不锈钢管道预制施工方案及对策（完整版）

1、一、Purpose 目的This statement is piled to ensure the construction quality of Bayer project pipe fabrication and meet the progress requirement.This statement is used to guide the fabricatio n of all Stai nless Steel pipe afforded by F in Bayer MDI为了保证工程管道预制工程的施工质量和满足工程进度要求，特编制本方案。 本方案用以指导拜耳异氰醋酸聚醚工程 MDI

2、联合装置 F 承当的所有不锈钢材质 管道的预制施工。二、Applicable Scope适用围This statement is applicable for all Stainless Steel pipe fabrication work afforded by F in Bayer MNB(V210) / WNILINE(V310).本方案适用于拜耳工程 MNB(V210)/WNILINE(V310)装置F承当的所有不锈钢 管道预制工程的施工。三、Reference 编制依据Technical specification and standard of this method state

3、ment:本方案编制依据的施工技术规和标准为：(1) GB50235-97construction and acceptance of industrial metal pipeprojectGB50235-97 工业金属管道工程施工及验收规(2) GB50236-98welding project construction and acceptancespecification of site equipment and industrial pipeGB50236-98 现场设备工业管道焊接工程施工及验收规 (3) Bayer releva nt tech ni cal docume nt

4、 sta nda 拜耳的相关技术资料 WN 标准4) 管道相关图纸四、Overview工程概况1 Work scope 工作围The scope of this project includes all Stainless Steel pipe fabrication ofMNB/ANILINE包括 MNB 、 ANILINE 两个装置中的所有不锈钢管道的预制 。2 Major project quantity 主要工程量Stainless Steepipe in MNB is about 4679m (pipe dia DN600), which amounts to 70 of the w

5、hole run.MNB装置中不锈钢管大约4679米管径W DN15- DN600占总管道的70%Stainless Steel pipe in ANILINE is about 1900m(pipe diW DN15- DN400), which amounts to 20% of the whole run.ANILINE 装置中不锈钢管大约 1900米管径W DN15- DN400占总管道的 20%。五、Tech ni cal con diti ons技术条件1 Technical documents 技术文件1.1 Three-dimensional piping drawing us

6、ed for industrialized prefabrication用于工厂化预制的管道三维图1.2 Relative construction technical documents (working instructor, process procedure) and management procedure相关的施工技术文件作业指导书、工艺规程和管理程序1.3 Construction technical clarification card施工技术交底卡1.4 Standard for piping materials and fittings管材及配件尺寸标准2 Quality

7、control documents质量控制文件2.1 Materials qualification or acceptance report 材料合格证或验收报告2.2 Working procedure handover slip操作工序交接单2.3 Conformance inspection table of piping prefabrication 管道预制件的符合性检查表2.4 Tracking drawing and tracking sheet for welding craters 焊口跟踪图及跟踪单2.5 Inspection report (RT, PT, VT)检验报

8、告 RT、PT、VT 六、不锈钢材料的验收及检验标准：1. 管道用材料，焊接用材料必须具有制造厂的合格证明书和质量证明书，请业主协助完成此项工作。质量证明书应包括以下容：产品标准号材料的牌号材料的炉罐号、批号、交货状态、重量和件数品种名称、规格及质量等级 产品标准中规定的各项检验结果 技术监视部门的印记。2. 按设计要求核对其规格、材质、型号。3. 外观检查：无裂纹、缩孔、夹渣、折迭、重皮等缺陷，所有管道壁厚均不得 有负偏差。4. 法兰、焊环及盲板密封面平整、光洁、不得有毛刺及径向沟槽，螺栓，螺母 的螺纹完整，无伤痕，无毛刺等缺陷，配合良好。垫片，无折损、皱纹等缺 陷。5. 经检验合格的管材，

