南海石化项目工艺管线施工技术方案（42页）.doc

1、工艺管线施工技术方案Construction Technique Scheme for Process Pipelines1 工程概况 我公司承建的中海壳牌石油化工有限公司南海石化项目苯乙烯、环氧丙烷及丙烯乙二醇装置位于广东省惠州市大亚湾区海畔.该项目由德悉尼布天辰化学工程（天津）有限公司设计，所处地区环境干燥温度最高38.5，最低2.3，湿润温度28.1，空气湿度大，雨期较长。2 编制依据2.1 德悉尼布天辰化学工程（天津）有限公司提供的工艺管道施工图；2.2 工艺管道设计技术交底（会议纪要）；2.4石油化工剧毒、可燃介质管道工程施工及验收规范（SH3501-1997）；2.5工业金属管道工

2、程施工及验收规范（GB50235-97）；2.6现场设备、工业管道焊接工程施工及验收规范（GB50236-98）；2.7埋地钢质管道环氧煤沥青防腐技术标准（SY/T0447-96）；2.8石油化工钢制通用阀门选用、检验及验收规范（SH3064-94）；2.9石油化工设备和管道隔热技术规范（SH3010-2000）；2.10工业设备、管道防腐蚀工程施工及验收规范（HGJ229-91）；2.11工业设备及管道绝热工程施工及验收规范（GBJ126-89）；2.12石油化工工程铬钼耐热钢管道焊接技术规程（SHJ520-91）；2.13电力建设施工及验收技术规范(管道篇)DL5031-942.14电力建

3、设施工及验收技术规范（火力发电厂焊接篇）DL5007-922.15石油化工企业设备管道表面色和标志SH3043-19912.16石油化工异种钢焊接规程SH3526-19922.17石油化工铬镍奥氏体钢、铁镍合金和镍合金管道焊接规程SH3523-19992.18压力容器无损检测（JB4730-94）；2.19石油化工施工安全技术规程（SH3505-99）；2.20工程建设交工技术文件规定（SH3503-93）；2.2150万吨/年延迟装置施工组织设计；2.22压力管道安装质量保证手册（QG/M4441.50.00-1999）；2.23压力管道安装质量程序文件(QG/P4443.50.00-199

4、9)；2.24压力管道安装工艺标准（QG/4441.52.00-1999）；2.25压力管道安装竣工技术文件规定（QG/M4441.53.00-1999）。3 工艺配管的特点： The character of pipe erection3.1 PTA装置中易燃，易爆及腐蚀性介质的管道较多，且物料大多为浆料和粉料，有强烈腐蚀性，故配管材料选用要求严格。本装置中大量使用超低碳不锈钢，包括304L、316L、317L等，并有少量钛管、海氏合金管及塑料管。IN PTA installation, there are many pipes with inflammable, explosive and

5、 corrosive medium, most of which are slurry and powder with strong corrosion. Therefore the required material of pipe erection is very strict. In this installation, we not only use a lot of low carbon stainless steel with specification of 304L,316L and 317L.but also some titanium pipe, alloy pipe an

6、d plastic pipe.3.2本装置动设备较多，必须保证无应力配管，不得对设备施加外力。配管应从设备开始向设备外配管，配管过程中应及时设置管道支吊架，不得让设备承受管道系统的重力。 There are many movable equipments in the installation, we need ensure pipe erection without stressing, and cannot impose external force on the equipments, In the pipe erection, we need start from the equipm

7、ent inside, and then the outside of the equipments. We need set up the pipe rack in time to avoid the gravity from the pipe system.3.3本工程管道焊接量大，需要投入大批量的优秀焊工。我公司目前有压力管道持证焊工685名，能够保证焊接要求。如我公司中标本项目，将派出具有行业及国家级先进水平的优秀焊工来承担本工程的焊接任务，能够确保装置的长期有效地运行。 The pipe welding quantities is very heavy in the project.

8、 It needs provide a large number of qualified welders. Now our company has 685 welders with certificates, which can comply with the welding requirements. Once tendered, we will send qualified welders to bear the welding task of the project, All the welders have much experience and advance technique,

9、 which can ensure the erection in good quality in a long time.3.4 本装置工艺配管工程量大，共有各类管道132km。为提高劳动效率，加快施工进度，我们将大力推进管道自动焊，实行管道预制工厂化、产品化。我公司有各种型号的自动化焊机多台，在管道预制过程中，配以高纯度氩气（99.99%）的气体保护管道自动焊，可以极大地提高劳动效率，有效地抑制焊接接头部位的氧化，保证接头内部平整、外型美观。.6.3.1.4 The quantities of Process pipe erection is heavy, It includes all

10、kinds of pipeof 132km.In order to enhance the work efficiency and speed the construction progress, we will try our best to push pipe automatic welding and perform pipe prefabrication in market. There are many automatic welding machines with models in our company. In the process of pipe erection, the

11、 application of arc protection automatic welding machine with high purity of argon can improve the work efficiency, hold back the oxidization of the location of welding joint, and ensure the inside of joint flat and on good look outside.4 管道安装工程量The quantities of pipe erection类别Type材质Material 规格（mm）

12、Specification 质量（t）Quality 数量（m）Quantity管材Piping +material CS 1/254 878.04 62813 SS 1/280 315.1 38850 钛材Titanium 3/480 38.53 650 合金钢Alloy steel 3/436 13.53 630 铜管Copper pipe 1/23/4 17.27 28403 塑料管Plastic Pipe 3/456 1.49 706 法兰Flange 114.92 配件Fittings 255.3 阀门Valve 273.21 弹簧支撑Spring Supporting 11.88

13、其它支撑Other supporting 157.45、 管道材料检验Pipe material inspection管道施工材料的质量保证是施工质量的基础。我公司具有一套成熟可行的原材料检验管理制度，我们将按照具体工程特点建立健全切实可行的材料检验管理体系以提供质量保证。The quality assurance of pipe construction material is the basis of the construction quality. Our company owns a available and mature management system of material

14、 inspection and we will adjust it according to the actual project character for quality ensure.5.1 成立专门的检验小组实施统一的管材管件检验，并按照相应标准组织检验。 Setting up a inspection group for pipe material and fittings check, and inspecting with relative standard.5.2 材料检验设有独立的检验场地，并划分出待检区、检验区、合格品区和不合格品区。 Setting up a indepe

15、ndent inspection area for material examination, and divide it into waiting inspection area ,inspection area, qualified production area and unqualified production area.5.3训练有素的检验人员将严格按照以下检验工艺进行检验： The trained person will strictly inspect material complying with the following procedure: 管材、管件接收Pipe ma

16、terial, fittings acceptance 品种、规格、数量检查Brand ,specification and quantities inspection 外观质量检查Configuration quality inspection 材质检查Material quality inspection 质量验证Erection quality inspection 产品标识和检验状态标识Production identification and inspection in situation identification5.4管道组成件的检验 Piping fitting inspec

17、tion5.4.1不锈钢管子、管件（包括螺栓、螺母），应用光谱分析仪对材质的主要化学成份进行复查，并作好检验状态标识。 Stainless piping and fittings (including bolts and screw nuts) shall be rechecked chemical combinations by spectrum analyzer, and located in inspection situation.5.4.2螺栓、螺母的螺纹应完整、无划痕、毛刺等缺陷，并应配合良好，无松动或卡刺现象。 The screw thread shall be free fro

18、m defects such as deformities , scratches and irregular of distance between thread to thread, and shall be in good quality without loosening and jamming .5.4.3法兰密封面、缠绕垫不得有径向划痕、松散、翘曲等缺陷，石棉垫表面应平整光滑，不得有气泡、分层、折皱等缺陷。 The area between flange to flange and circle pad shall be protected from scratches loose

19、ning, twisting and so on. The surface of asbestos shall be flat and smooth , and be free from bubbles ,multi-layers ,crease and so on.5.4.4阀门检验 Valve inspection5.4.4.1阀门试验、检验前，专门成立阀门检验、试验小组，其成员应由施工班组、相关技术人员和质量检查人员组成。同时必须进行专门的技术交底，并配置相应的工装设备。 We will set up a valve check and test group before valve i

20、nspection, which include construction team, relative technique personnel, quality inspector. Meanwhile We will transfer necessary technique information and assemble proper work equipment.5.4.4.2阀门检验、试验程序见图3-1。 The valve inspection and test procedure see drawing 3-15.4.4.3阀门试验应从每批中抽查10%，且不少于1个，进行壳体压力

21、试验和密封性试验。当不合格时，应再抽查20%抽查，仍然不合格时，该批阀门不得使用。 10% of valves shall be take for inspection from each batch of it. And no less than 1 piece to shell pressure and densification test. In case it is not qualified, another 20% of it shall be rechecked. If unqualified again, the valves cannot be used. 5.4.4.4阀门

22、的壳体压力性试验和密封性试验必须用洁净水进行。不锈钢阀门试验用水的氯离子含量不得超过25ppm. Clean water should be used in the valve shell pressure and densification test .The content of chlorine used in stainless steel valve should not overpass 25ppm5.4.4.5阀门的壳体试验压力应为公称压力的1.5倍；试验时间不得少于5min，以壳体、填料无渗漏为合格。Valves shell tested pressure should be

