巴斯夫工藝管道施工方案

目錄Contents一、工程概況General 2二、編制依據(jù)Reference 3三、施工準(zhǔn)備ConstructionPreparation 3四、施工管理ConstructionManagement 4五、管道安裝Pipeinstallation 10六、材料管理Materialmanagement 40七、施工進(jìn)度控制與管理ControlandManagementofConstructionProgress 42八、人力計(jì)劃ManpowerPlan 42九、機(jī)具動員計(jì)劃Mobilizationplanofequipmentsandtools 44十、安全文明施工Safetyandhousekeeping 45十一、安全分析Safetyanalysis 48

一、工程概況General本工程位于馬來西亞關(guān)丹吉本工業(yè)園的檸檬香精項(xiàng)目。業(yè)主方為巴斯夫馬來西亞國油化學(xué)公司(簡稱BPC)，管理公司由FLOUR負(fù)責(zé)，綜合專業(yè)工程C420區(qū)域由中國化學(xué)工程馬來西亞公司（以下簡稱“CCEM”）承建。The

project

isBPC

LemongrassProjectwhichislocatedinGebengIndustrialParkofKuantanMalaysia.TheOwneristheBASFPETRONASChemicalsSDNBHD(BPC).OwnerrepresentativeisFLUOR.Multi-disciplinework(AreaC420Citralplant)iscontractedandconstructedbyChinaChemicalEngineering(M)SDNBHD.(HereinafterreferredtoasCCEM)㈠、工程簡介Projectdescription 1、本項(xiàng)目地上工藝管道主要由管廊管道和裝置區(qū)域管道工程組成。管道總長約42.5KM，約22.0萬DB，主要材質(zhì)有碳鋼A106-B、A53-B、A312-TP316/316L、A312-TP304/304L、合金鋼及非金屬管道HDPE等。TheA/Gprocesspipesoftheprojectaremainlyforthepiperackandtheplantarea.Thetotallengthofthepipesisabout42.5km,whichconsistsofabout120,000DBintotal.AndthemajorspecificationsarecarbonsteelA106-B,A53-B,A312-TP316/316L,A312-TP304/304L,Alloyandnon-metalpipe,suchasHDPE,etc.2、管道的主要連接形式有焊接、法蘭連接以及螺紋連接和卡套連接等。Themainconnectionwaysforthepipeincludewelding,flangeconnectingandthreadconnectingandjacketconnecting.3、從管道輸送的介質(zhì)及操作溫度、壓力等級劃分為常壓及壓力管道。Thepipesaredividedintoatmosphericpressurepipeandpressurepipebyservicemedia,operationtemperatureandpressurerating.㈡、工程特點(diǎn)Projectfeaturesandchallenges1、本管道工程材質(zhì)多樣，管徑跨度范圍大，溫度、壓力范圍廣，這給施工方面帶來較大難度。Therearevarioustypesofpipematerials,whichhavewiderangeofpipediameters,temperaturesandpressures,bringingmuchdifficultytoconstruction.2、本工程有易燃、有毒介質(zhì)管線，施工質(zhì)量要求高，特別對焊接質(zhì)量更為嚴(yán)格。Theprojecthaspipesservicinginflammableandtoxicmedia,whichdemandshighstandardonconstructionquality,especiallyonweldingquality.3、該工程的設(shè)備較多，增加配管難度；閥組、儀表調(diào)節(jié)元件多且要求配管質(zhì)量高，增加管道施工的復(fù)雜性及難度。Theprojecthaslargeamountofmechanicalequipment,whichmakestubingmoredifficult.Valvesetsandinstrumentshavemanyregulatingelements,whichdemandshighstandardsonpipeworkquality,andmeanwhilemakesitmorecomplicatedanddifficult.4、管道的總DB量較大，走向復(fù)雜，管線密集，加大施工工作量；工作任務(wù)重，施工人員多，加大管道施工管理工作難度。ThepiperoutesarecomplicatedandconcentratedwithlargeDiameterBorequantity,whichmakesworkquantitymorewhileheavyworkloadandlargeamountofconstructors,andmakespipeconstruction&managementworkmoredifficult.二、編制依據(jù)Reference 1、施工設(shè)計(jì)圖紙及技術(shù)要求；Constructiondesigndrawingandspecifications&code;2、本項(xiàng)目的施工合同；ProjectConstructionContract3、國際通用標(biāo)準(zhǔn)：InternationalStandardsa．ASMEb．ASTMc．