9、应按规格尺寸分别放置在专门设置的地方，严禁与钢材 混堆和直接接触或碰伤。6. 材料负责人检查并收集管道、管件、阀门、焊丝等所有管材的合格证及质量 保证书。7. 弯头、异径管、三通、法兰、盲板及紧固件等进展检查，其尺寸偏差应符合 现行标准，材质应符合设计要求。8. 石棉、橡胶、塑料等非金属材料垫片应质地柔和，无老化变质或分层现象。 外表不得有折损，皱纹等缺陷。金属垫片的加工尺寸、精度、光洁度及硬度 应符合要求，外表应无裂纹、毛刺、凹凸槽径向划痕及锈斑等缺陷，包金属 及缠绕式垫片不应有径向划痕、松散等缺陷。9. 对验收后的不锈钢材料管子、管作、法兰每批进展5%的光谱分析检查。七、Fabricati

10、on preparation and ste施工预制准备和步骤10. Preparation for fabrication制准备10.1. According to the demand of Bayer project work, Stainless Steel fabrication yard is set in (F Weiwu Road).根据拜耳要求和施工的需要分别设置两个预制场地： 不锈钢预制场设置 在 F 卫五路10.2. Before fabrication, pipe professional technician shall timely do the shift wor

11、k of drawings, mark weld NO. SW-shop weld; FW-field weld. The principle of drawing shift: e*pand fabrication depth based on the convenient transportation and installation together with plan sketch, in order possibly to finish fabrication work in fabrication shop and管道预制前，管道专业技术人员要做好图纸转换，标定焊口号：SW表示预制

12、焊口，FW现场焊口，预制分段。图纸转换的原则是：为了尽可 能多在预制车间完成管道的制作， 结合平面图在考虑方便运输与安装的 前提下，尽量扩大预制深度。10.3. Any people who join the fabrication work (helper e*cluded) must be proficient technician. Worker who does pipe welding must hold effective certificate being conformed to the work they conduct. These people must have rec

13、eived the welder trai ning of this project and has qualified the te 凡参加管道预制作业的人员 辅 助工除外必须是熟练的技术工人。参与管道焊接的工人必须持有与所从 事的作业相符且在有效期的合格证书，并经业主焊工培训考试合格的施工人员。10.4. Properly requisite fabrication material as per fabrication progress, received material must have certificate and re-check report. The vent and h

14、ygiene shall be good infabrication yard, equipment process ability in fabrication shop shall meet the operatio n requireme nt and have good operati on performa nee. Tool and mach ines in fabrication shop shall be plete, having special lay down area and full time keeper. Equip one set of 3用 oil-free

15、pressor and corresp onding line arran geme nt for in-pipe blow of pipe fabricati on piece.根据预制进度方案合理领用预制材 料，领用的材料必须具有产品合格证或复验报告。必须是经过标色的不锈钢管道：HB/1.4306褐色;H2/1.4404无；H1/1.4307/1.4306蓝色;HU/1.4539桔黄色。预制场地应有良好的通风状态和卫生环境，预制车 间的设备加工能力须满足预制的操作要求，并具有良好的操作性能。预制 车间的工机具应齐全，并有专门的堆放场所和进展专人管理。预制场地需要隔离的地方，用橡胶皮或石棉板

16、做好隔离准备。配制一台3m3无油空压机及相应的管线布置，用于管道预制件的管吹扫。2Fabricatio n step (see Appe ndi*1 施工预制步骤material requisiti on and chec领料、核对材料IDransfer of pipe 管子标识移植size lin eatio n划线标注尺寸bait ing and cutt ing下料切割 Pipe ID tran sfer 管子标识移植Groove treatme nt坡口加工aSta in less 卜Steelembly and weldg组对、焊接weld ID 焊缝标 一VisualInspect

17、ion 目视检查NDT inspection NDT 检查spools clear管段清洁spool ID管段标识seal a nd storage封口保护、堆放储存2.1 Batchi ng 配料Full-time material pers on shallbe in charge of batchi ng, in prin ciple, batch ing of piping fittings shall be pleted as isometric a*is drawing, all requisited material must bemarked for batch ing and