23、1.5 times of nominal pressure , and the test should last 5 minutes, It will be qualified in the case of shell and packing be free from leakage.图3-1 阀门检验、试验工艺流程图 Drawing 3-1 Valve Inspection and Test Flow Plan阀门外观质量检查valve configuration quality inspection质量证明文件核查、确认Review and Confirmation of Qualific

24、ation Documentqiquuqq成立阀门检验、试验小组Setting Up valve inspection and test group严密性试验Pressure test强度试验intensity test 不合格unqualified检验、试验状态标识Inspection ,test situation identification工装设计制作检验场地准备Process assembly design and fabrication inspection yard preparation yard 编制技术措施并进行技术交底Prepared Technique and Tran

25、sfer it 不合格品处置Nonqualified production disposal合格交付安装Erection available合格5.4.4.6除止回阀、节流阀外，阀门的密封试验宜以公称压力进行，以阀瓣密封面不泄漏为合格。Except back and throttling valves, valve qualified inspection shall be determined by nominal pressure and no leakage in the densification area of valve petal.5.4.4.7公称压力小于1MPa，且公称直径大

26、于等于600的闸阀，壳体压力试验宜在系统试验时，按系统的试验压力进行试验，闸板密封试验可采用色印等方法进行检验，接合面上色印应连续。 As for the gate valve with nominal diameter more than 600 and nominal pressure less than 1Mpa, When doing the shell pressure test, It is better to examine according to the system testing pressure. Slide plate may use the color papers

27、 for testing and the continuation area should be continued. 5.4.4.8合金钢阀门的壳体材质必须逐件进行快速光谱分析，不合格时该批阀门不得使用。 The shell material of alloy steel valve should be analyzed one by one by high speed spectra. If unqualified valves in it, this batch of valves are forbidden to using.5.4.4.9试验合格的阀门，应及时排净内部积水、吹干密封面

28、上应涂防锈油，关闭阀门，封闭出入口。 Internal water in the valve acceptable should be drained in time and density area should be dried and coated with rust preventive oil. The valve should be closed .The egress and ingress should be closed.5.4.4.10安全阀按设计文件规定的定压值进行调试，允许偏差为3%。调试介质：管道内介质为气体时，优先酇用氮气调试；管道内介质为液体时，应使用液体调试。调

29、压时的压力应稳定，每个安全阀启闭次数为3次。要求起跳压力明显，无前漏、后漏现象。由于安全阀进出口压差较大，不进行壳体压力试验，密封试验时，压力小于定压值，不得泄漏，可在安全阀出口贴纸进行目测。Constant pressure of safety valves should be adjusted according to the document regulations and +/-3% deviation is permitted. We will use different mediums as follows according to the specified conditions

30、: Using nitrogen first in case of air in the piping . Using liquid in case of liquid in the piping. The pressure should be stable when adjusting and every safety valve should be opened and closed three times. The up and down pressure should be clear without internal and external leakage. Because the

31、 pressure deviation between safety valves ingress and egress is relative far ,the pressure is less than its constant pressure in density test .in this condition, the leakage is not permitted and the labels can be made on safety valve ingress and egress for visual check.5.5 质量检验人员均对检验过程做出详实的检验记录，以备随时

32、查证。 Quality inspector shall make detailed inspection record for verifying anytime.5.6 装置区工艺管道材料经检查合格后，均将做出不同色标加以标识。防止施工过程用错材料，并方便检查人员监查确认。各种管道配件在易于辨认处做出两处标识，各种管材、型材均做出通长标识。After checked qualified ,the piping material shall be identified with different color tags ,which can avoid mistake of material

33、utilization and make a convenience for supervisor checking and assurance .Two tags shall be made on the clear area of every kind of piping fittings and general tags shall be made on every kind of tube material and shape steel.6 管道的预制加工 Piping prefabrication and processing 6.1为了减少现场预制带来的技术管理、材料管理、设备管

34、理的工作负担，搞好文明施工，开辟第二现场，设置管道预制场地，进行管道的工厂化、产品化的预制加工，而后再在现场进行安装。管道预制加工厂设有轨道式天车、车床、摇臂钻床、剪板机、坡口加工机、自动焊机等施工机具。We have track crown blocks, lathes, beam drills, plate shears ,groove processing machine and automatic welding machines in the piping prefabrication yard to avoid field work bearing such as techniqu

35、e management ,material management and equipment management, make housekeeping ,develop the second site, set up piping prefabrication yard ,make piping prefabrication process in the market and then erect in the jobsite 6.2 预制前仔细核对单线图与平面图，核对基础、设备、管架、预埋件、预留孔是否正确，对于最后封闭的管段应考虑组焊位置和调节裕量。Before prefabricat

36、ion, We will check the isolated drawings and plans carefully , align the foundations ,equipments, pipe frames ,embedded parts and preformed holes in correct, and consider the welding position and adjust the size under the actual construction condition to the piping sections closed last.6.3 管道预制应按单线图

37、规定的数量、规格、材质选配管道组成件，预制过程中的每一道工序均应核对管子的标记，并做好标记的移植，做到用料正确、尺寸准确、标识明显。 In piping prefabrication progress, We will purchase piping fittings according to the specification, quantities and material quality formed in isolated drawings. We will check the piping tags in every steps and make changed tags in go

38、od consequence for using correct material and size and making clear tags.6.4 钢材的切割及管道坡口的加工应采用以下方法：镀锌钢管和公称直径50的碳钢管，采用机械切割，公称直径大于DN50的碳钢管采用氧乙炔焰法切割；不锈钢管应用机械或等离子的方法切割，304L、316L和317L材质的钢管用砂轮切割或修磨时，应有专用砂轮片。管子切口表面应平整、无裂纹、重皮、毛刺、凸凹、缩口、熔渣、氧化物、铁屑等。 Steel material cutting and piping groove process should use me

39、thods as follows; For galvanized steel tubes and carbon steel tubes with nominal diameter 50 using mechanical cutting .For carbon steel tubes with nominal diameter less than DN50 using oxygen acetylene cutting ,For stainless steel tubes using applied mechanical or plasma cutting ,For steel tubes wit

40、h specification of 304L,314L and 317L using abrasive wheel cutting or another alternative using special emery plate to grind. Tube cutting should be flat and smooth and no cracking, sand crust, fins ,uneven open track ,melted residue ,scrap and oxidization. 6.5 预制好的管段，按单元或区域摆放整齐，以便于运输和安装。管道施焊时，按规定的焊

41、接工艺执行。管道焊接、无损检测工作完成后，应在预制厂内除锈、喷砂和防腐，但焊口两侧各100mm的范围内不允许涂漆，焊工钢印号、管道编号以及管线号不允许涂漆，待系统水压试验合格后再进行防腐涂漆。为保证焊接质量，工艺管道焊接均采用氩电联焊的工艺进行。Prefabricated piping section shall be laid in order to transportation and erection. We will weld complying with regulated welding process. After piping welding and non-destructi

42、ve test. The derusting, blasting and anti-rotting steps should be done in the prefabrication yard. But 100mm away form two sides of welding joints and welders sign, piping number and pipeline number are not permit to paint, it should be done after system water pressure test qualified. In order to en

43、sure welding quality, all the process piping use argon continuation welding .6.6 预制完成的管段进行管线号、预制管段号标识，并用人工或压缩风将管膛内清除干净，用塑料布封闭管口分门别类摆放。不锈钢和碳钢在切割和存放时，严格区分开。We make identification tags for pipeline number and prefabrication piping section number which are completed the prefabrication, clean piping insi

44、de by hand and pressure wind, Classify and lay down them with piping mouth closed by plastic cloth. When cutting and storing ,stainless steel and carbon steel should be divided strictly.7 管道焊接 Piping weldingPTA装置焊接工程中，工艺管道母材的不锈钢比例在60以上，且有钛一类特殊材质的管道，焊接难度大、工艺标准要求高是该工程的主要特点。焊接质量直接决定整个安装工程的质量，因此，我们应从焊接材

45、料、焊接工艺、施焊过程、焊接检验诸方面对焊接质量进行严格控制，确保每个焊接环节都处于受控状态。In PTA assembly welding process, Because there is 60% of stainless steel in process piping parent material and piping has the especial titanium, the main character of the project is the difficult welding and high requirements of process standard. Weldin

46、g quality determine the overall erection project quality. we will control the welding material, welding process, welding operation ,welding inspection and so on to ensure welding quality and every welding steps in control.焊材型号和规格选用应严格执行焊接工艺评定。焊前检查、修正接缝的间隙、错边量等；焊接作业期间，注意自然环境对焊接作业的影响，焊后检查焊缝表面质量、角变形，及时

47、作出质量评定，并按要求进行无损检测，及时填写焊接施工记录。The utilization of the welding models and specification shall be strictly complied with welding process qualification such as checking before welding and correcting the distance in continued joints and misalignment. We will notice welding operation effects by native envi