ANSI4、馬來西亞香精項(xiàng)目管道工程相關(guān)標(biāo)準(zhǔn)和技術(shù)文件:RelatedpipingspecificationsofLemongrassProject9355-C400-EPSP-ACC-001REV.0-PipingmaterialspecificationLineClass–processofliftingpiping9355-C400-EMSP-ACC-0022REV.1-Generalmaterialrequirement9355-C400-EMSP-ACC-0004REV.0-pipesupport9355-C400-EMSP-ACC-0009REV.1Specificationforpositivematerialidentification9355-C400-EMSD-ACC-0001REV.0-jackedpipingdetail9355-C400-EMSP-ACC-0014REV.0-shopandfieldfabrication/installationandHandingprocess/utilizingpiping9355-C400-EMSP-ACC-0017REV.0-PipePressureTesting9355-C400-EMSP-ACC-0006REV.1-SpecificationforweldingandNDEforequipment/fieldfabricatedpipingJB-9-017-Rev.0-FieldmaterialmanagementcontrolprocedureJB-15-003-Rev.0-LemongrasssiteNonDestructiveTestExecutionPlanJB-15-004LemongrasswelderTestcenterPlan5、我公司企業(yè)標(biāo)準(zhǔn)CompanyStandards壓力管道安裝《質(zhì)量手冊》（QG/CC-7.PP.0501-00）QualityHandbookforPressurePipeInstallation壓力管道安裝《質(zhì)量體系文件》（QG/CC-7.PP.0502-00）QualitySystemDocumentforPressurePipeInstallation壓力管道安裝《作業(yè)指導(dǎo)書》（QG/CC-7.PP.0503-00）WorkGuidebookforPressurePipeInstallation三、施工準(zhǔn)備ConstructionPreparation.標(biāo)準(zhǔn)、規(guī)范準(zhǔn)備PreparationofStandardandSpecification3.1.1.收集管道施工要求的規(guī)范、標(biāo)準(zhǔn)。Topreparestandardandspecificationofpipeconstruction3.1.2.收集施工記錄和交工資料表格。Toprepareconstructionrecordandhandoverdocument.3.1.3.熟悉業(yè)主關(guān)于管道施工的特殊要求。Toknowthespecialrequirementofpipeconstruction3.2.技術(shù)準(zhǔn)備TechnicalPreparation3.2.1.圖紙會審Drawingjointreview；管道預(yù)制、安裝方案的編制與審批MethodstatementcompilationandApprovedforpipefabricationandinstallation；根據(jù)管道單線圖、平面圖、流程圖組織技術(shù)交底.Technicaldisclosureworkshallbedoneasperpipeisometricdrawing,elevationplanandworkflowchart.3.3.其他Others3.3.1.施工計(jì)劃編制ConstructionMethodStatementPreparation根據(jù)工程實(shí)際及工期要求，編制施工計(jì)劃。Theplanshallbecompiledaspersiteconditionandrequiredconstructionduration.3.3.2.施工人員準(zhǔn)備ManpowerPreparation根據(jù)現(xiàn)場施工條件，合理組織管道安裝人員（人力計(jì)劃詳見附表）；Thepersonnelforpipeinstallationshallbemobilizedsuitablyaccordingtositecondition.(seeattachmentofmanpowerplan)3.3.3.施工機(jī)具準(zhǔn)備EquipmentandToolsPreparation根據(jù)現(xiàn)場施工條件，合理組織管道安裝的施工機(jī)具（施工機(jī)具詳見附表）。Theequipmentandtoolsforpipeinstallationshallbemobilizedsuitablyaccordingtositecondition.(Seeattachmentofequipmentandtools)四、施工管理ConstructionManagement4.1.建立健全質(zhì)量保證體系Toestablishqualityassurancesystem4.1.1.建立以項(xiàng)目經(jīng)理為第一質(zhì)量責(zé)任人，各專業(yè)質(zhì)量工程師、質(zhì)檢人員為主導(dǎo)的質(zhì)量控制體系。質(zhì)量文件的建立和管理要細(xì)化到每個環(huán)節(jié)，分工明確、責(zé)任分明。TheprojectmanagerisfirstresponsibilitypersonandeachdisciplineengineerandQA/QCinspectorsareleadingrolesforQA/QCcontrolsystem.4.1.2.建立明確的質(zhì)量責(zé)任制度，質(zhì)量責(zé)任分解到各個崗位、各個環(huán)節(jié)、各個工種。從制度上落實(shí)誰管生產(chǎn)誰管質(zhì)量，誰施工誰負(fù)責(zé)質(zhì)量，誰操作誰保證質(zhì)量。Toestablishqualitysystemdefined,whichshallbeappliedtoeachposition,eachstepandeachdisciplinetoensurequalitycontrolduringconstruction.4.1.3.積極主動配合業(yè)主、管理機(jī)構(gòu)的工作，認(rèn)真和嚴(yán)格地執(zhí)行其發(fā)出的指令、意見和建議。Toassistandexecutetheinstruction,suggestionandcommentbyOwnerandmanagementagency.4.1.4.對有特殊資格要求的管理人員和操作人員須經(jīng)資格審查和確認(rèn)，持證上崗。Formanagementpersonandoperatorwithspecialrequirement,thequalificationcertificatesshallbeexaminedandconfirmed.4.2.壓力管道施工質(zhì)量保證體系QA/QCSystemofPressurePipe防腐保溫施工隊(duì)防腐保溫施工隊(duì)質(zhì)檢責(zé)任師工藝責(zé)任師焊接責(zé)任師設(shè)材責(zé)任師計(jì)量責(zé)任師項(xiàng)目質(zhì)保工程師專業(yè)技術(shù)人員管道施工隊(duì)壓力管道質(zhì)量保證體系理化責(zé)任師各專業(yè)質(zhì)檢員無損檢測責(zé)任師圖（1）圖（1）QASystemofPressurePipeQASystemofPressurePipeProjectQAEngineerProjectQAEngineerWeldingprincipleProcessprincipleQualitycheckupWeldingprincipleProcessprincipleQualitycheckupprincipleMeasurementprincipleMeasurementprincipleMaterialprinciplePhysicalandchemicalprincipleNDEprinciplePhysicalandchemicalprincipleNDEprincipleQualityinspectorQualityinspectorDisciplinetechniciansPipingteamsAPipingteamsAnti-corrosionteamSketch1Sketch14.2.1.