18、 con structiofiE料应由专职材料员负责，原则 上按等 轴图进 展管 配 件 配 料 ，所有领用的材料必须进展标识后， 方可领出配料施工 。2.1.1 Batching work shall be made according to prefabrication weekly plan and material delivery as per isometric a*is drawing 料工作应根据预制周方案和材 料到货情况按等轴图进展配制。2.1.2 Special bo* can be used separately for storage as each isometric

19、 a*is drawing. It is also allowable to batch in several drawings or tens of drawings;furthermore, batched material schedule shall be pasted on the 可o 按每等轴图用专用箱子 分开配放，也可几或几十图纸开在一起配好， 并在箱子上贴上配好的材料清单。2.1.3 When prefabrication personnel requires (of specially delivery), requisition persons shall recheck

20、 according to material schedule and sign it for confirmation. One list shall be in two copies; requisition person and material person keep each one copy.预制人员领用或专送时，领用者应按材料清单进展复查并在清单上签 字确认，清单一式两份，领用者和材料员各保管一份。2.2 Bating and cutting 下料切割2.2.1 Spool field bating and cutting shall be done after reviewin

21、g spool isometric,the major reviewing point:管段现场下料切割前应首先对管段单线图进展审核，主要Drawing number, line number, spool number and material is as per designor not. 图号、管线号、管段号及材质是否与设计相符；Spool segment and reserved weld for field installation of each isometric a*ial drawing is reasonable or not, and field resurvey for

22、 spool fabrication size shall be necessarily conducted. Accurately calculate when confirming baiting size of each spool, mainly considering about difference between fabrication spool size and baiting spool size, baiting spool size shall deduct theoretical size of elbow, tee and reducer, as well as r

23、egulated weld assembly gap; and thickness of flange and gasket, as well as theoretical size of other fittings (such as valve, filter; etc). confirm practical size of fabrication baiting after measuring in order to increase the measuring accuracy. 每一等轴图的管段分段、现场安装预留口是否合理，并应 对管段预制尺寸进展必要的现场复测。在确认每一段下料尺寸

24、时， 应准确计算，主要考虑预制段尺寸和下料段尺寸之间的差异，下料 段尺寸应去除弯头、三通、大小头等管配件的理论尺寸以及规规定 的焊口组对间隙；法兰、垫片的厚度以及其它配件如阀门、过滤 器等的理论尺寸。以提高测量准确度，测量后确定预制下料的实 际尺寸。2.2.2 Original mark shall be transferred before cutting pipes, pipe material without mark or with blurry mark shall not be used.管子切割前应移植原有标记， 没有标记或标记模糊不清的管材不得使用。2.2.3 Pipe cut

25、ting generally adopts mechanical method, any following machine can be adopted accordi ng to situatio n管子切割必须应采用机械方法，根据情况可采用以下任何一种机械：Pipe lathe管子车床Band saw machi n带锯床Abrasion wheel cutting machine不锈钢专用 砂轮切割机和砂轮片2.2.4 Stainl ess steel pipe also can be cut by plasma cutt ing mach不 锈钢管也 可以用等离子切割机进展切割。2.

26、2.5 When stainless steel pipe is cut by abrasion wheel cutting machine or grinded by abrasive disk, must use alumina substrate, and abrasion sheet which has cut or grin ded sta ini ess steel cannot be used to cut or grind sta ini ess steel pi 不锈钢 管用砂轮切割机切割或用砂轮打磨时， 必须用氧化铝基的砂轮片， 且切割或 打磨过碳素钢的砂轮片不能用来切割或

27、打磨不锈钢管。2.2.6 Pipe cut shall be as per the followi ng requireme nt管子切口质量应符合 以下要求：Cut surface shall be smooth, free of crack, double skin, burr, concave and conv e*, con tracted ope ning, sin ter, o*ide, slag or other defects or de切is. 口外表平整，无裂纹、重皮、毛刺、凹凸、缩口、熔渣、氧化物、 铁屑等。Tilting error of cut end face sh