48、ronment, check welding joints surface quality and twisted angels after welding ,make quality qualification in time ,execute non-destructive inspection with requirements and make record of welding construction in time.7. 1 焊接施工一般要求 General requirement of welding construction7.1.1 焊工应在合格的焊接项目内从事管道的焊接，

49、且在有效期内。 Welders shall work on piping welding in acceptable welding project and in available period.7.1.2 焊材应有产品合格证明书，并经复验合格。 Welding material should have qualified production certificates and acceptable after checking again.7.1.3 焊条应按说明书或焊接作业指导书的要求进行烘干，并在施焊过程中，使用保温筒保持焊条干燥。 Welding rod shall be dried

50、 by instruments and guide book of welding operation. Insulation tank shall be used for electrode drying in welding operation. 6.3.5.1.4 焊工按指定的焊接工艺卡（焊接作业指导书）施焊。焊接工艺卡应按与之相对应钢材的焊接工艺评定进行编制，并按程序进行审批。 Welders do their job with welding technique card,. Which will be prepared and reviewed by equivalent stee

51、l welding process qualification and procedure. equivalent steel welding process qualification and procedure. 7.1.5 当出现下列情况如没有防护措施时，应停止焊接工作： Welding operation must be stop in case following problem happened without protecta. 手工电弧焊时，风速8m/s，氩弧焊时，风速2m/s；The wind velocity is8m/s in SMAW, the wind velocit

52、y is 2m/s in arc welding.b. 相对湿度90%；Relative moisture is 90%c. 下雨；Raining7.1.6 焊接完毕后，及时在焊缝两侧50mm范围内打上焊工钢印号，不锈钢钢管不做钢印标识，但是应在管道单线图上标注清楚。 Welders stamps NO. shall be made in the 50mm range away from welding joints in time, Rebar marks will not be done in stainless steel tubes, but it should be indicate

53、d in piping isolated drawings.7.2 焊接材料的选择 Welding Material Alternative焊接材料选用表 5-1List for Welding Material Alternative 序 号No. 管 道 材 料Piping material 焊 丝Welding wire 焊 条Welding rod 备 注Remarks1API5L GR BER105-2E7016-15 2ANSI 304ER308E308-16 3 ANSI 304LER308LE308L-16 4 ANSI 316ER316E316-16 5 ANSI 316LE

54、R316LE316L-16 6ANSI 317LER317LE317L-16 7C276ERNiCrMo-4EniCrMo-4 8 TI 1ERTi-17.3 奥氏体不锈钢管道焊接 Stainless piping welding 7.3.1奥氏体不锈钢焊接坡口形式和尺寸应符合下表的规定： The groove spec and size of stainless steel tubes should comply with following regulation:焊接坡口形式和尺寸 Welding Groove Type and Size 5-2序厚度(mm)Thickness坡口类型Gr

55、oove Type坡口形式Groove Type坡口尺寸Groove size 备注Remarks号NO.间隙b(mm)Distance钝边P(mm)坡口角度()Groove angle Angle123I型坡口Type I groove01.5-单面焊Single Weldng23.68V型坡口V type Groove0202655单面焊Single welding奥氏体不锈钢管道焊口组对质量应符合以下要求： Stainless piping welding mouth to mouth should comply following requirements:7.3.2.1管口应做到内壁

56、平齐，其错边量不应超过壁厚的10%，且应0.5mm； The inside wall of piping mouth shall be flat and smooth, the misalignment shall not be more than 10% of wall thickness, and should be less than or equivalent to 0.5mm7.3.2.2焊接坡口应经砂轮打磨，坡口应整齐光洁，坡口表面的油污、锈蚀和坡口两侧各1015mm范围内的氧化层应清理干净，清理范围内应无裂纹、夹层等缺陷。 Welding groove should cleane

57、d by abrasive wheel ,Groove should be flat and smooth, The oil ,rusting and oxidization of groove surface should cleaned very well. In clean range should have no defects such as cracking and double layers.奥氏体不锈钢焊接时，应采用小规范、短电弧、快速焊和窄焊道工艺进行焊接，并应控制层间温度不得超过150，必要时，应采取强制冷却措施。 In stainless steel welding op

58、erations, We will weld with process such as small specification, short arc, and high speed welding and narrow welding. And will control the interpass temperature less than 150.If necessary we will use cooling measures in force.7.3.4为保证管口背面焊接成型质量，奥氏体不锈钢管道焊接全部采用氩弧焊打底。打底焊接时，管道内应充氩保护。预制管口焊接时应采用整体充氩，充氩时管

59、子两端应进行封堵，焊口处应用医用胶布密封，随焊接随揭开；安装管口焊接时，应在焊口组对前，在焊口内部放置易溶纸，采取局部充氩的方法进行充氩保护。充氩时，应将管口内部的空气置换干净，待坡口处有氩气均匀流出时方可进行焊接。氩弧焊打底焊接后，应及时进行打底焊缝的检查，确认打底焊缝合格后方可进行次层焊道的焊接，以防产生打底焊接缺陷。In order to ensure the welding shape quality of pipe mouth backing, All stainless tubes welding should use argon arc welding to make a bot

60、tom, When making the bottom. Argon should be filled the tubes. We should fill argon when prefabricated tubes mouth welding, it should be done in the condition of two tube mouths are closed. The welding area should sealed with hospital adhesive tape and opened with welding progress. When erecting the

61、 tubes welding, we will lay down lyotropic paper in welding mouth inside before correcting the welding mouth group and use filled arc locally to protect. We should change air in the inner tube until the arc in the groove flow in uniform. After the first pass welding, we need check the first welding

62、joint and continue to weld next when qualified to avoid the welding defects.7.3.5奥氏体不锈钢管道焊接过程中，应避免横向摆动，焊道不宜过宽，焊接应连续，要一次完成，不应中断。During the SS piping process, we should complete one time, with proper width of welding pass.7.3.6奥氏体不锈钢管道焊接时，严禁在被焊工件表面引燃电弧、试验电流；施焊过程中，应注意接头和收弧的质量，收弧时应将溶池填满，多层焊的焊接接头应错开。Mate

63、rial surface is prohibited from fired arc and tested current when welded. Pay attention to the quality of butt and arc, the filled pool, the divided complex butt.7.3.7为确保氩弧焊焊接成型质量，在每瓶氩气 正式投用施焊前，均应对每瓶氩气的纯度进行试焊检查，试焊检查不合格的氩气不得用于正式焊接施工。To make sure shape quality of arc welding, we should test the purity

64、 of arc prior to formal welding. If unqualified, it is not permitted to use.7.3.8焊接检验Welding Inspection奥氏体不锈钢管道的焊缝外观成型应良好，且应平滑过渡；焊缝宽度应以每边不超过坡口边缘2mm为宜；焊缝表面不得低于母材表面，焊缝余高h应1+0.2b（b为焊缝宽度），且应1.5mm。The welding configuration is in shape, the welding joint width is within 2mm of the groove edge. 奥氏体不锈钢焊缝表面不

65、允许有裂纹、未熔合、气孔、夹渣和飞溅等缺陷存在；焊缝无损检测质量，应符合设计规定的无损检测质量要求。Such defects are not permitted to stand, such as crack, non-fusion, bore, and splash. The NDT quality complies with standard.奥氏体不锈钢管道的焊缝咬边深度应0.5mm，连续长度应100mm，且焊缝两侧咬边总长度不得超过该焊缝长度的10% The height is within 0.5mm, the length is within 100mm, and the tota

66、l length is within the 10% of the welding joint length.7.4 钛管道焊接Titanium Pipe Welding7.4.1 一般规定General regulations7.4.1.1钛管焊接采用钨极氩弧焊，电弧采用高频电源，焊接设备采用性能稳定的直流氩弧焊机，正接法。Tungsten argon arc welding and arc with heatronic electrical power are applied for titanium welding; direct current argon arc machine of

67、 stable performance are applied for welding equipment, using positive polarity.7.4.1.2所有母材金属的接头表面，热影响区根部及表面在温度达到200以上时，应完全处于气体保护状态，保护气体应选用高纯度氩气（99。99），气体含水量不应大于50mg/m3，保护气体输送采用透明塑料软管。When the temperature reaches over 200 degree, which include the surface butts of all base metals, the root and the su

68、rface of hot effected location, the titanium pipe should be in protected gas estate. The protected gas, which has high purity argon with moisture of 50mg/m3, conveyed by clearing plastic tube.7 焊接作业均应在无风区进行，且场地洁净，因此必须在施工现场搭一封闭的作业篷。The work of welding can be carried out in non-wind location with clea

69、nness, therefore, we have to cast an obscure sail at the construction site. 7参加钛管焊接的焊工必须先按ASME 要求考试合格，并配备铰刀、不锈钢丝刷、氧化锆铝砂轮、丙酮洗剂、保护罩等专用工具。焊前应根据WPQR编制焊接工艺卡。The welders for titanium tube welding should have a test required for ASME IX, equipped by exclusive use tools, such as reamer, SS brush, backing sh

