不锈钢管道预制施工方案及对策

1、-一、 Purpose 目的This statement is piled to ensure the construction quality of Bayer project pipe fabrication and meet the progress requirement.This statement is used to guide the fabrication of all Stainless Steel pipe afforded by F in Bayer MDI。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

3、statement:本方案编制依据的施工技术规和标准为：（1） GB50235-97"construction and acceptance of industrial metal pipeproject GB50235-97 " 工业金属管道工程施工及验收规"（2） GB50236-98"welding project construction and acceptance specification ofsite equipment and industrial pipe"GB50236-98 " 现场设备工业管道焊接工程施工及验

4、收规"（3） Bayer relevant technical document standard 拜耳的相关技术资料WN 标 准. z.-（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 Steel pipe in MNB is abou

5、t 4679m (pipe diaDN15-DN600), which amounts to 70 of the whole run.MNB 装置中不锈钢管大约 4679 米管径DN15-DN600 占总管道的 70Stainless Steel pipe in ANILINE is about 1900m(pipe dia DN15-DN400), which amounts to 20 of the whole run.ANILINE 装置中不锈钢管大约 1900 米管径DN15-DN400占总管道的 20。五、 Technical conditions 技术条件1 Technical d

6、ocuments 技术文件1.1 Three-dimensional piping drawing used for industrialized prefabrication用于工厂化预制的管道三维图1.2 Relative construction technical documents (working instructor, processprocedure) 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. z.-1.3 Construction technical clarification card施工技术交底卡1.4 Stand

7、ard for piping materials and fittings管材及配件尺寸标准2 Quality 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

8、craters焊口跟踪图及跟踪单2.5 Inspection report (RT, PT, VT)检验报告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. z.- 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

9、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，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

10、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、 Fabrication preparation and step 施工预制准备和步骤10. Preparation for fabrication 预制准备. z.-10.1. According to the demand of Bayer project work, Stainless Steel fabrication yard isset 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 fabricati

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

12、orkin fabrication shop and管道预制前，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 proficienttechnician. Worker who does pipe welding must hold effective certificate being

13、 conformed to the work they conduct. These people must have received the welder training of this project and has qualified the test.凡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 mat

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

15、down area and full time keeper.Equip one set of 3m3 oil-free pressor and corresponding line arrangement forin-pipe blow of pipe fabrication piece. 根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

16、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。2 Fabrication step (see Appendi*1) 施工预制步骤material requisition and check 领料、核对材料 ID transfer of pipe 管. z.子标识移植 sizelineation 划线标注尺寸baiting and cutting 下料切割Pipe ID transfer 管子标识移植Steelem

17、bly and welding 组对、焊接Groove treatment 坡口加工weld ID 焊缝标识aStainlessVisualInspection 目视检查NDT inspection NDT 检查spools clean 管段清洁 spool ID 管段标识 seal and storage 封口保护、堆放储存2.1 Batching 配料Full-time material person shallbe in charge of batching, in principle, batching ofpiping fittings shall be pleted as isom

18、etric a*is drawing, all requisited material must be-marked for batching and construction.配 料 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.配料工作应根据预制

19、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 a*is drawing.It is also allowable to batch in several drawings or tens of drawings;furthermore, batched material schedule shall be pasted on the bo*.可按每等轴图用专用箱子 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

20、prefabrication personnel requires (of specially delivery), requisitionpersons shall recheck according to material schedule and sign it for confirmation. One list shall be in two copies; requisition person and material person keep eachone copy.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.