28、all not be 1% bigger than e*ternal diameter of pipes, and no more than 3mn切口端面倾斜偏差不应大于管子外径 的1%,且不超过3mm。如执行的标准不同时，按相应标准执行2.3 Groove Processing 坡口加工2.3.1 Groove shall be processed after marking and cutting on pipe (material) by construction personnel according to fabrication isometric drawing shifted

29、bytechnical person. Beveled spool shall be put on process bench (fabrication shop)for groove grinding. 施工人员依据技术人员已转化的预制单线图纸对管道素材进展划线、切割下料后进展坡口加工。 坡口加工的管段应放置在加 工台上预制车间进展坡口打磨；2.3.2 Groove type and size of pipe and fitting shall be conformed to requirement of corresponding to drawing and design documen

30、t, when there is no demand on design, confirm as per item ofGB50235-97 Appendi*B.管子、管件的坡口型式和尺寸应符合相应的图纸和设计文件的要求，当设计无规定时，按GB50235-97规附录B第条规定确定。Processingof piping slope is monly adopting mechanicalmethod, for e*ample, after slope is processed in a way of heat processing,o*ide skin, sinter and surface

31、layer that will have effect on the quality of joints at slope shall be removed, and the place that is conve* or concave shall be ground and leveled.Stainless steel shall be cut or grinded by special abrasion sheet, and cannot be mi*ed with carbon steel abrasion sheet.管道坡口加工一般采用机械方法， 不锈钢管道的坡口加工可采用坡口机

32、加工 或等离子切割加工方法。 采用 等离子切割 方法加工坡口后， 必须除去坡口外 表的氧化皮、 熔渣及影响焊接质量的外表层， 并应将管子端面的凹凸不平处 打磨平整。不锈钢切割或打磨时应使用专用砂轮片， 不得与碳钢砂轮片混用。No matter which method is used, after slope opening is processed, oil, water, rust and other debris shall be cleaned无论用哪一种方法， 坡口加工完毕后， 均应去除油圬、水份、铁锈等杂物。2.4 Weld assembly 焊口组对z.2.4.1 Assembl

33、y 组对Whe n assembli ng, clea n groove and its internal and e*ter nal surface as perthe followi ng table:组对时，对坡口及其外外表应按下表要求清理干净：Pipe material管道材质Clea n range清理围Clea ning materia清理物Clea ning method清理方法CS碳素钢SS不锈钢AS合金钢 10Oil, paint and rust油、油漆铁锈等Manual or mach ine手工或机械Alumi num or A-alloy铝及铝合金 50Oil and

34、 o*ide film油、氧化膜Useorga nicdissolve nttoremove oil, use chemicalormecha ni cal method to remove o*ide film.用有机溶剂除油，用化学方法或机 械方法除氧化膜Copper and copperalloy铜及铜合金 20Tita nium 钛 50Use gasket material to isolate the bench and support used for sta ini ess steelassembly.对于不锈钢管组对用的台架、支承架等，应用衬垫材料进展隔离After asse

35、mbli ng, shall keep pipe straighfi 对后，应保持管子的平直。As for the thin wall pipe easily deforming during welding, use special clamp to fi* it during assembly. 对于焊接时易产生变形的簿壁管，组对时 应使用专用夹具进展固定。During weld assembling, inner wall shall be smooth , unfitness of inner wall shall not be bey ond 10% of wall thick ne

36、ss and not more tha n 2m#i 口 组 对时，应做到壁平齐，壁错边量不宜超过壁厚的 10%，且不大于 2mm。During assembling pipe ponent with uneven wall thickness, repair as per item .b and then assemble. 不等厚管道组成件组对时，应按 .b 条要求 进展修整后再进展组对。Further check whether there is scratch on sealing surface of flange or not during assembly, if there i