70、ield. Welding process card can be reviewed in accordance to WPQR prior to welding.7.4.1.5钛管的搬运、对口、吊装等作业应使用无铁索具，作业过程应避免使钛管道接触铁类物质，防止铁污染。We use ironless rigger to convey, correct and hoisting the titanium pipes. During the course, the titanium pipe should be kept from iron material to prevent iron pol

71、lution.7.4.2 焊前准备Preparation before the welding7.4.2.1坡口及两侧各25mm以内的内外表面除油污后，应用奥氏体不锈钢丝刷、铰刀等机械方法清除其氧化膜，毛刺和表面缺陷，清理干净后的表面应使用丙酮进行脱脂处理，严禁使用氧化物溶剂。填充焊丝也应用丙酮清理干净。After the eliminated oil fouling of the groove and 25mm of the two sides, the mechanic method such as the applied SS brush and reamer are used to e

72、liminate the oxidized sheet, fin and defective face. The cleaned face is handled by acetone and avoided by oxidization. In addition, the welding wires should be cleaned by the acetone.7.4.2.2 焊工配带的手套应经过水洗或丙酮洗涤，在施焊前去除毛边、毛屑。The gloves for welders should be washed by water or acetone, and eliminated th

73、e rough edge and the fur prior to the welding performance.7.4.2.3 管子组对时应做到内壁平齐，对口错边量不应超过壁厚的10且不大于1mm。When align piping group, we should make the wall inside flat and smooth, the butt misalignment should be not more than 1mm and not more than 10% of wall thickness7.4.2.4 组对卡具的金属成份应与母材成份一致，并在焊接后小心将其磨掉

74、。定位焊应采用与正式焊接相同的焊接材料及焊接工艺，其焊缝长度一般为10mm左右，高度不超过壁厚的2/3，焊点数应根椐管径和壁厚确定。The metal component of the tool, which is the same as the base, should be carefully ware off after welding. The fixed welding, which is the same as the formal welding in welding material and welding process, is applied, with the weldi

75、ng joints about 10mm length, the height about 2/3 of the wall. The number of the welding is based on the tube radius and the wall thickness.7.4.3 焊接工艺Welding Technical7.4.3.1 施焊时不需预热，层间温度冷却至100以下时方可进行下层焊道的焊接，在保证熔透及成形良好的情况下，应选用小规范焊接。The operating welding need not be preheated, the temperature of the

76、layer need be lowered to 100% below prior to next pass , we choose small area welding in the case of good shape.7.4.3.2 焊接作业均应在氩气保护下进行，采用焊炬喷嘴保护熔池，焊炬拖罩保护热态焊缝，管内充氩气保护焊缝及近缝区的内表面。保护措施应充分可靠并应符合下列要求：焊炬喷嘴直径宜选用1020mm，喷出的氩气应保持稳定层流。焊炬拖罩型式应根据焊件型状和尺寸决定，做到保护可靠，操作方便管内应提前充氩，排净空气，并保持微弱正压和呈现流动状态。The welding working

77、should be carried out in the protect of argon, using welding torch jet to protect puddle and welding torch shield to protect weld bead. We protect the weld bead and the inner face of the weld bead location with argon tube. The protected measurements should be reliable and complied with the following

78、 requirements:1. The diameter of the welding torch jet is suitable between 10mm and 20mm, to make sure the ejected argon is stable.2. The shape of the welding torch shield is based on the shape and the size of the weldment, to make sure the operation is convenient.3. .The tube should be filled with

79、argon and discharged air, keeping dim positive pressure and flow status.7.4.3.3起弧时焊炬应提前送气，并采用高频引弧，不允许在焊件上引弧。熄弧时焊工先切断焊接电流，保持接头处于气体保护之下，直到焊缝金属冷却到200以下。Gas should be conveyed to the welding torch prior to started arc, with high frequency arc. On putting out the arc, the welders should cut off the weldi

80、ng current to keep the butt under protect of air, and this status of the joint metal should be cooled under 200 degree.7.4.3.4焊接过程中焊丝熔化端始终处于惰性气体的保护之下，熄弧后，焊丝不得立即暴露在大气中，应在焊缝脱离保护时取出。In the course of the welding, the side of weld wire is under the protect of inertia gas.7.4.3.5焊接过程中如发生夹钨现象，应立即停止焊接，更换或修磨

81、钨极，并将污染区磨掉Once tungsten phenomenon happens during the course, the welding work should be stopped immediately. Then you should change or repair the tungsten polarity and erase the pollution area.7.4.3.6 底层焊道均应进行渗透探伤，以无裂纹和其它任何表面缺陷为合格。The layer of the welding need take NDG, the product with no crake an

82、d defective face is acceptable.7.4.3.7以后每层焊道也应进行外观检查，以无裂纹和其它任何表面缺陷为合格；同时应仔细检查每层焊道颜色：如焊道为明亮的金属银白色或兰紫色则为合格；如为暗灰色或白兰色则该焊道为不合格。Each layer of the welding pass should be taken visual examination, with no crack and surface defect acceptable. Meanwhile, the color of the welding pass should be examined caref

83、ully, with silver white color or blue purple color acceptable and dark gray or white orchid color unacceptable.7.4.3.8 管道焊后必须对焊缝进行外观检查：焊缝宽度以每边不超过坡口边缘2mm为宜；焊缝余高不超过1.5mm；角焊缝的焊脚高度应符合规定，余高为焊脚高度的15，其外形应平滑过渡。After the welding pass, we should take visual examination on welding joint, as follows: The width

84、of each welding joint is within 2mm of the groove, the surplus height of the welding joint is within 1.5mm, the height of fillet welding should be in accordance with such regulations: the surplus height is 15% of the welding bottom, the shape should be smooth.焊接完成后，所有对接焊缝应进行射线探伤，评定标准按设计标准执行。After th

85、e completion of the welding, all the welding joint should be examined by ray to carry out in accordance to the design standard. 8 管道安装Pipe Erection 根据PTA装置工艺管线的特点，管道安装工程将提供以下质量保证： 保证管道材料（材质、规格、型号）使用正确 保证管道内部清洁及与其连接设备内部清洁 保证阀门安装方向及阀门手轮方向安装正确 保证管道材料从接收、检验、保管、领用记录详实，使所用材料具有可追溯性 保证管道焊接质量可靠 保证管道试压吹扫气密质量可

86、靠 保证管道施工过程记录真实完整In accordance to the character of PTA, pipe erection works will afford such quality assurance.1. The pipe material(material quality, specification and size) should be used correctly.2. The inner of the pipe and the linked fittings should be cleaned.3. The valve as well as the handwhe

87、el should be erected in correct position.4. The pipe material has a detailed record of receiving, checking, keeping and using, and the used material is ascendable.5. The quality of the weld pass is trust6. The quality of the pressuring pipe is trust7. The records of the weld construction is true8.1管

88、道安装的基本原则The basic principle of pipe erection遵循先大管，后小管；先干线，后支线；先主管，后伴管；先公用工程，后工艺物料配管；先管廊后设备配管的施工顺序。由于受管件、配件的到货时间以及相关作业的影响，安装顺序可作适当调整。The construction sequence should be big tube prior to small tube, main wire prior to branch wire, main tube prior to second tube, public engineering to technical engine

89、ering. The sequences can be adjusted for the impact by tube, the received date and concerned work.8.2 安装的一般要求General requirements of erection8.2.1管道安装按管道平面布置图和单线图进行，重点注意标高、介质流向、支吊架型式及位置、坡度值、预拉值、管道材质、阀门的安装方向；在施工中若出现管线相碰，尽量减少管道的修改，避免受材料影响而影响施工进度。The pipe is erected in accordance to the sketch. We shou

90、ld lay emphasis on the erection position, such as the height, medium flow, supporting form and position, groove value, prestress value, pipe material and valve. If the pipe wire bumps during the construction, we should reduce the amendment of the pipe to avoid the construction degree impacted by mat

91、erial.8.2.2管道安装时，不宜采用临时支吊架,更不得用铁丝、麻绳、石块等作为临时支吊架，须安装正式支吊架。管架制安严格按图进行，特别是热力管线和机器出入口管线，未经设计或监理商书面同意，严禁变动其型式或规格、材质。支吊架焊接管道焊接施工工艺相同，焊肉要饱满，焊接完毕须经检查人员检查合格后，方可安装。In the course of the pipe erection, we choose formal supporting rack, and forbid to choose temporary supporting rack, especially iron wire, twine

92、and stone. Pipe supporting is carried out by sketch, especially hot pipe wire and machine tube wire. The specification or regulation together with material cannot be amended unless permitted by designer or supervisor. 8.2.3固定口接缝可采用卡具来组对。不得使用强力组对或增加斜垫或多层垫片等，来消除端面的过量空隙偏差、错口、不同心度等缺陷，若有这样的缺陷应查明原因进行修改。We

93、 can correct fixed welding butt joint in tools, but these defects such as deviation of surface ,wrong butt should not made up by force and adding pads and inclined pads.8.2.4法兰连接应保持同轴，保证螺栓能自由穿入。同一法兰使用同一规格的螺栓，安装方向一致。螺栓紧固应均匀对称，松紧适当，要保证螺母满扣，且外露长度两端基本保持一致。紧固后的螺栓与螺母宜平齐，设计温度高于100的管道用螺栓螺母和不锈钢材质的螺栓螺母，安装时，涂抹

