledpersonwillbeinchargeofweldingelectrodedryingwork,strictelectrodeissuingrecordsystemshallbecarriedout>.Meanwhile,differentbrandsofelectrodesshallbeidentifiedwithdifferentcolormarkingorothertypesofmarkingattheelectrodeends.Wrongelectrodewilldirectlyaffectweldquality.Therefore,weldersshallrequestforelectrodeswithelectroderequestsheetsissuedbytheinstallationtechnician,andshalluseformalelectrodedryer.Weldersshallcheckassemblyconditionspriortotackwelding.Thebevelangle,buttclearanceandinternalwallunfitnessshallbeasperweldingproceduresheet.Thesurfacewithin50mmoftheweldingbevelendshallbegroundtillsoundmetalpriortotackwelding.Pipeweldingprocedureshallbeinaccordancewiththecorrespondingweldingproceduresheet.Slagandspattershallberemovedimmediatelyafterwelding.Theweldsurfaceshallbecleanedandvisuallyinspected.Whenweldingisfinished,markthewelderNo.,craterNo.,weldingdateonthecorrespondingcrater.Markingshallbedoneaccordinglyonthesingle-linediagram.Fabricatedpipelineshallhavetheirendscoveredwithpipecaps<plastic>toprotectingressofforeignmatters.焊接檢查焊縫外觀檢查不允許有裂紋、未溶合、氣孔、夾渣、飛濺存在；咬邊度<0.5mm,焊縫兩側咬邊總長不大于該焊縫全長的105,且不應大于100mm；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；焊接接頭錯邊量不應大于壁厚的10%,且不大于2mm。焊縫質量：管道焊縫質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。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。WeldinginspectionWeldvisualinspectionNocracks,lackoffusion,porosity,slaginclusionorspatterarepermitted.Undercutshallbelessthan0.5mm,totalundercutlengthonbothsidesoftheweldshallnotbelargerthan10%oftotalweldlength,andshallnotbelargerthan100mm;Theweldsurfaceshallnotbelowerthanthatofbasemetal,excessweldmetalshallbeaspercoderequirementprovidedbydesigninstitute;Weldjointunfitnessshallnotexceed10%ofwallthickness,andshallnotbelargerthan2mm.Weldquality:pipeweldqualityinspectionshallproceedasperrelativeweldinspectionrequirementsinthepipeinstallationcode<GB50235-97>providedbydesigninstitute.Fillinpipeweldingrecordsforqualifiedweldsandenterproperqualificationdataintothecomputer.Therecordshallbetight,accurateandclean.Unqualifiedproductshallberepairedandradiographedbytheoriginalmethod,andshallfollowcode<H-331>requirement.Qualifiedcratershallbeaccordinglymarkedonthesingle-linediagramorweldingrecord.管道安裝前應具備的條件與管道安裝的土建或鋼結構工程已檢驗合格,滿足安裝要求,并辦理好交接手續(xù)；與管道連接的設備已找正合格,固定完畢；管道內部清潔度已檢查合格,對管內有特殊要求的管線其質量應符合設計文件的要求；設計需要修改的位置及管道上的開孔應在安裝之前完成。ConditionsbeforeinstallationCivilorstructureworksassociatedwithpipeinstallationhavebeencompletedandinspectedtobesatisfactoryforpipeinstallation.Properhandoverhasbeendone;Equipmenttobeconnectedwiththepipesarealignedandfitted;Thepipeinternalcleannesshasbeeninspected.Forpipelineswithspecialrequirementsfortheirinternal,theirqualityshallbeasperrequirementsinthedesigndocuments;Locationmodificationsrequiredbydesignandopeningonthepipeshallbecompletedpriortopipeinstallation.