37、s scratch that shall influence flange sealing, this flange shall not be used法兰时应进一步检查法兰的密圭寸面有无径向 划痕，如果发现有影响法兰密封的划痕，该法兰不得使用。If the flange is connected with valve, ensure site installation of valve is as per the desig n requireme nt duri ng assembly如 果是连接阀门的法兰， 在组对时要保证阀门在现场安装时符合设计要求。Put pad under the

38、butt-welded pipe to ensure it is firm, in order to avoid the deformation during welding, strong force shall not be used for assembly during connecting pipe. 管子对口后应垫置结实，防止焊接过程中产 生变形，管道连接时不得强力组对。All assembled welding joint size shall ply with the requirement of designdocument or drawing. 所有组对好的焊接接头尺寸应

39、满足设计文件 或图纸的要求。2.4.2 Welding 焊接Operation requirement during the whole welding(including pipe welding, non-destruction inspection, weld repair; etc) see pipe welding method statement of pipe fabrication plant. 整个焊接过程包括管道焊接、无 损检测、焊口返修等工序的操作和要求 详见管道预制厂管道焊接 方案 和焊接工艺卡 。2.5 Superficial treatme nt of sta in

40、 less steel pipe wel不 锈钢管道焊缝的外表处理2.5.1 If there is requirement in design document regulation or implementation standard, superficial treatment shall be used for all stainless steel pipe weld, remove o*idizi ng layer un til the base metal color shall be e*posed.女口设计文件的规定 或执行的标准有要求， 应对所有的不锈钢管焊缝的外外表进展处

41、理， 去除外 表氧化层，到达金属母材本色。2.5.2 Generally use pickling cream (mordant) to wash it, also shall use other methods to brush it, like stainless steel wire, the concrete operation shall be as per corresponding standard. 处理方法一般采用酸洗膏 酸洗液进展酸洗， 涂液 4 小时后在焊口处 用不锈钢钢丝刷进展刷擦，具体操作应执行相应的标 准。2.6 Mark on pipe fabrication p

42、iece管 道预制件的标记2.6.1 Mark all pipe fabricati on piece accord ing to spool NO on isometri对所有管道预制件进展标记，按等轴图上的管段编号进展。2.6.2 use mark pen or pain to mark Welder ID (welder NO or weld NO)工标识焊工号及焊口号应采用记号笔或油漆进展。 注意：油漆必须和底漆一 样 cl- mmp2.6.3 Mark shall be clear and remain for a long time at least when this spool

43、 isfinished installation标记应清晰，且能保持较长时间。至少应保持到该管段安2.7 Clea nn ess of pipe fabricati on piec管 道预制件清洁度Cleannessinspection shall be conducted on fabricated spool, there is no foreign matter inside pipe, such as welding slag, oil, rubble, if there is debris, use scrub or air blow to clean them. 对于预制好的管段进

44、展清洁度检 查，管不得有焊渣、油迹、石子等外来物，如有杂物，应用擦洗或 压空吹扫的方法来进展去除， 去除后立刻进展管口的包装保护，防止异 物再次进入 。2.8 Con formity in spect ion of fabricati on piece预制件的符合性检查Conformity inspection (as per proportion)is conducted to pipe fabrication piece according to design document requirement, main content is as follows: 应根据设计文件要求，对管道预制

45、件进展符合性检查按比例 ，主 要容如下：2.8.1 En sure the material specificati on, type and material is correct 认使用材 料的规格、型号、材质正确无误。2.8.2 En sure pipe fabricati on spool size is con formed to draw ing requireme 确认管道预制段的尺寸符合图纸要求2.8.3 Ensureweld appearance quality and non destruction inspection is conformed to design doc

46、ume nt requireme nt确认焊缝的外观质量和无损检验满足设计文 件要求。2.8.4 Fill in conformity inspection record of pipe fabrication piece(seeattachment 2) 填写好管道预制件符合性检查记录见附录2Note: conformity inspection record of fabrication piece is confirmed and filled in by QC personnel. 说明：预制件的符合性检查记录由 QC 人员 负责检查确认填写。2.9 Pack for pipe fab