94、指定的（二硫化钼油脂、石墨机油或石墨粉）油脂。 Flange continuation should keep the spindle and ensure bolts can penetrate free. Same flanges use the same specification bolts, Blot fixing should be in uniform and in proper tight and loose. And the two external end should keep the same .8.2.5不锈钢管道与碳钢支吊架之间，垫入氯离子含量不超过50ppm的橡胶

95、石棉垫，防止不锈钢因渗碳而腐蚀。8.3 连接机器的管道安装The linking machine 与传动设备连接的管道,从机器侧开始安装,首先安装管道支架或者先做好临时支架,这样,管道和阀门等的重量和附加力矩,就不会作用在机器上。The pipe linked with rotary machine is fixed from pipe supporting or temporary supporting. Therefore, additional torque and weight of piping and valve will not be imposed on the machine

96、.8.3.2连接机器的管道，其固定焊口要远离机器。The fixed welding mouth is remote from machine.8.3.3管道连接前，应在自由状态下检查法兰的平行度和同轴度，允许偏差符合表61的规定。Before the linking of pipe, the level and same spindle degree should be checked in native condition, and the tolerance complies with the following table.法兰平行度、同轴度允许偏差 Flange level and

97、spindle degree tolerance 表61机器转速(r/min)machine speed平行度（mm）level同轴度（mm）spindle degree3000-60000.150.5060000.100.208.3.4管道系统与机器最终连接时，应在联轴节上设百分表监测机器位移，转速大于6000r/min时 ，位移值小于0.02mm；转速小于等于6000r/min时,位移值于0.05mm。The supervisor is fixed in linking spindle, with 0.02 mm of 6000r/min over and 0.05mm of 6000r/

98、min below.8.3.5管道安装合格后，不得再承受设计以外的附加载荷。Piping should not bear external load after acceptable erection.8.4 法兰安装Flange erection 法兰安装前，再检查一遍法兰密封面及垫片，不能有影响密封性能的划痕等缺陷。对于高压法兰应用煤油清理密封面环槽并涂锂基脂进行保护。We will check flange density area and pad again, It should be no defects such as scrap to affect the density per

99、formance. 法兰紧固尽量采用液压紧固器，根据给定的力矩值进行紧固，同时用游标卡尺进行监测。 The seal and pad should be checked again prior to the flange erection, to avoid the defect such as scorch which effect the seal character.The pressured wrench is used in tightening flange in accordance with pressure degree, meanwhile, the nonius is u

100、sed to supervise. 8.5 阀门安装 阀门应当在干净的前提下安装，除了焊接和热处理时将阀门开启之外，在配管过程中不得将阀门打开。The valve should be erected under cleanness. We should not open valves in the piping erection except the condition of welding and heat treatment. 安装有流向的阀门时，应按照配管图使其流向一致。对于阀门流向与管线的流向相反时，要特别注意。We will keep the same direction betwe

101、en drawings and actual construction when erecting valves with direction. Pay more attention when valve flow is contradictive to piping flow direction.8.5.3阀门手轮的安装方向应符合图纸要求，严禁随意改变方向。 The erection direction of valve hand wheel shall comply with the direction indicated in drawings .No change the direct

102、ion.8.6 支吊架安装Supporting and pipe rack erection 管道支吊架按照管架详图进行安装，部分预制好的支吊架稍作修整即可安装，支吊架安装牢固，并与管子接触良好。We will erect the piping supporting and rack according to the pipe rack detailed drawings. Part of fabricated supporting can erect immediately after some correction. Supporting Erection should be fixed

103、tightly and have a good contact with piping. 无热位移的吊架，吊杆垂直安装。有热位移的吊架，吊点在位移相反方向1/2位置。有热位移的管道的固定支架的安装方向要特别注意。The hanger rod should be vertically erected .The hanger point is in 1/2 opposite position Of displacement. The erection direction should be payed more attention for piping fixing rack with heat

104、displacement.8.6.3弹簧支吊架安装高度，按照设计文件的要求进行调整。管道未固定前，先用临时支架代替，待管道定位后，再安装弹簧。弹簧的限位板，在试车前拆除。The height of spring hanger supporting should be adjusting according to the requirements of designed documents. We will use temporary rack before piping fixed and erect spring after fix the piping. The spring restri

105、ction plates should be dismantled before commissioning.8.6.4管道临时支架的使用应注意，不得将其焊在管道上，管道定位后，及时将临时支架更换为正式支架。Pay more attention to the using of piping temporary rack, It is not permitted to weld on the pipe .The temporary rack should be changed to formal rack in time after fixing the piping.8.6.5管道支吊架安装完

106、毕后，逐个核对，确认。 The completed erection of piping supporting and hanger should be checked and aligned one by one.8.6.7 补偿器的安装 Reinforcement machines erection. 补偿器的安装，严格按照设计文件的规定进行预拉伸或预压缩，合格并确认后，设置临时约束装置，负荷试车前，再将临时装置拆除。 The reinforcement machines erection should be strictly pre-tensioned and pre-compresse

107、d according to designed document. After checked and qualified ,We will set temporary restriction assembly and dismantled it after commissioning bearing load. 8.7.2 补偿器的吊装使用指定的吊耳。 The rigging shackle should be used in rigging of reinforcement machines. 在安装之前，让一个法兰松动，在焊接之前，对松动的法兰进行调整。 We should loose

108、one flange before erection and adjusting it before welding 8.7.4补偿器的安装方向要与流向一致。 The erection direction of reinforcement machines is the same as the flow direction.8.7.5安装过程中，防止压瘪，焊接飞溅以及杂物禁止进入波纹褶皱之间。 In erection process ,the welding flashing and debris are prohibited to enter the weave and folding.8.

109、8 伴热管的安装 UT erection 伴热管与主管平行安装，并自行排液 ,一根主管有多根伴热管时,伴热管之间的距离应固定。UT erection should level with main piping and drainage by itself. If one main piping has several UT, the distance of every UT should be fixed. 8.8.2水平伴热管安装在主管的下方或靠近支架的侧面，铅垂伴热管均匀分布在主管周围。The erection of level UT is under the main tubes and

110、 at the side of near rack. Vertical UT are distributed surrounding the main tubes.8.8.3不得将伴热管直接点焊在主管上，可采用内径比伴热管外径稍大且材质与主管相同的管子，用无齿锯切成15mm左右的短管点焊在主管上，伴热管从中穿过。也可捆扎在主管上，弯头部位捆扎不少于三道。 UT is prohibited to welding directly to the main tubes. We can use tubes with inside diameter more than outside diameter

111、of UT and with the same type of main tubes and cut tubes to 15mm by saw and then weld on the main tubes. The UT pierce it or bind on the main pipe ,and binding of long radius degree should at least three times.8.8.4从分配站到被伴热管和离开被伴热管到收集站的伴热管安装，必须排列整齐，尽量不要互相跨越和就近斜穿。支架上钻孔，用卡子固定。 From distribution stop t

112、o UT and away from UT to collection stop, the UT erection should be lined in uniform and no crossing and inclined piercing The rack should be drilled and fixed with clamps.8.8.5不锈钢管伴热捆扎采用不锈钢丝等非渗碳物。 Non-penetrated carbon material such as SS wire shall be used to bind the SS UT.8.9 钛管的安装Titanium pipin

113、g erection8.9.1施工前，准备好无铁索具，使用钢丝绳吊装时，可用橡胶板或石棉板与管子隔离。 Prepare riggings before construction and using rubber and asbestos plates to separate piping when rigging with steel wire. 8.8.9.2吊装过程中严禁损伤管道，并不能与其他材质接触。 It is no permit to injure piping during rigging process and no contact with other material.8.9

114、.3管道与支架之间的接触面按设计要求加置隔离板。 Adding separate plate required in design on the contact area between pipe and rack 8.9.4钛管安装完毕后，挂设警示牌“严禁在钛管上打火、生根支架、绑扎铁丝、搭设架杆、挂手拉葫芦等”The warning tag “No permit to lighting , binding wires, setting up frames and hanging things on titanium piping ”should be hanged after comple

115、ting titanium piping erection.8.10浆料粉料管道安装 Slurry and powder piping erction 该部分管道的材料均为超低碳不锈钢，工艺上既有防腐蚀要求又有防阻塞要求。施工时应严格控制焊口内焊缝的平滑度，对口时严格控制错边量，焊接全部用氩弧焊打底，活动焊口的内充氩装置在焊接完成后立即从管道中取出，固定焊口的可溶性纸保护垫应使用浆糊粘贴，禁用不干胶和胶布，以防吹洗不净。该部分管道采用水冲洗法吹洗，冲洗干净后通入压缩空气吹干。The material of this part of piping material is low carbon s

116、teel .It require to prevent rotting and jamming. We should strictly control smooth degree of welding joints and misalignment in butting process. All cleanliness of this part of piping can use water flushing and then drying the pipe by introducing compressed air.8.11 临时垫片的安装 Temporary pad erection.8.