壓力管道安裝時，為確保其安裝質(zhì)量其處于受控狀態(tài),應(yīng)建立如圖(1)的壓力管道安裝質(zhì)量保證體系。Wheninstallingthepressurepipe,QA/QCsystem(seesketch1)ofpressurepipeinstallationshallbesettedforcontrollinginstallationquality.4.2.建立健全安全管理體系Tosetintegralsafetymanagementsystem4.2.1.建立以項(xiàng)目經(jīng)理為第一安全責(zé)任人，專業(yè)安全工程師、安全人員為主導(dǎo)的安全控制體系。BuiltaHSEcontrolsystem,whichshallincludeprojectmanagerasafirstresponsibilitypersonandHSEengineerandsupervisoraskeypersons.4.2.2.落實(shí)安全責(zé)任到施工班組、到施工責(zé)任人。Safetyresponsibilityshallbeputintoworkteam/groupandpersonal.4.2.3.現(xiàn)場施工人員必須遵守現(xiàn)場的安全規(guī)定，定期進(jìn)行安全學(xué)習(xí)與培訓(xùn)。Constructionstuffshallcomplywiththesafetyrequirement,andcarryoutsafetytrainingregularly.4.2.4嚴(yán)格執(zhí)行各安全制度與操作規(guī)程，做到安全、文明、環(huán)保施工。Safetysystemandoperationspecificationshallbecarriedoutstrictlyforsafety,healthandenvironmentalprotectionconstruction.4.3工藝管道檢驗(yàn)與試驗(yàn)計(jì)劃Inspectionandtestplanofprocesspipe在工藝管道的施工過程，全方位的質(zhì)量監(jiān)督。并極力配合業(yè)主、管理公司、監(jiān)理、質(zhì)檢站對各檢查點(diǎn)的監(jiān)督檢查工作；嚴(yán)格執(zhí)行停檢點(diǎn)、必檢點(diǎn)的監(jiān)督檢查。在管道施工過程中，應(yīng)切實(shí)重點(diǎn)做好質(zhì)量監(jiān)督檢查控制工作，以便更好地控制管道施工的質(zhì)量，執(zhí)行相關(guān)ITP計(jì)劃。Duringprocesspipeconstruction,WellcooperatedwithBPC/FLOUR,supervisionandrelativegovernmentbureauforsupervisionofeachinspectionpoint.Strictlycomplywithsupervisionandinspectionrequirementsonholdpointandwitnesspoint.Duringpipeconstruction,thefollowingissuesshallbefocusedonforbetterfabricationquality.4.4.工序交接Workprocedurehandover4.4.1.做好各道工序之間的交接工作，確保上道工序不合格的產(chǎn)品嚴(yán)禁進(jìn)入下道工序。Handoverbetweeneachprocessshallbewellperformedtoensurenounqualifiedproductbeingusedinthenextprocess.4.4.1.1.管件、閥門、管材等工程材料經(jīng)檢驗(yàn)不合格者，禁止用于本工程施工；同時臨時管道，管件和閥門材料需要合格。Itisforbiddentousenon-conformingconstructionmaterial,suchaspipefitting,valveandpipematerial,inthisproject；Thetemporarymaterialsshouldbequalifiedtoo.4.4.1.2.管道除銹、防腐檢查及管件組對不合格，不得進(jìn)行焊接工作。Poorfit-uppipefittingscannotbewelded.4.4預(yù)制產(chǎn)品安裝前，必須經(jīng)相關(guān)的質(zhì)量檢查人員或?qū)I(yè)工程師檢查，確認(rèn)合格后，方可用于安裝施工。Beforeinstalling,fabricatedproductsmustbeinspectedandapprovedbyrelatedqualityinspectorordisciplineengineer.4.4.1.4預(yù)制管段安裝前需對管段內(nèi)部垃圾進(jìn)行清理，并組織檢查，檢查合格后才能繼續(xù)安裝。Theinternalwasteofpre-fabricatedspoolsshouldberemovedbeforeinstallationofpre-fabricatedspools,theinspectionwillbeperformed,thepre-fabricatedspoolscanbeinstalledafterpassingtheinspection.4.4.1.5預(yù)制管段安裝前需對有法蘭面的管道進(jìn)行保護(hù)，法蘭面安裝時需安裝臨時橡膠墊，避免對法蘭水線照成機(jī)械損壞。Thepipewithflangefaceshouldbeprotectedbeforeinstallationofpre-fabricatedspools,thetemporaryrubbergasketneedtobeinstalledwhileflangefaceisbeinginstalled,toavoidthemechanicaldamageforflangesealsurface.4.4.2.施工過程必須加強(qiáng)施工班組的自檢工作，嚴(yán)格“三檢”制度（自檢、互檢、交接檢），確保每道工序產(chǎn)品合格。Duringconstruction,internalinspectionofconstructionteamshallbeimproved.