鋼制管道安裝管道安裝時,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。法蘭連接應與管道同心,并應保證螺栓自由穿入。法蘭螺栓應跨中安裝。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。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。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。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。管子對口時應在距接口中收200mm處測量平直度〔見下圖。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。管道對口平直度管道連接時,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。支管與主管連接時,當工藝要求按介質流向傾斜,傾斜度按設計規(guī)定。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15標高架空及地溝室外±20室內±15水平管道平直度DN≤1002L‰,最大50DN＞1003L‰,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間距20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。閥門安裝閥門安裝前,應檢查填料,其壓蓋螺栓應留有調節(jié)余量。閥門安裝前,應按設計文件核對其型號,并應按介質流向確定其安裝方向。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。水平管道上的閥門,其手柄方向宜安裝在上半周范圍內,閥門操作和機構應靈活,指示準確。支架安裝管道安裝時,應及時固定,高調整支架。支架位置應準確,安裝應平整牢固,與管子接觸應緊密。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。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。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。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。活動架的位移方向及導向性能應符合設計規(guī)定。管托不得脫落。固定支架牢固可靠。伴熱管安裝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。不允許將伴熱管直接點焊到主管上,伴熱管的固定按設計要求進行。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。SteelPipeinstallationForpipesconnectedtostaticequipment,noadditionalstressisallowedwithflangedconnection.Theequipmentopeningsshallbecoveredwithsheetsteelorasbestosrubberplateforseparation;Flangeconnectionshallkeepconcentricwithpiping;ensureboltscanbefreeintoholes.Flangeboltsshallbesetatstridingtocentermethod.Parallelshallbekeptbetweenflanges,whichdeviationshallbenotmorethan1.5%ofO.Dofflange,andnotmorethan2mm.Forpipingwhichtemperatureunder200℃,Teflontapeisapplicableforthethreadjointsealingmaterial.Theflangesealingfacesshallbesmooth,anydamagedfaceshallberepairedorreplaced;duringbolting,theflangefaceshallmaintainaxialityandparallelismtoensureevenforceonthegaskets.Whenpipinginstallationonoutdoororinambientcorrosionenvironment,bolts&nutsshallbesmearedwithsupramolygrease,graphiteengineoilorgraphitepowder.Whenfittinguppipe,theevennessshallbemeasuredat200mmplaceawayfromconnectingjoint<seefollowingfigure>.Whennominaldiameterofpipeislower100mm,allowabledeviationis1mm,whenitisover100mm,allowabledeviationis2mm.Fulllengthallowabledeviationshallbe10mm.Pipingfit-upevennessWhilepiping,extraforcefit-upisforbidden,andbyaddingleanshimormulti-layerpadtoeliminatespace,gap,offsetoreccentric,etcwaysareforbiddenhere.Whenbranchpipeconnectingmainpiping,andprocessrequiresinclineaspermediumflowdirection,theleandegreeshallbeasperdesignspecification.Pipinginstallationallowabledeviationtableasfollows:〔unit:mmitemAllowabledeviationCoordinateInelevationortrenchOutdoor25Indoor15ElevationInelevationortrenchOutdoor±20Indoor±15LevelpipingevennessDN≤1002L‰,Max.50DN＞1003L‰,Max.80Verticalpipingperpendicularity5L‰,Max.30Spacebetweenrowedpipelines15Spacebetweencrosspipelinesorinsulationlayers20Whenexpansionjointinstallation,itshallbestretchedaccordingtodesignrequirement,allowabledeviationis±10mm.ValveerectionPackingofvalveshallbeinspectedpriortoerectionofvalve,whichpresscovershallleaveadjustmentallowance.Beforevalveerected,whichtypeshallbecheckedasperdesigndocument,andinstallationdirectionshallbeconfirmedaccordingtomediumflowingway.Whenflangeorthreadisusedtoconnectvalveandpiping,valvesshallbeerectedunderclosingstatus.Forvalvestobeerectedonhorizontalpiping,whichhandledirectionshallbewithinupperhalf-cyclerange,valvesoperationshallbeagile,andindicationbecorrect.SupportinstallationWhilepiping,pipingsupportshallbefixedandadjustedintime,whichlocationshallbecorrect,installationforitshallbelevelandfirm,thesupportshalltouchedfirmlywithpiping.Forheating-displacementpiping,slidingsurfaceofguidesupportorslidingsupportshallbecleanandlevel,deflectionandblockareforbidden.Itserectionlocationshallbeexcursionfromsupportingcentertoreversedirectionofdisplacement,theexcursionquantityshallbe1/2ofdisplacement,orinaccordancewithdesignspecification,andinsulationlayershallnotdisturbitsdisplacement.Rootsupportshallbeasperdesignspecification;andonsameonepipeline,above2rootsupportsshallbenotallowable.Temporarysupportisnotavailableforpiping,whenhavetousetemporarysupport,itshallnotconflictwithformalpipesupport,whichshallbemarkedobviously.Afterpipingcompleted,temporarysupportsshallbedismantled.Afterpipingerected,supporttypeandlocationshallbeinspectedonebyoneasperdesigndocument.Displacementdirectionandguideperformanceshallbeconformitywithdesignrequirement.Pipingshoesshallbenotfalloff.Rootsupportsshallbefirmandreliable.InstallationoftracingpipeThetracepipeshallbeinstalledinparallelwiththemainpipe,andshallhaveitsowndrain.Horizontaltracepipeispreferablyinstalledunderthemainpipeoronthesideclosetothesupport.Verticaltracepipesshallbeevenedarrangedaroundthemainpipe,thetracepipeshallbefittedonthemainpipebygalvanizedironwire.Tracingpipeotherinstallationmethodisassameasmainpiping<includingpressuretestandblowingoff>.不銹鋼管安裝材料檢驗與保管不銹鋼管及管件必須具有制造廠的合格證書、化學成分和機械性能等資料。不銹鋼管子及管件使用前應按規(guī)范要求進行外觀檢查,表面不得有裂縫、重皮等缺陷。搬運不銹鋼管時,應避免與碳鋼管相互摩擦、碰撞,堆放時應與碳鋼管用橡膠板分開隔離,并防止雨水、鐵銹等腐蝕。不同材質的不銹鋼管要進行標記,并分別堆放,以免混用。對材質有疑問時,可進行光普分析材料成分。管子切割和坡口不銹鋼管管徑≤100的采用砂輪機切割。不銹鋼管管徑＞100的采用等離子切割。不銹鋼管坡口采用砂輪機進行坡口。管道焊接不銹鋼管及低合金鋼管焊接采用氬弧焊打底,手工電弧焊蓋面的方法。管道材質焊接材料牌號焊絲牌號備注304LA002H00Cr21Ni10316LA002H0Cr20Ni14Mo3A335P11/P22R507H1Cr5Mo采用氬弧焊時,所焊接管道內應充氬保護,氬氣純度宜在99.9%以上,鎢極可選用釷鎢棒或純鎢棒。