117、11.1临时垫片将用于临时组装、压力试验、配管的清洗和吹扫。 The temporary pad will be used in temporary assembly ,pressure testing and cleanliness or flushing of piping erection.8.11.2在试运转之前，所有的临时垫片都要更换成正式垫片。 All temporary pads shall be changed to formal pads before trying to use.8.11.3临时垫片的放入部位： The location of temporary pads

118、临时组装的短管或部件Temporary assembled spools and components.临时过滤器Temporary filters孔板的定位距板Orifice fixing torque plates. 在配管的试验和吹扫时拆下的在线仪表The dismantled instruments in piping erection testing and blowing.控制阀 control valves流量计 tachomter液位计level gage压力表pressure gage分析仪 analyzer其他 miscellaneous 在进行配管试验和冲洗时拆掉配管组件

119、或者是安装盲板的部位Dismantling piping erection components or the location of erecting blind plate in the process of piping erection testing and flushing.安全阀 safety valve防爆膜 explosion proof sheet其他 miscellaneous 在进行配管试验和吹扫时安装盲板的法兰连接部位Erecting blinding plates flange contact location in piping erection testing

120、and flushing.8.114为了在把临时垫片安装到管线上之后，能够对其进行识别，在临时垫片的外导向环的外侧表面，全部进行颜色标记，颜色为红色。 In order to identify temporary pads after erected on the pipelines, the red tags should be made on the outside guided circle surface of temporary pads.8.12 热力管道安装 Heat power piping erection.固定架的位置必须符合图纸规定，不得遗漏或多加固定支架。 The lo

121、cation of fixing frame shall comply with the drawing requirements, fixing racks should not be omitted and added.8.12.2不得遗漏或多加导向支架和固定支架。 No need to omit and add guided and fixing racks8.12.3弹簧支、吊架定位应准确，弹簧压缩、拉伸值应符合设计规定。 Ensuring spring racks and hanging frames in correct position, The spring compressi

122、ng and tensile shall comply with designed regulations.8.12.4高温管道不得变动其安装位置与尺寸,若有变更时,必须有设计部门的变更通知单。The erection position and size of high temperature cannot be changed ,if any, The notification from designed department is needed.8.12.4支吊架按要求加置木块、软金属垫、石棉板、热垫等垫层时,不要随意取消垫层。For racks and hanging racks, It

123、 is required to add timber plates, soft metal pads, asbestos ,heat pads and so on. All should not be moved at random.9 管道系统试验Pipe system test管道安装完毕，应按设计规定对管道进行强度及严密性试验、吹扫或清洗、泄漏性试验等。After the completion of pipe erection, the pipe should have tightness test, sweep or cleanness and leak test in accorda

124、nce with design regulation. 9.1试验前的检查The examination before test组织业主代表、监理代表、设计代表、施工单位代表进行共检，试验前经共检合格。检查内容有： 管道系统施工完毕，符合设计及有关规范的要求；支、吊架安装完毕，临时加固措施安全可靠；焊接工作结束，并经检验合格；焊缝及焊缝编号、管线号其它应检查的部位，未经涂漆和绝热；管线材质、规格、壁厚系列应符合图纸及设计要求；按PI图核对流程是否正确，一次部件是否完成；按配管图核对管线尺寸、阀门和部件尺寸，按管道平面图、管架图核对管架位置、数量、型式、尺寸，质量应符合要求；根据施工记录核对射线

125、探伤、表面探伤情况；凡不合格处要及时处理，做好记录，检查合格后方可进行压力试验。 The client, supervisor, designer, constructor should take exam together, then continue to next step. The contents include:1. The pipe system construction comply with the requirements of design.2. Temporary strength regulation is reliable after completion of s

126、upporting.3. The welding works is acceptable.4. The weld joint with size, and the examined location should not be covered with lacquer and insulated.5. The material, regulation and thickness of the pipe line should be complied with the sketch and design required.6. See whether the flow is correct ac

127、cording to PI, 9.2试验范围的确定 Ensuring testing scopes水压试验前，必须具有完善的、并经批准的试验方案，根据工艺流程，按压力等级或介质分类，编制出切实可行的试验流程图，构成试压单元(试压包)，且要求完善试压包资料。Before hydraulic pressure test, the testing scheme should be completed and approved. According to process flow and classification of pressure level and medium grade, We wil

128、l prepare a available test flow plan , develop testing unit(pressure package) and ensure the pressure package information.试验前，应将不能参与试验的系统、设备、仪表及管道附件等加隔离，安全阀、防爆板应拆卸，加盲板的部位应有明显的标记。Before testing, We shall separate piping system, instruments, equipment and piping fittings which cannot used in test. Cle

129、ar tags should be made in the location of adding blinding plate and safety valves and explosive proof plate and safety valves should be dismantled.试压范围确定后，应在试压流程图上作出标记，并把加盲板、装压力表以及放空的位置标注在试压流程图上。 Tags should be made in the pressure flow drawings after ensuring the pressure range and also location of

130、 adding the blinding plates ,pressure gage, and the vent area.9.3压力试验Pressure test9.3.1液压试验使用的介质为洁净水。不锈钢管道使用水做压力试验时，水中氯离子含量不超过25ppm，环境温度宜在5以上，否则应采取防冻措施。试验前，注水时排净管道系统内的空气。The clean water is used in the hydraulic testing, In the pressure test of SS piping ,the environment should be above 5.C otherwise

131、 the frozen proof measure should be used.Before test, air in piping system should be drained cleanly during water pouring.液体压力试验时，至少安置两块经校验合格的压力表，精度不低于1.5级，表的满刻度值为最大被测压力的1.52倍。一块压力表放在系统最高处，一块压力表放在泵出口，试验时以最高处压力表读数为准In hydraulic test ,two qualified pressure gage shall be put which the accuracy should

132、be more than 1.5 .One pressure gage put at the top of system and the other at the pump mouth. The standard pressure can get from the first pressure gage.应分级缓慢升压，达到试验压力后停压10min，然后降至设计压力，停压30min，以不降压、无泄漏、无渗漏、目测无变形为合格。When lifting pressure, we will lift it gradually according to classification and then

133、 stop 10mim after up to testing pressure, the next step is to reduce it to designed pressure and stop 30min and to be qualified in the condition of no reducing pressure ,no leakage, no penetrating and no twisted shape in visual inspection.如果气温较低，而管道的试验压力1.6MPa、公称直径300或试验压力0.6MPa、公称直径300的管道，可用气体试压，但必

134、须有可靠的安全技术措施，并经现场技术总负责人批准。The pneumatic pressure can be used in low temperature for piping with available safety technique measurement and be approved by site technique general responsible person.The pipe test pressure 1.6mpa with the nominal diameter 300 with testing pressure 0.6MPa气体试验介质为蒸汽、压缩空气或氮气

135、。首先根据气体压力试验压力的大小，在0.10.5 Mpa 范围内进行预试验。气体压力试验时，应逐步缓慢增加压力。当压力升至试验压力的50%时，稳压3min，未发现异常或泄漏，继续按试验压力的10%逐级升压，每级稳压3min，直到试验压力，稳压10min，再将压力降至设计压力，用中性发泡剂对系统进行仔细巡回检查，无泄漏为合格。The medium of pneumatic test is steam, compressed air or nitrogen .Pre-test should be used in the test pressure range of 0.10.5Mpa .Lifti

136、ng pressure gradually is permitted. We can continue to lift pressure without leakage and debris .试验过程中若有泄漏，不得带压修理。缺陷消除后应重新试验。Once found leakage ,It is not permitted to repair with air. Test again is needed after making up defects.管道系统试验合格后，应缓慢降压，顶部放空阀先打开，试验介质排放到指定地点。 After piping system qualified, W

137、e will gradually decrease pressure and open the top valves and make sure the testing medium is vented to appointed place.管道系统试压完毕，应及时拆除临时盲板及临时试压管路。After system pressure test are completed, the temporary blinding plate and piping road should be dismantled.系统试验完毕，试验介质宜在合适地点排放，并注意安全。及时拆卸盲板，核对记录，并填写管道系统

138、试验记录。 When venting testing medium after testing in proper place, pay more attention to safety ,dismantle blinding plates ,align record and fill the 10 管道系统吹扫与清洗Piping system flushing and blowing管道吹扫与清洗工作，应按生产工艺流程、按系统进行。Piping flushing and blowing should comply with the system and production process

139、flow.吹洗方法应根据对管道的使用要求、工作介质及管道内表面的脏污程度确定。吹洗顺序应按主管、支管、疏排管依次进行，吹出的脏物不得进入已合格的管道。公称直径600mm的液体或气体管道，宜采用人工清理；公称直径600mm的液体管道宜采用水冲洗；公称直径600mm的气体管道，宜采用空气吹扫；蒸汽管道应以蒸汽吹扫；非热力管道不得用蒸汽吹扫。The flushing and blowing methods should be determined by the requirements of using piping ,work medium and dirty situation of pipe

140、surface inside. The sequence should be from main pipe, secondary pipe to venting pipe. Dirty debris flushed is prohibited to enter the qualified pipe. Manual cleanliness can be used to liquid and air pipe with diameter 600mm吹洗前应将系统内的仪表件、阀门等妨碍吹洗的元件拆除，待吹洗合格后复位。吹洗时管道内的脏物不得进入设备。Before cleanliness, Preve

141、nted components such as instruments, valves should be dismantled and replaced them after qualified. The dirty debris in piping should not enter the equipment.10.1吹洗前的检查 Check before flushing10.1.1吹洗前不应安装孔板、法兰连接的调节阀、节流阀、安全阀、仪表件等。对已焊上的阀门和仪表，应采取相应保护措施；Before flushing and blowing, orifice plate, control

142、led valves, choke valves, safety valves and instruments connection with flange should not be erected. As for welded valves and instruments, the protected measure should be used.10.1.2不参与系统吹扫的设备及管道系统，应与吹扫系统隔离； The equipment and piping system which will not be flushing and blowing should be separated.