“ThreeInspections”Regulation(internal-inspection,mutual-inspectionandjointinspection)shallbestrictlycompliedtoensureproductsusedineachprocessarequalified.4.5.工藝管道焊接質(zhì)量保證體系QA/QCsystemforProcesspipewelding4.5.1.現(xiàn)場施焊人員資格審查；Qualificationexaminationforsitewelder4.5.2.焊接工人上崗前，現(xiàn)場實(shí)際操作考試；Weldershallpassweldingtestinsitebeforeanywork.4.5.3.焊接過程合格率考核與控制；Testandcontrolofweldingqualificationrate4.5.4.焊接工程師及焊接質(zhì)量檢查人員現(xiàn)場指導(dǎo)、檢查；Siteguidanceandinspectionactedbyweldingengineerandweldingqualityinspector.4.6施工技術(shù)及資料管理Constructiontechniqueanddocumentcontrol4.6.1.施工過程中必須嚴(yán)格執(zhí)行相關(guān)的規(guī)范、標(biāo)準(zhǔn)、要求等。Relatedspecification,standardandrequirementshallbeperformedstrictlyduringconstruction.4.6.2.嚴(yán)格按照我公司質(zhì)量體系文件運(yùn)行程序進(jìn)行施工和管理。Relatedspecifications,standardsandrequirements,etc.shallbestrictlycompliedintheprocessofconstruction.4.6.3.施工圖紙管理Managementofconstructiondrawing(IFCdrawing)4.6.3.1.施工前，施工圖紙必須經(jīng)專業(yè)工程師審查，并進(jìn)行圖紙會審。IFCdrawingmustbereviewedandjointreviewedbydisciplineengineerbeforeconstruction.4.6.3.2.圖紙收發(fā)必須進(jìn)行登記，以便核查。圖紙版次更替應(yīng)做到及時，確保施工圖紙一直處于最新版次。對于舊版次應(yīng)即刻回收，并做好登記保管，做到無遺漏。Drawingissuancestatusshallberecordedforeasycheck.Drawingversionshallbeupdatedtimelytomakesurealwaysusingthelatestversion.Oldversionshallbereturnedbacktimely,recordshallbemadeaswelltoavoidmissingitems4.6.3.3.施工圖紙發(fā)放前，必須對施工隊(duì)進(jìn)行技術(shù)交底及圖紙答疑。TechnicaldisclosureanddrawingclarificationshallbedonetoconstructionteamsbeforeissuingIFCdrawing.4.6.3.4.圖紙?jiān)O(shè)計(jì)變更應(yīng)及時傳達(dá)到施工隊(duì)，并及時對圖紙進(jìn)行修改，并及時執(zhí)行設(shè)計(jì)變更。Designchangeshallbeinformedtoconstructionteam，drawingshallberevisedtimelyanddesignchangeshallbecompliedtimelyaswell.4.6.4.施工過程記錄應(yīng)做到及時、準(zhǔn)確，并簽字保存妥當(dāng)。Constructionprocessrecordsshallbemadetimely,accuratelyandwell-kept.4.6.5為加強(qiáng)質(zhì)量管理，保證為業(yè)主提供合格的工程項(xiàng)目產(chǎn)品，在施工過程管理工作中，使用公司開發(fā)的管道施工管理系統(tǒng)軟件，跟蹤、記錄管道的主要施工信息、質(zhì)量日檢信息、無損檢驗(yàn)信息等，以便施工人員及時了解相應(yīng)的質(zhì)量進(jìn)度信息，便于質(zhì)量管理和控制，同時輔助生成主要的交工資料，提高交工的質(zhì)量。ToimprovequalitymanagementandprovidequalifiedproducttotheOwner,companydevelopedpipeconstructionmanagementsoftwarewillbeusedintheconstructiontotraceandrecordmajorconstructioninformation,dailyqualityinspectioninformation,NDEinformation,etc,whichmakeconstructorknowrelatedqualityprogressinformationwellandeasytomanagementandcontrolquality.Mainhandoverdocumentwillbegeneratedasauxiliaryfunction,whichimproveshandoverqualityaswell.4.7.現(xiàn)場安裝管道的標(biāo)識Pipeidentificationforsiteinstallation4.7.1.管材、管件的追溯檢查Traceabilityofpipematerialandpipefitting4.7.1.1材料到預(yù)制區(qū)域后按管道預(yù)制過程標(biāo)識和出廠標(biāo)識的要求嚴(yán)格執(zhí)行，以實(shí)現(xiàn)管材鑒定到管道安裝的全過程可追溯性。Arrivedatfabricationarea,materialsshallbemarkedasperrequirementsonpipeinstallationprocessandmanufacturetomaketraceabilityofwholeprocessfrompipematerialidentificationtopipeinstallationpossible.4.7..材料使用前，應(yīng)先確認(rèn)材質(zhì)色標(biāo)是否符合規(guī)定。Ensurethematerialcolorsystemappliestotherequirementpriortouse.4.7.1.3.材料分離、分割而使原標(biāo)識不全時，要進(jìn)行原標(biāo)識的移植；Originalidentificationshallberelocatedifmaterialisincompletebyseparatingorcutting.