焊接前應將坡口極其兩側20mm寬度范圍內的油污清除干凈,并在坡口兩側各100mm寬度內涂上白堊粉,防止焊接飛濺物粘附在管壁上。焊后應對焊縫極其附近的管子表面進行酸洗,然后用熱水沖洗干凈,再進行鈍化處理。預制好的管子應進行標記,防止不同材質的管子混裝。管道安裝不銹鋼管道安裝應在支架全部固定好之后進行,安裝時不得用鐵質工具敲擊。不銹鋼法蘭用的非金屬墊片,其氯離子含量不得超過50ppm。不銹鋼管不準直接與碳鋼支架接觸,應在管道與支架之間墊入石棉橡膠板或橡膠皮。管子穿墻壁或樓板時,均應加裝套管,管子與套管之間的間隙應不小于10mm,并在空隙里填加絕緣物,絕緣物內不得有鐵屑等雜物,絕緣物一般為石棉繩。不銹鋼管焊縫表面清洗不銹鋼管道焊接完畢后,應用砂輪磨光機對焊縫表面的飛濺物進行打磨,然后涂上酸洗膏浸泡,用鋼絲刷進行焊縫清洗,最后用水進行沖洗,焊縫表面呈現(xiàn)金屬亮光色澤,通過THEOWNER質檢人員檢查確認后為合格。InstallationofstainlesssteelpipingMaterialinspection&testandcustodyItisnecessaryforS.S.pipeandS.S.fittingstohavequalificationcertificate,chemicalcontentandmechanicalperformance,rmation.VisualobservationisnecessaryforS.S.pipeandS.S.fittingspriortousageasperrelevantcodesandstandards,whichsurfaceshallnotexistcracks,overlap,etc.defects.WhenhandlingS.S.pipe,itshallavoidfrictioninmutual,andwhenliftingS.S.pipe,nylonstripisnecessary,andrubbersheetisapplicabletoseparateS.S.pipe,andpreventfromrain,rustcorrosion,etc.ItisnecessarytomakeidentificationfordifferentmaterialS.S.pipe,whichshallbestoreseparately,toavoidconfusion.Whendoubtingmaterial,spectralanalysisisavailableformaterialcontent.CuttingandbevelingS.Spipesize≤100mm,itshallbecutwithgrinder.S.S.Pipesize＞100mm,itshallbecutwithplasmacutter.GrinderisavailabletochamferbevelofS.S.pipe.S.S.pipingweldingArgonarcweldingforjointrootandmanualelectricalarcweldingforcoveringareapplicableforS.S.pipeandlowalloysteelpipe.<pipesize≤2’’,argonarcweldingisutilized.>PipematerialWeldingmaterialbrandWeldingwirebrandremarks304LA002H00Cr21Ni10316LA002H0Cr20Ni14Mo3A335P11/P22R507H1Cr5MoWhenusingargonarcwelding,pipinginsideshallbefilledwithargontobeshielded,andargonpurenessshallbe99.9%andabove,tungstenelectrodecanusethoriumtungstenbarortungstenbar.Beforewelding,bevelanditsbothsideswith50mmshallbecleanedandfreeoil,andchalkpowdershallbesmearedtopreventfromspattersattachingpipe.Afterwelding,picklingshallbeexecutedforweldingjointandpipesurfacenearbyjoint,thenusewaterwashingit,finally,passivationcanbeperformed.Fabricatedpipeshallbemarkedtopreventfromdifferentmaterialspipesintermixed.PipinginstallationAllsupportsshallbefixedpriortoinstallstainlesssteelpiping,othersteelorirontoolsareforbiddentoknockS.S.pipe.FornonmetalgasketusedforS.S.flange,itschlorineioncontentshallbenotover50ppm.S.S.pipeisforbiddentotouchC.S.support;asbestosrubbersheetorrubbersheetshallbeputbetweenpipingandsupport.Pipingthroughwallorfloor,jacketpipeshallcovermainpiping,andanyweldisnotallowableforthemainpipinginsideofjacketpipe.Spacebetweenpipingandjacketpipingshallbenotover10mm,whichshallbefilledwithinsulationmaterial;thematerialgenerallyusesasbestosrope.WeldsurfacecleaningofstainlesssteelpipeAfterS.S.pipewelded,spattersontheweldssurfaceshallbegrindedwithgrinder,thensmearpicklingpasteonit,andbrushthesurfacewithsteelwirebrush,flushitwithwater,tilltheweldssurfaceappearmetalbasebrightcolor.WhenTHEOWNERinspecterconfirmsit,itcanbeaseligible.FRP/PP管的安裝InstallationforFRP/PPPiping所有聚丙烯/玻璃鋼管的開口必須用塑料護套保護,以防止碰傷或外物進入管中。