143、10.1.3管道支、吊架要牢固，必要时应予以加固； Piping rack and hanger should be fixed hardly. If necessary, adding.10.1.4吹扫压力不得大于容器与管道系统的试验压力。 The flushing pressure should not more than the test pressure between vessels and piping system.10.2吹洗方法Flushing method吹洗有四种方法：水冲洗法、空气吹扫法、蒸汽吹扫、油冲洗法。物料管道系统采用蒸汽吹扫；蒸汽管道系统采用蒸汽吹扫，水管道采用

144、水冲洗；其它采用空气吹扫。Flushing method is as following: water flushing, air blowing, steam cleanliness and oil flushing.Using steam flushing in material pipe, using steam flushing in steam piping ,using water flushing in water piping ,the other air flushing.11 系统气密 Air seal系统气密是装置实现高标准中交的先决条件，以保证装置联动试车及投料试车后能

145、安、稳、长、满、优运行。本项工作的关键是高度责任心，并认真按工艺要求做好螺栓冷紧和热紧，对确有泄漏的密封面要充分重视，置系必要时应进行研磨或重新加工密封面和换垫。Air seal is the first condition to carry out the high standard to ensure assembly continued commissioning in good condition. The key steps of this work is making bolts in cooling and heat tight according to process requ

146、irements with high responsibility. The leakage seal should be paid more attention.12 管道防腐、绝热 Piping rotting proof and insulation12.1管道防腐 Piping rotting proof12.1.1管道涂漆前根据设计要求采取机械或喷砂方法清除被涂表面的铁锈、焊渣、毛刺、油水等污物。 Before piping painting, We will use chemical or blasting method according to designed requirem

147、ents to clean dirty debris on the surface such as iron rust, fins, welding debris and oil.12.1.2第一道底漆应在预制时涂刷，但应留出焊缝部位。其余涂层应在试压合格后进行。 The first bottom paint should be done in the prefabrication. But the welding joint location shall leave. Other paint layer should be processed after pressure qualified

148、.12.1.3一般涂漆范围：碳钢裸管和支、吊架宜涂刷底漆和面漆，绝热管表面只涂刷底漆，不锈钢管道、镀锌钢管、镀锌铁皮和铝皮保护层，不宜涂漆。但具体情况应按设计院有关文件规定执行。General paint scope: Bottom paint and surface paint should be used in the carbon steel and pipe rack and hanger supporting. As for the insulated steel surface, it needs bottom paint. Painting cannot be used in t

149、he SS steel pipe, galvanized steel pipe and iron sheet, the protect layer of aluminum sheet.12.1.4涂层质量应符合下列要求： The quality of paint should comply with below requirements:a. 涂层完整、均匀，颜色一致，无损坏、无漏涂；The painting layer is in the same color ,non-destroyed and smooth,b. 漆膜附着牢固，无剥落、皱纹、气泡、针孔等缺陷；The painting s

150、heet should be fixed in strength and no wrinkle, exfoliation and tread holesc. 漆种、层数、颜色、标记应符合设计要求。Painting type, layer ,color and tag should comply with the designed requirements12.2管道绝热Piping insulation12.2.1绝热工程的施工应在管道试压及涂漆合格后进行。施工前，管道外表面应保持洁净、干燥。Insulation work should be done after piping pressur

151、e and painting qualified. The surface of piping outside should be clean and drying.12.2.2需要进行蒸汽吹扫的管线，宜在吹扫后进行绝热工程的施工。If the pipeline need steam flushing, the insulation construction should be done after flushing.12.2.3绝热工程主要材料应有制造厂合格证明书或分析检验报告，其种类、规格、性能符合设计要求。The insulation main material shall be sup

152、plied with manufactures acceptable certifications and analyzing inspection reports and its type, specification ,properties should comply with the designed requirements.12.2.4金属保护层表面应压边、箍紧，不得有脱壳或凹凸不平，铁（铝）皮搭接或咬口，缝口应朝下，铁（铝）皮端应封闭。绝热层施工，应单根进行。 The metal protecting surface should be even and tight.金属保护层表面

153、平度允许偏差5mm，绝热材料厚度允许偏差5%。 The level of metal protecting surface is allowed to be 5mm,and the insulation material thickness 5%严格按设计要求选用绝热材料，重点控制绝热材料的容重和导热系数等参数，严把材料的质量关。在施工中要严格控制绝热厚度及分层搭接等符合规范要求，外保护层的施工要符合设计要求并力求美观。 We choose insulation material strictly comply with the designed requirements and pay mo

154、re attention to its volume weight and guided-heat parameter to control the material quality. In construction, the insulation thickness and divided layer butt shall strictly comply with the specification. The protecting layer construction should comply with the designed requirements to ensure in good

155、 look13质量保证和质量控制13.1基本原则承包商ISO9002质量手册是工程项目施工中质量保证的基本要求。如有不满足德西尼布公司要求或与德西尼布公司的要求相抵触的条款应作适当调整，以满足德西尼布公司合同的具体要求。在质量管理方面以德西尼布公司要求及相关规范标准和承包商ISO9OO2质量手册QG/M44.0000-99的要求进行质量控制，为现场施工管理方面提供质量保证。1编制依据 国家现行质量法规、标准和规范要求； 德西尼布公司合同规定的技术规范及附件要求； 承包商ISO9002质量手册QG/M44.0000-99 承包商质量程序文件QG/P44.0000-99； 承包商压力管道安装质量保

156、证手册； 承包商压力管道安装质量程序文件； 承包商ASME质量控制手册QC001-1997。1质量方针和质量目标 质量方针：坚持质量第一，凭质量赢得信誉，靠质量赢得用户。 质量目标：施工质量零缺陷。13.1.3 承包商独立承担工程合同工作范围内阿莫克珠海45万吨/年PTA工程。并独立完成工程质量检验和试验。13.2质量保证管理机构计量质量负责人无损检测质量负责人项目质量经理德西尼布公司、业主政府监督工艺质量负责人器材质量负责人焊接质量负责人热处理质量负责人施工班组质量检查员施工队专职质量检查员施工作业人员 项 目 经 理检验质量负责人13.2.1质量管理人员任命 待项目合同签定后，承包商将在两

157、星期内以文件形式任命质量保证管理机构责任人员，报德西尼布公司批准。13.2.2 质量保证体系责任人员代号序 号质 量 体 系 责 任 人 员代 号1项目经理P M2质量经理Q M3工艺质量负责人X E4器材质量负责人X C5焊接质量负责人X H6检验质量负责人X Y7热处理质量负责人X R8计量质量负责人X J9无损检测质量负责人X W13.3 质量责任人员职责1项目经理 对工程项目施工质量负全责。1质量经理 质量经理是工程项目质量控制的总负责人，具有项目工程质量管理的最高管理权。 负责工程项目施工的资源配置和施工的组织与管理，负责在工程项目施工中贯彻执行技术标准、规范和质量法规。有权停止、拒

158、绝违反规定和合同的工作，可以命令拆除并返工某些不符合合同要求的工作，建议工程施工方法，有权拒绝不符合合同要求的材料使用。 负责对外质量工作联络，参加有关方面召开的质量控制会议。协调项目部与业主、德西尼布公司的业务关系。 质量经理在工程项目施工过程中应在施工现场。不在现场时应有书面文件指定委托人实施现场质量控制。13.3.3 专业质量负责人负责工程项目施工过程中归口业务范围内的质量控制工作。13.3.4 施工队专职质量检查员 负责分管业务范围内的质量管理工作，严格执行施工验收规范、质量评定标准、设计施工图纸、施工技术文件和质量管理规章制度。 对现场施工质量实施过程监督、检查、指导，且对本专业范围

159、内的特殊过程进行全过程跟踪监控。13.3.5 施工班组质量检查员 负责施工班组施工过程的自检、自控，对施工班组的施工全过程进行跟踪监控。1施工作业人员质量职责 严格按图纸、技术措施/作业指导书和岗位操作规程进行施工，保证施工质量。接受质量监督部门的检查、指导。13.4接受政府质量监检与工作协调承包商负责联络和满足政府机构工作验收的全部质量保证和检测要求，负责获得阿莫克珠海45万吨/年PTA工程要求的所有当地政府的证书或批准。满足所有适用于此工程的政府质量保证和检测要求，并负责合同范围内与政府主管部门的一切工作联络，以便使施工工作不受妨碍或不受额外的不利因素影响。13.5 质量控制计划13.5.