4.7.2.安裝管段的標(biāo)識Pipespoolidentificationforsiteinstallation

4.7.2.1.管段及焊口的編號和標(biāo)識工作貫徹管段安裝全過程。采用在單線圖上標(biāo)明焊口檢驗(yàn)狀態(tài)，在實(shí)物上用記號筆做標(biāo)識方法進(jìn)行標(biāo)注。Serialnumberandidentificationofpipespoolandweldjointshallbemadeduringwholepipespoolinstallationprocess.MarkinspectionstatusofweldjointintheISOdrawing.Markidentificationonspoolbymarkerpen.

4.7.2.2.管端上的焊工號、焊口號及安裝管段號不得用打鋼印，而采用記號筆（不得含鋅、氯離子等對母材有危害的成分）在距焊縫邊緣50mm處標(biāo)注，字跡清晰工整。Welder’sIDnumber,No.ofweldjointandNo.ofinstallationspool,whichareinthepipeend,shallnotbesteelstampedbutbemarkedat50mmawayfromweldjointedgebymarkerpen(freeofzinc,andcholrion,whichisharmfultobasemetal)inavisibleandneatlyway.

.2.3.管段及焊口的標(biāo)識方法如下：管道標(biāo)識的責(zé)任：焊工代號由焊工填寫，質(zhì)檢員代號由質(zhì)檢員檢驗(yàn)后填寫，其余標(biāo)識（預(yù)制管段號、管段長度或爐批號）均由管工填寫。管工和焊工自檢合格，且所填內(nèi)容齊全后，由管工班長或焊工統(tǒng)一向質(zhì)檢員報檢，經(jīng)質(zhì)檢員外觀檢查合格后報FLOUR檢查，由FLOUR點(diǎn)口確定需檢測的焊口并在焊縫上用記號筆按照要求作為無損檢測的標(biāo)識（RT、PT等）標(biāo)識內(nèi)容見圖（2）：Identificationmethodofpipespoolandweldjointasfollows:Responsibilityofpipeidentification:welder’sIDnumberwillbefilledbywelder,qualityinspector’sIDnumberwillbefilledbyqualityinspectorafterinspection,otheridentifications(No.offabricatedpipespool,lengthofpipespoolorheatNo.)willbefilledbypipefitter.Pipefitterandweldershallinspectfabricatedpipeandcompleteidentificationsfirstly,thenpipefitterleaderorwelderleadershallreporttoqualityinspectorforinspection.QualityinspectorwillreportittoFLOURifvisualinspectionisaccepted.WeldjunctionshouldbedeterminedaccordingtoFLOURspotweldjunction,andmarkedNDE(RT,PT,etc.)ontheweldjointbymarkingpenasperrequirements.RefertoSketch(2)fordetailedmark.

DiagramDiagram2PipespoollengthL=No.ofpipespoolFabricatedareaWeldseamSpoolfabricationIdentificationPipematerialISODwgNo.No.ofweldWelder’sIDNo.Welddate五、管道安裝Pipeinstallation5.1.施工準(zhǔn)備Preparation

5.1.3.3.施工人員準(zhǔn)備Manpowermobilization

根據(jù)現(xiàn)場施工條件，合理組織管道安裝人員（人力計(jì)劃詳見附表）；Pipeinstallationpersonshallbemobilizedaccordingtositeconstructioncondition.(detailedmanpowerplanisattachedasbellow)

5.1.3.4.施工機(jī)具準(zhǔn)備Equipmentandtoolspreparation

根據(jù)現(xiàn)場施工條件，合理組織管道安裝的施工機(jī)具（施工機(jī)具詳見附表）。Equipmentandtoolsshallbemobilizedaccordingtositeconstructioncondition.(detailedequipmentandtoolsplanisattachedasbellow)

5.2.管道安裝Pipeinstallation

5.2.1.安裝流程Workingprocedure

管道施工安裝流程如圖（圖一）Pipeinstallationprocedureisshownassketch1.

安裝位置核查Inspectionoflocationforpipeinstallation

管道安裝前，檢查土建基礎(chǔ)、結(jié)構(gòu)、設(shè)備管口的尺寸、標(biāo)高、位置等是否與管道圖紙相符。Beforepipeinstallation,inspectdimension,elevation,positionofcivilfoundation,structureandequipmentnozzleaccordingtopipedrawing.

5.2.3.預(yù)制管段安裝前內(nèi)部清理檢查Checkinginteriorcleaningstatusbeforeinstallingfabricatedspool.

安裝前，通過預(yù)制記錄及預(yù)制管線標(biāo)識找查安裝的管線，檢查預(yù)制管段的管內(nèi)部清潔度。Beforeinstallation,findthepipelineaccordingtofabricationrecordandpipeidentification,andchecktheinternalclearnessofpipespoolfabricated.

管道安裝的一般流程（管道安裝的一般流程（圖一）管線上儀表元件的拆除試壓方案確定試壓臨時管線安裝試壓裝置準(zhǔn)備腳手架搭設(shè)進(jìn)度計(jì)劃編制人力、機(jī)具準(zhǔn)備設(shè)備、結(jié)構(gòu)驗(yàn)收材料、驗(yàn)收施工前準(zhǔn)備按PID圖檢查按支架安裝圖檢查預(yù)熱、熱處理及其他處理支架和一次部件的安裝吊裝前管內(nèi)清潔檢查按管道圖檢查不合格氣密試驗(yàn)（泄漏性試驗(yàn)）管道油漆現(xiàn)場組對、安裝吹掃方案確定管線檢查管道壓力試驗(yàn)管線吹掃、沖洗管線復(fù)位管線復(fù)位檢查臨時管道安裝現(xiàn)場焊接管線整改管道調(diào)整段預(yù)制安裝支架安裝管線最終檢查方案確定管道伴熱管道絕熱移交方案確定方案確定方案確定試壓包資料審查RT、PT等RT、PT等

PT、RTPT、RTetcPipeinsulationHandoverConfirmationofmethodPipepressuretestandgoldjointInspectionaccordingtoworkflowInspectionaccordingtosupportinstallationdrawingInspectionaccordingtoworkflowAirleakagetestPaintingConfirmationofflushingmethodPipelineinspectionPipelineblastingandflushingPipelinereplacementInspectionofpipereplacementTemporarypipeinstallationPipelinemodifySupportinstallationFinalinspectionConfirmationofmethodElectricheattracingConfirmationofmethodConfirmationofmethodTestPackDocumentCheckRemovalofpipeinstrumentonthepipelinePressuremethodconfirmTemporarypipelineinstallationEquipmentpreparationWorkflowofpipeinstallation(sketch3)materialandacceptancePreparationPipePreheating,heattreatmentorothersBracketandon-lineinstrumentcomponentinstallationPipeinternalcleaningbeforeliftingUnqualifiedFitting-upandinstallationonsiteWeldingonsiteAdjustedpipefabricationandinstallationScaffoldingerectionMakeconstructionplanManpowerandequipmentEquipmentandstructureacceptance

5.2.4.管道安裝的允許偏差A(yù)llowableDeviationofpipeinstallation

架空及地溝平面坐標(biāo)：室內(nèi)允許偏差15mm，室外允許偏差25mm。Coordinateofoverheadlayerandtrench:indoorshallbe15mm,outdoorshallbe25mm.