Allopeningsofpolypropylene/glass-reinforcedplasticpipeshallbeprotectedwithplasticcover,toavoiddamagedorotherarticlesintopipe.存放粘結劑的箱子,應加以保護,避免太陽直曬。Toprotectbondagentbox,inordertoavoidsunlight.調配完成的粘結劑,未使用完必須妥善處理,不要隨意拋棄,以免造成污染。Totreatproperlyremainingbondingagent<alreadyprepared>,withoutleaveitinanyplace,toavoidpollution.施工時每一道涂層必須硬化后,方可進行下一道施工。包覆的玻璃布必須完全浸透,兩道玻璃布間的紋路必須交叉。Aftereachcoatinghardened,nextprocedurecanbedone,wrappedglassclothshallbesaturatedfully,andlinesbetweentwolayersofglassclothshallbecrossed.所有原料在使用前必須先查驗其有效的存放期限,過期則不可使用,如果沒有標識,樹脂存放超過兩個月則不可以使用。環(huán)氧樹脂則存放不可超過一年,樹脂若涂刷不易或已開始膠化,均不可使用。Validdateshallbecheckedbeforeallmaterialused,ifinvalid,materialshallbeuseless,ifnoanymarkidentification,resinstoragebeyond2monthsshallbeuseless.Epoxyresinstoragetimeshallbenotover1year,ifresinbrushingisdifficultorgohardened,itshallbeuseless.在工作接頭接合的兩個小時前,所有要進行接合包覆的已硬化端口必須徹底且均勻地加以研磨,然后將此端口的氧化物與污物清除干凈,加工面必須比欲包覆面積大。Before2hoursthatjointsbonded,allhardenedjoint<needtobewrapped>shallbegrindeduniformlyandentirely,thencleanoutoxideandcontainmentofthisjoint,preparedfaceshallbemorethanwrappedarea.已處理完畢準備包覆的端口表面,若再遭到污染,或超過兩個小時沿未進行包覆,則此端口表面須再作研磨加工才能所覆。Forjointwaitingforwrapped,ifpollutionagain,ornotwrappedmorethan2hours,itshallbegrindedagain,thenwrappingit.經過研磨后,將要包覆的端口必須是一個粗糙的表面,在包覆前保持干凈且干燥。Aftergrinded,jointtobewrappedshallbecomecoarse,keepitcleananddrybeforewrapping.在接合端口的間隙,必須用樹脂填平,以保持表面的平整。Clearancebetweenjointsshallbefilledwithresintokeepflatface.在接頭完成包覆后,任何已經過研磨的外露表面均必須加上一層樹脂保護。Afterjointwrapped,anyexposedface<alreadygrinded>shallbeprotectedwith1layerofresin.須作多層包覆加強的接頭,每層加強材的端緣要互相交錯,避免在同一切面上。接頭包覆完畢后要等到完全硬化后才能移動。Forjointneedtobestrengthenedwithmulti-layerwrapping,edgeofeverystrengtheningmaterialshallbecrossed,toavoidtheminthesameonetangentplane.Afterwrappedandhardened,theycanbemoved.下料后的管子切斷面,必須涂上樹脂保護,不可讓纖維外露,且任何空隙都要用樹脂填滿,若端口出現(xiàn)綻開,則視為不合格品,不可使用。Cuttingfaceofpipeneedtobeprotectedwithresin,fibershallbenotexposed,andanygapshallbefilledwithresin,ifendcracked,itcanberegardedasunqualifiedproduct.PP管的施工ConstructionmethodforPPpipingPP管道連接以承插方式為主。SockedtypeisappliedforPPpipingconnection.FRP/PP管連接時,先清除PP管插口處的油脂污物,涂上粘貼膠后再插入承口,承插口外接合面進行電熱空氣熔化焊接封口,施焊過程中,為防止過熱,應不斷的擺動焊槍噴嘴,使焊條和焊槍均勻受熱,焊條排列均勻,以使焊縫飽滿平整無皺紋和凹癟。WhenconnectingFRP/PPpiping,oil&containmentshallbecleanedforPPpipingfaucet,afteritbondedwithbondingmaterial,itcanbeplacedintofaucet,socketoutsidebondingfaceshallbeclosedinelectricalheatingairfusionweldingway,duringwelding,inordertoavoidpostheating,weldinggunshallbeswungcontinuously,keepweldrodandgun