160、1 内部质量审核计划 项目工程内部质量保证体系审核，承包商依据QG/P 44.0002-99内部质量审核管理程序组织实施，开工30天后进行首次审核，工程项目竣工前进行一次审核，审核结果应提交德西尼布公司备案。 德西尼布公司有权对承包商质量保证体系进行评估。1检验和试验计划 工程项目质量控制设H、W、R三种需德西尼布公司确认的检测点。当业主或德西尼布公司有其它要求时，可进行补充修订并批准该计划，该计划经德西尼布公司批准后，任何修订必须得到德西尼布公司的书面许可。序号质量检测点控 制 要 素1H点（停检点）未经德西尼布公司现场检验合格后，不得进入下道工序。2W点（见证点）未经德西尼布公司批准，不得

161、进入下道工序。3R点（审核点）文件、资料经德西尼布公司确认后，方可进行施工。 阿莫克珠海45万吨/年PTA工程质量控制点计划序号控 制 环 节 内 容1钢结构安装质量控制环节2整体立式设备安装质量控制环节3卧式设备安装质量控制环节4动设备安装质量控制环节5压缩机组安装质量控制环节6碳钢管道安装质量控制环节7不锈钢管道安装质量控制环节8钛管道安装质量控制环节9储罐组焊安装质量控制环节10料仓组焊安装质量控制环节11防腐保温质量控制环节12电气安装质量控制环节13仪表安装质量控制环节14 HSE安全技术管理措施14.1施工过程中可能发生的安全事故风险分析14.1.1管道安装作业多数属于高空作业、立

162、体交叉作业，发生高空坠落及物体打击事故的可能性较大。在平台、坑、洞口旁作业或路过时发生坠落事故。14.1.3施工过程中经常使用氧/乙炔焰切割、管道防腐及装置投料试车等，有可能发生火灾、爆炸事故。14.1.4吊装作业过程中，发生吊装物件倾倒，损坏吊车等。14.1.5触电事故。射线伤害。14.1.7管道系统试压、吹洗、化学清洗、系统气密的意外伤害。14.1.8施工高峰集中在5月9月,正直高温、雨季天气,有可能发生中暑。14.2 相应对策14.2.1加强安全教育，严格执行班前安全讲话和周一安全活动制度，有针对性地交代近期工作中的安全注意事项。14.2.2针对物体打击和高空坠落事故的原因，采取下列措施

163、：(1) 施工人员进入现场必须戴好安全帽，系好帽带，高处作业挂好安全带，管带下必须张挂好安全网。(2) 高处作业应使用合格的脚手杆、吊架、梯子、脚手板，防护围栏，挡脚板和安全带，作业前应认真检查所用安全设施是否坚固、牢靠，脚手架应经安全员检查认可后，挂牌标识，并办理工序交接手续后，方可使用。登高作业时应穿着防滑鞋，防止坠落、摔伤。(3) 梯子不得缺档，不得垫高使用，梯子横档间距以300mm为宜，使用时上端应扎牢，下端采取防滑措施，单面梯与地面的夹角以6070为宜，禁止两人同时在梯子上作业。(4) 吊装管段时，其下方严禁有人停留或行走，待其固定后，方可卸去吊具。敷设管道，应同时安装支、吊架或管座

164、，并将管道固定牢固，防止滚下。(5) 在坑、洞、平台边缘等“四口五临边”处设置护栏，防止高空坠落事故。(6) 高处作业所用的工具、材料等应放在安全、不易失落处。随身携带的工具应随手放入工具袋中，上下传递工具、物品应用溜绳，严禁上下随意抛掷。(7) 班前严禁饮酒，夜间作业应有充足的照明，在施工现场高处设置大功率探照灯，保证光线充足。14.2.3针对有可能发生爆炸事故的原因，采取下列措施：(1) 严格执行“动火票”制度，按照济南分公司的有关规定，办理手续。(2) 为防止火灾、爆炸事故的发生，做到氧气瓶、乙炔瓶与用火点间距，三者之间应大于10m，并应立放氧气瓶、乙炔瓶。两者不得混放在一起，避免爆炸事

165、故的发生，违反者给予重罚，并给予通报；进入施工现场（厂区内）严禁吸烟，违者重罚；在安装现场动火，就近应有必备的消防设施，厂区内动火必须办理动火票。(3) 施工所用油漆，应设专人看守，严禁刷油与动火作业同处进行，并远离明火。存放油漆的库房，应备有足够的灭火器，并挂警示标志。(4) 施工人员严禁在非施工区域逗留，严禁开关和施工无关的阀门、开关等。14.2.4针对吊装作业过程中，发生吊装物件倾倒，损坏吊车等的原因，采取以下措施：(1) 吊装作业时应信号明确，吊装前应先试吊合格后方可起吊。如遇大雨、五级以上大风等恶劣气候，影响施工安全时，应停止吊装作业和高处作业。雨、雪、大风前后，要检查现场临时设施，

166、发现问题应果断采取有效措施。(2) 为防止发生吊装事故，手拉葫芦使用前应检查是否完好，不得超载使用，严禁强拉硬拽；吊装作业时，人员不得站在重物正下方，指挥应统一、明确。作业前，将可能发生事故的区域隔离，无关人员不得入内。14.2.5针对可能发生触电事故的原因，采取以下措施：(1) 为防止触电事故的发生，现场接线均应严格按“三相五线制”进行，现场所用板房、焊机房、焊接平台、配电盘、开关箱、电焊机应按规定接地良好,电线不得与金属物绑在一起；现场使用的手持电动工具和可移动式电动工具必须安装高灵敏度的漏电保护器，并应先试转合格后再使用；严禁擅自接用电源，非电工不得从事电气作业，维修用电设备时应先切断电

167、源，并挂“有人工作，严禁合闸”警告牌。(2) 一般低压行灯不得超过36V，潮湿金属容器内携带的行灯，电压不得超过12V，并须设置触电保护器和防护罩。(3) 现场使用的手持电动工具，必须匹配漏电保护器，在使用时应先试转，合格后方可使用。14.2.5针对射线伤害，管道系统试压、吹洗、化学清洗、系统气密的意外伤害的原因，采取以下措施：(1) 危险处、射线作业区应设置明显的警告牌。射线作业前将作业时间、地点通知现场施工人员。(2) 管道系统试压、吹洗、化学清洗、系统气密设警界线,并挂上明显的警告牌，无关人员不得入内。14.2.6高温季节施工,认真做好防暑降温的各项工作；患有高血压、心脏病、贫血及其他不

168、适合于高处作业的人员，不得从事高处作业。14.2.7现场文明施工，杜绝事故发生。各施工班组在施工中必须做到有条不紊，电焊机要成行，电焊把线、气焊带要放置整齐，边角料要堆放到指定地点。每天下班前，施工现场要清理干净。15交工技术文件管道施工完毕，工程管理部应按第十建设公司质量体系文件QG/4441.53.00-1999压力管道安装竣工技术文件规定和SH3503-93工程建设交工技术文件规定整理编制交工技术文件，其内容应包括：15.1J1O1 封面；15.2J102 交工技术文件目录；15.3J103 交工技术文件说明；15.4J104 开工报告；15.5J105 隐蔽工程记录；15.6J108

169、图纸汇审记录；15.7J109 合格焊工登记表；15.8J111 设计变更一栏表；15.9J112 交工验收证书；15.10J401 阀门、管件试验记录；15.11J402 管道补偿器安装记录；15.12J403 安全阀调整试验记录；15.13J404 高压管件检查验收记录；15.14J405 高压钢管检查验收(校验性)记录；15.15J406 管道静电接地测试记录；15.16J407 管道强度、严密性试验记录；15.17J408 管道吹洗(脱脂)记录；15.18J409 管道隔热工程施工记录；15.19J411 管道焊缝热处理质量检验记录；15.20J412 管道焊接工作记录；15.21J4

170、13 固定管架及弹簧支、吊架调整记录；15.22J414 管道泄漏量试验记录；15.23J726C 防腐绝缘层电火花检测报告；15.24J727C 热处理报告（热处理班组提供原始曲线图）；15.25J728C 焊缝超声波探伤报告；15.26J729C 焊缝射线探伤报告；15.27J730C 焊缝表面探伤报告；15.28硬度报告（由检验部门提供）；15.29相关探伤报告（由探伤整理提供）（包括RT、UT、MT、PT）；15.30材料合格证及有关试验、复验报告（由供应部门整理）；15.31材料代用单（由供应部门整理）；15.32竣工图（由资料室提供）（按济南分公司归档的有关规定整理）15.33设计变更单（由资料室提供，技术员整理）16劳动力组织工艺管道安装工程施工所需劳动力计划见表-16。17施工机具计划工艺管道施工所需主要机具见表-17。18主要施工技措用料主要施工技措用料见表-18。19总体施工进度计划工艺管道施工总体进度计划见表-19。