架空及地溝標(biāo)高：室內(nèi)允許偏差±15mm，室外允許偏差±20mm。Elevationofoverheadlayerandtrench:indoorshallbe±15mm,outdoorshallbe±20mm.

水平管道平直度：DN≤100，允許偏差為2L‰，最大50mm。DN＞100，允許偏差為3L‰，最大80mm。Straightnessofhorizontalpipeline:ifDN≤100,allowabledeviationshallbe2L‰,maximumdeviationshallbe50mm.ifDN≤100,allowabledeviationshallbe3L‰,maximumdeviationshallbe50mm.

立管鉛垂度：允許偏差為5L‰，最大30mm。Theverticalityofriserpipeline:allowabledeviationshallbe5L‰,maximumallowabledeviationshallbe30mm.

成排管道的間距：允許偏差15mm。Theintervalofpipeinarow:theallowabledeviationshallbe15mm.

交叉管或絕熱層間距：允許偏差20mm。Theintervalofcrosspipelineorthermalinsulationlayer:theallowabledeviationshallbe20mm.

5.2.5.管道各類焊縫間距要求intervalspacerequirementofvariousweldjoint

管道各類焊縫間距要求詳見（圖3）及表二Pleasereferto(sketch3)andform2forintervalspacerequirementofvariousweldjoint

t(mm)t(mm)D(mm)ACDBBBBB管道焊縫間距要求示意圖（圖3）Sketchforintervalspacerequirementofpipeweldjoint(sketch3)表二(form2)

cipionofWTpe焊縫最小間距（選最大者）MinimumDistanceBetweenWeldToes(whicheverisgreater)A120°oror5t（1）B120°oror5t（2）C100mmor2t（3）D50mmor2tDimensionaltolerancesforfabricatedpiping采用氣體烏弧焊和氣體金屬弧焊預(yù)制的焊口錯邊量不得超過2.4mm(0.8mm)MISALIGNMENTACROSSANYDIAMETERATWELD采用氣體烏弧焊和氣體金屬弧焊預(yù)制的焊口錯邊量不得超過2.4mm(0.8mm)MISALIGNMENTACROSSANYDIAMETERATWELDPREPARATIONSSHALLNOTEXCEED2.4mm(0.8mm)FORGTAW/GMAWWELDS偏離中心線不得超過+/-+/-3.2mmMAXOFFCENTRELINEROTATIONOFFLANGESFROMTHEINDICATEDPOSITIONMEASUREDASSHOWN1.6mmMAXIMUM法蘭/100mm直徑。MISALIGNMENTACROSSANYDIAMETERATFLANGEFACESSHALLNOTEXCEED0.25mmPER100mmDIAMETER，F(xiàn)ORTOLERANCESONBENDPROFILESSEE4滾筒rollor支撐架bracket管架梁beam固定板fixedplate圖(4)1000竄管器管線鋪設(shè)Pipelinelaying

管廊管道鋪設(shè)Rackpipelaying

A.管廊穿管Pipelaying

滾筒rollor支撐架bracket管架梁beam固定板fixedplate圖(4)1000竄管器C.管道牽引Pipetrailing管廊在竄管器上牽引一般采取人工形式或采用倒鏈牽引。對于同層管道數(shù)量大且直徑相對較大時，可采用卷揚(yáng)機(jī)牽引，如圖（5）。Piperackshallbetrailedbymanualorchainblock.Foralargequantityanddiameterofpipeinthesame,itshallbetrailedbywindlass.Seesketch(5)

竄管器竄管器Pipeconnector卷揚(yáng)機(jī)windlass工藝管道Processpipe圖（5）

5.2.6.2.設(shè)備間管線鋪設(shè)與安裝Pipelinelayingandinstallationbetweenequipments安裝時，首先測量好現(xiàn)場已安裝完成的管線連接設(shè)備間距離、標(biāo)高等參數(shù)，預(yù)制管段。將連接設(shè)備兩端法蘭固定在設(shè)備口，螺栓擰緊，數(shù)量不得低于4顆。Pipespoolshallbefabricatedaccordingtothedistance,elevationetc.betweenpipeinstalledandequipment.Fixtheflangeontheendofequipment,tighteningthebolt,andshouldbenotlessthan4.

然后采用吊車將預(yù)制管段吊裝就位，組對，點(diǎn)焊好。LiftPipespoolfabricatedtothecorrectpositionbyhoist,fitupandspotweld。

點(diǎn)焊好后，應(yīng)采用臨時措施加固避免變形（防變形的臨時加固件，應(yīng)在焊接工作徹底完成后才能拆卸）。待焊口根部焊縫完成后，拆卸組對管線，在地面完成剩余的焊接、探傷、試壓、清洗等工作，然后復(fù)位安裝。Afterspotwelding,pipespoolshallbestrengthenedbytemporarymeasurestopreventdeforming(Thetemporarymeasurescan’tberemoveduntilweldingcompletefinish).Afterfinishrootweldingofweldjoint,removethepipespoolfittedup,whichshallbetreatedbywelding,crackdetection,cleaningontheground,andberepositedandinstalledatlast.

5.2.7.管道對口Pipefittingup

5.2.7.1.管道對口連接時，不得用強(qiáng)力進(jìn)行組對，亦不得通過松或強(qiáng)緊連接螺栓或添加法蘭連接墊片來調(diào)整組對間隙及管口平直度。Duringfittingupwork,pipecannotbejointedbytheactionofastrongforce,alsonotbeadjustedtheintervalandstraightnessbyflangegasket.

5.2.7.2.管口組對時，應(yīng)符合圖（6）要求.

當(dāng)管子公稱直徑小于100mm時，允許偏差值α為1mm；當(dāng)管子公稱直徑大于或等于100mm時，允許偏差值α為2mm；但全長的偏差值不得超過10mm。管道坡口加工時，壁厚＜3mm采用I型坡口，壁厚≥3mm采用V型坡口；組對間隙應(yīng)控制在2~4mm；允許最大錯邊量為壁厚的10%且不大于2mm。Pipefittingupshallmeettherequirementofsketch(6).Whenthenominaldiameterofpipe<100mm,allowabledeviationvalueαshallbe1mm.Whenthenominaldiameterofpipe≥100mm,allowabledeviationvalueαshallbe2mm,butthewholedeviationshouldnotexceeds10mm.Forthepipefit-up,adoptItypegrooveforthethicknesslessthan3mm,andadoptVtypegrooveforthethickness≥3mm;thespaceofthefit-upshouldbecontrolledwithin2~4mm;permittedmaximumunfitnessvalueis10timesofthewallthicknessbutnotexceed2mm.圖（6）Sketch6圖（6）Sketch6鋼板尺steelruler200α5.2.7.3.作為封閉管段組對時，其首先應(yīng)根據(jù)現(xiàn)場實(shí)測的安裝長度進(jìn)行下料加工，其偏差不得超過1.5mm，確保焊口間隙，保障焊接質(zhì)量。Sealpipespoolshallbefabricatedaspersurveyedinstallationlengthwithallowancenomorethan1.5mm,tokeepaintervalbetweenweldjointswithahighqualityofwelding.

5.2.8.法蘭安裝Flangeinstallation

5.2.8.1.法蘭連接應(yīng)與管道同心，并確保螺栓自由穿過螺栓孔；Connectedflangeshallbeasamecenterwithpipe.

5.2.8.2.垂直或傾斜法蘭面螺栓孔應(yīng)垂直跨中安裝，其連線水平度不得大于1.5mm；水平法蘭面螺栓孔安裝應(yīng)跨裝置南北或東西方向；Allboltholesofflangeshallstraddleverticalandhorizontalcentrelinesofthepipe.Levelnessshallbenomorethan1.5mm.Flangeboltholesonhorizontalpipeshallstraddlethesitesystemlines,i.e.sitePlantNorth/SouthorPlantEast/West.

5.2.8.3.水平法蘭水平度及垂直法蘭的鉛錘度不得大于法蘭外徑的1‰，且不得大于2mm。Theverticalityofhorizontalandverticalflangeshallbenomorethanouterdiameter1‰(2mm).

5.2.8.4.當(dāng)法蘭采取螺紋連接時，管端應(yīng)低于法蘭密封面1.5mm.Iftreadedconnectionisusedtoflanges,theendofpipeshallbelowerthanthesealingface1.5mm.

5.2.8.5.不得用強(qiáng)緊螺栓的方法或松螺栓方法來消除歪斜。同時，不得加偏墊或多層墊等方法來消除法蘭接口端面的間隙、偏斜、錯口或不同心等缺陷。Itisnotallowedtotightenorlooseboltforadjusttiltedsurfaceofbolt,meanwhilenotallowedtoaddpartialpadorcushionstoeliminatedefectsofclearance,deviations,mismatchanddisalignment.

5.2.8.6.動設(shè)備法蘭口最終連接時，必須在聯(lián)軸器上架設(shè)百分表監(jiān)視動設(shè)備的位移。

當(dāng)動設(shè)備額定轉(zhuǎn)速大于6000r/min時，其位移值應(yīng)小于0.02mm；當(dāng)額定轉(zhuǎn)速小于或等于6000r/min時，其位移值應(yīng)小于0.05mm。Flangeconnectionofrotaryequipmentmustbetestedwithdialgauge.installingthedialindicatoroncouplertomonitorequipment'sdislocation.Whenratedspeedismorethan6000r/min,thedislocationvalueshouldbelessthan0.02mm,whenratedspeedisnotmorethan6000r/min,it'sdislocationvalueshouldbelessthan0.05mm.

5.2.9.墊片安裝Gasketinstallation

5.2.9.1.墊片安裝前，應(yīng)按圖確認(rèn)其型號規(guī)格是否滿足設(shè)計(jì)要求。法蘭安裝前，應(yīng)檢查法蘭密封面及密封墊片，不得有影響密封性能的徑向劃痕、斑點(diǎn)、破損、皺折等缺陷。同時，配對法蘭環(huán)槽密封面與金屬環(huán)墊還應(yīng)作接觸線檢查，當(dāng)金屬環(huán)墊在密封面上轉(zhuǎn)動45°檢查接觸線不得有間斷現(xiàn)象。Beforegasketinstallation,thetypeandspecificationshallbeconfirmedtomeettherequirementofdesign.Beforeflangeinstallation,checkthesealingfaceandsealinggasketwhichfreeofscratch,stain,damagedandwrinkledetc..Contactinglinecheckbetweenflangeringsealfaceandmetalringgasketshallbedoneinthemannerthatnodiscontinuouslineexistingwhenrotatemetalringgasketfor45°.

5.2.9.2.安裝時，必須確保墊片安裝位置應(yīng)在法蘭密封面中心，1個密封面只安裝1塊墊片，禁止安裝多層墊。Duringgasketinstallation,gasketmustbeplacedinthecenterofflangesurface,only1piecegasketcanbeusedforflangesurfaceinsteadofmulti-piece.

閥門安裝Valveinstallation

5.2.10.1.閥門安裝前應(yīng)檢查閥門的規(guī)格型號是否與設(shè)計(jì)一致，并檢查填料其壓蓋螺栓應(yīng)留有調(diào)節(jié)余量。Thetypeandspecificationofvalveshallbecheckedformeetingtherequirementofdesign,asuitablespaceshallberemainedbetweenglandboltandfillingmaterial.