47、rication piece管 道预制件的包装保护2.9.1 Use polyethylene cap to seal for pipe end of small bore pipe fabrication piece.If pipe cap is loose ning, use adhesive tape to fi* on pip对于小口径的管道预制 件的管端用聚乙烯管帽进展封口， 如管帽较松时，可用胶粘带固定在管子上。2.9.2 Use clean white glabrous cloth or polyethylene plastic cloth to pack and use adh

48、esive tape to fi* for pipe end of big bore pipe fabricatio n piece 对于大口径 的管道预制件的管端用清洁的无毛白布或聚乙烯塑料布包扎并用胶粘带固定。2.9.3 Flange surface generally use adhesive plate to pack, use nylon (galvanized iron wire) to bind and fi* through the hole pre-drilled on flange bolt and cover plate. 法兰面一般用胶合板进展包装， 包装方法可用尼龙绳

49、 镀锌铁丝 通过法兰 螺栓孔和盖板上预先钻好的孔绑扎固定。2.9.4 If there is additional requirement for design, use polyethylene film to packthe whole stainless steel fabrication piece. 如果设计另有要求，对整个不锈钢预制件用聚乙烯薄膜包裹起来。2.9.5 对检查合格以及包装保护好的预制件按照指定的地点存放。存放的原 则是先装置后系统再管线。2.9.6 对检查合格以及包装保护好的预制件及时输机进展有效管理，保持预 制件的可追溯性。八、 Safety and techniq

50、ue measure (JHA Appendi* 3)平安技术措施JHA分析附录3All workers entering fabrication shop must wear uniform work clothes, helmet and crash-proof shoes进入预制现场的所有作业人员必需穿公司统一工 作服，戴好平安帽，穿防砸劳保鞋。No smoking in construction area and site office area, smokers shall go to in dicated place for smoke施工区域、预制场办公区域严禁吸烟，吸烟人 员必

51、须到指定地点吸烟。Major danger: fire and e*plosion proof must be done as per relevant regulation when welding or cutting, fire work must be done with permit and as per regulation. People who conduct site groove grinding or cutting with angular abrader, abrasion wheel cutter and acetylene cutter must wear pro

52、tective glasses and mask; set isolation screen if necessary in order not to damage people around. Mask must be worn to protect eyes when cooperating with welding work. Change abrasion sheet when its effective radius is grinded into 1/3 of orig inal radius, abrasi on sheet with defect and crack is pr

53、ohibited to us主 要危险点：焊接或切割时要做好防火防爆措施，必须按防火防爆平安施 工有关规定。使用角向磨光机、砂轮切割机以及乙炔割刀进展预制场坡 口打磨或火炬切割作业人员必需戴防护眼镜或防护罩； 为了不伤及周围 作业人员，必要时设置隔离屏风。配合电焊作业时，须戴防护面罩以保 护眼睛。砂轮片的有效半径磨损到原半径的 1/3 时必须更换，砂轮片有 缺损或裂纹者严禁使用。O*ygen and acetylene bottle must be far away from fire and be vertically located and fi*ed. 氧气、乙炔气瓶必须远离动火点， 并

54、且绑扎固定竖直立 放。Before welding and cutting, first clean environment around, remove bustibles or use fire-proof cloth (blanket)to isolate bustibles in order to protect flammable equipment and modity. E*tinguisher must be set in fabrication yard during work. 在进展焊接或切割作业前，要先清理周围环境，移除或用 防火布毯隔离可燃物、保护易燃易爆的设备及物品。班组作业时预 制现场必需放置消防灭火器材。 危险点Far away from gas and heat source in order to prevent e*plosion which hurt people. 远离气源、热源，小心爆炸发生造成人身伤害。Follow site safety management department and obey management and demand of F