5.2.10.2.當(dāng)閥門與管道以法蘭或螺紋方式連接時，閥門應(yīng)以關(guān)閉狀態(tài)安裝。當(dāng)閥門與管道以焊接方式連接時，必須將閥芯打開焊接；承插焊閥門安裝時，應(yīng)確保管段光滑，并與閥門內(nèi)凸臺留出1-1.5mm間隙。Whenvalveisconnectedtopipebythreading,itshallbeinclosedstatus.Whenvalveisconnectedtopipebywelding,itshallbeinopenedstatus.Whenvalveisinstalledbysocketwelding,pipespoolshallbesmoothandkeepadistanceof1-1.5mmwithvalveboss.

5.2.10.3.水平管線閘閥安裝時，應(yīng)水平斜45°以上范圍，以圖紙為基準(zhǔn)，以避免閥芯因重力而脫落或發(fā)生故障。Forhorizontalpipelinegatevalveinstallation,whichshallbeanangleof45degreetopreventvalvecoredropofforgowrongduetogravity.

5.2.10.4.如無特殊要求，對于截止閥應(yīng)按閥體標(biāo)識方向安裝，低進(jìn)高出的原則。Globevalveshallbeinstalledaccordingtodirectionofinstructiononthevalvebody,baseontheprincipleoflowtohigh.

5.2.10.5.對止回閥安裝方向，閥體標(biāo)識方向必須與工藝管道流向一致。Forinstallationdirectionofcheckvalve,thedirectionofinstructiononthevalvebodymustaccordwithflowdirectionofprocesspipeline.

5.2.10.6.安全閥的安裝應(yīng)符合以下規(guī)定：Safetyvalveinstallationshallcomplywithregulationisshownasbellow.

A.安全閥應(yīng)垂直安裝；Safetyvalveshallbeinstalledvertically.

B.管道投入運(yùn)行前，安全閥必須經(jīng)具有資質(zhì)的專業(yè)機(jī)構(gòu)進(jìn)行調(diào)校，安全閥經(jīng)最終調(diào)校合格后，應(yīng)進(jìn)行鉛封并作好相應(yīng)的資料；Beforepipelineusing,safetyvalveshallberegulatedbyqualifiedorganization,andthenbesealedwithlead.Makerelevantdocument.

5.2.10.7.調(diào)節(jié)閥、流量計(jì)安裝，必須在其兩端增設(shè)臨時盲板，以防止異物進(jìn)入閥體內(nèi)，其安裝方向應(yīng)按閥體標(biāo)識方向與介質(zhì)流向保持一致。孔板、流量計(jì)前后直管段的長度應(yīng)符合圖紙和規(guī)范要求?？装?、連接流量計(jì)的法蘭內(nèi)壁焊縫必須打磨平整。Forcontrolvalveandflowmeterinstallation,theblankplateshallbesetontheendsofthemtopreventforeignmatterformentering.Thedirectionofinstallationshallbethesamewithflowdirectionofprocesspipeinaccordwithvalvebodysign.Thestraightpipelengthconnectingtheorificeandflowmetershouldapplywiththerequirementofthedrawingandspecification.Theinnerwallofflangefortheorificeandflowmetermustbegroundflatly.

5.2.10.8.取樣閥安裝，其位置應(yīng)符合圖紙，且便于操作。Thelocationofsamplevalveshallmeetthedrawingandbeeasytowork.

5.2.10.9.對于球閥、蝶閥等，一般無方向要求，為便于檢修，安裝時應(yīng)按閥體標(biāo)識進(jìn)行安裝。Forballvalveandbutterflyvalveinstallation,whichshallbeinstalledaccordingtovalvebodysign,shallbeeasytomaintainandrepair,andnorequirementofdirection.

5.2.10.10.所有的閥門安裝時，必須確保操作方便、安全可靠。所有碳鋼閥門絲桿在閥門安裝必須涂抹好油脂進(jìn)行保護(hù)。Allvalveinstallationmustbesafetyandeasytooperation.Oilgreaseshallbeusedforprotectcarbonsteelvalverod.

5.2.11.螺栓安裝Boltinstallation

5.2.11.1.法蘭連接螺栓應(yīng)使用同一規(guī)格，安裝方向一致。螺栓緊固后應(yīng)與法蘭緊貼，不得有楔縫。需安裝墊圈時，每顆螺栓不得超過1只。緊固后，螺栓應(yīng)與螺母保持齊平或1～2個螺距。為拆卸方便，一般地應(yīng)使用雙頭螺栓。Thesametypeboltshallbeuseforflangeconnection,andkeepthesameinstallationdirection.Tightenboltandkeepclosetoflange,freeofinterval.Whengasketisinstalled,thereshallbenotmorethan1piece.Afterbolttightening,thedistanceof0-5mmshallbekeptfrombolttonutinordertotaketheboltdowneasily.Threadedstudshallbeusedingeneral.5.2.11.2.所有不銹鋼螺栓、合金鋼螺栓安裝時，必須涂抹二硫化鉬油脂，以防止緊固過程中發(fā)生過燒，致使螺栓不能拆卸；所有露天裝置和用于設(shè)計(jì)溫度高于100℃或低于0℃的碳鋼螺栓安裝時，必須涂抹黃油。Wheninstallingstainlesssteelbolt,alloysteelbolts,Molybdenumdisulfidegreaseshallbecoveredtoavoidboltistoohot,whichaffecttheboltremoval,Fordeviceinopenair,andcarbonsteelboltinstallation,whichthedesigntempratureismorethan100℃o