21、2 Bating and cutting 下料切割2.2.1 Spool field bating and cutting shall be done after reviewing spool isometric,the major reviewing point:管段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 design ornot. 图号、管线号、管段号及材质是否与设计相符；. z.-Spool segment and reserved weld for

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

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

24、rder to increase the measuring accuracy. 每一等轴图的管段分段、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 materialwithou

25、t 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 cutting generally adopts mechanical method, any following machine can be adopted accordingto situation: 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：. z.- Pipe lathe 管子车床 Band saw machine 带锯床 Abrasion wheel cuttingmachine 不锈

26、钢专用砂轮切割机和砂轮片2.2.4 Stainless steel pipe also can be cut by plasma cutting machine. 不锈钢管也可以用等离子切割机进展切割。2.2.5 When stainless steel pipe is cut by abrasion wheel cutting machine or grinded by abrasive disk, must use alumina substrate, and abrasion sheet which has cut or grinded stainless steel cannot be

27、 used to cut or grind stainless steel pipe. 不锈钢 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打磨不锈钢管。2.2.6 Pipe cut shall be as per the following requirement: 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 andconve*, contracted opening, sinter, o*ide, sla

28、g or other defects or debris.切 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 shall not be 1% bigger than e*ternal diameterof pipes, and no more than 3mm.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 cutt

29、ing on pipe (material) byconstruction personnel according to fabrication isometric drawing shifted by. z.-technical person. Beveled spool shall be put on process bench (fabrication shop) forgroovegrinding. 施工人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

30、size of pipe and fitting shall be conformed to requirement of corresponding to drawing and design document, when there is no demand ondesign, confirm as per item ofGB50235-97 Appendi*B.管子、管件的坡口型式和尺寸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。Processing of piping slope is monly adopting mechan

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

32、 special abrasion sheet, and cannot be mi*ed with carbon steel abrasion sheet.管道坡口加工一般采用机械方法， 不锈钢管道的坡口加工可采用坡口机加工 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, r

33、ust andother 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 Assembly 组对 When assembling, clean groove and its internal and e*ternal surface as perthe followingtable: 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CS 碳素钢SS 不锈钢AS 合金钢Aluminum or A-alloy铝及铝合金Copper

34、 and copperalloy 铜及铜合金Titanium 钛Clean range清理围10502050Cleaning material 清 Cleaning method理物 清理方法Oil, paint and rust Manual or machine油、油漆铁锈等 手工或机械Useorganicdissolvent toremove oil, usechemical orOil and o*ide film mechanical油、氧化膜 method to removeo*ide film.用有机溶剂除油，用化学方法或机械方法除氧化膜 Use gasket material

35、to isolate the bench and support used for stainless 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。. z.- After assembling, shall keep pipe straight. 组对后，应保持管子的平直。 As for the thin wall pipe easily deforming during welding, use special clampto fi* it duringassembly. 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

36、 weld assembling, inner wall shall be smooth , unfitness of inner wallshall not be beyond 10% of wall thickness and not more than 2mm.焊口组 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 peritem .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

37、组对。 Further check whether there is scratch on sealing surface of flange or notduring assembly, if there is scratch that shall influence flange sealing, this flange shallnot beused. 法兰时应进一步检查法兰的密封面有无径向 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

38、 is asper the design requirement during 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 butt-welded pipe to ensure it is firm, in order to avoidthe deformation during welding, strong force shall not be used for assembly duringconnecting pipe. 管子对口后应垫置结实，防止焊接过程中产 生变形，管道连接时不得强力组对。 All a

39、ssembled welding joint size shall ply with the requirement of design. z.-documentordrawing. 所有组对好的焊接接头尺寸应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 fabrica

40、tion 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 treatment of stainless steel pipe weld 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, removeo*i

41、dizing layer until the base metal color shall be e*posed. 如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 othermethods to brush it, like stainless steel wire, the concrete operation shall be as percorrespondingstandard

42、. 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 piece 管道预制件的标记2.6.1 Mark all pipe fabrication piece according to spool NO on isometric. 对所有. z.-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)焊工标识 焊工号及焊口号应采用记号笔或油漆进展。

43、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 is finished installation 标记应清晰， 且能保持较长时间。 至少应保持到该管段安 装完毕。2.7 Cleanness of pipe fabrication piece 管道预制件清洁度Cleanness inspection shall be conducted on fabricated spool, there is no foreign matter inside pip

44、e, such as welding slag, oil, rubble, if there is debris,use scrub or air blow to clean them. 对于预制好的管段进展清洁度检查，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 Conformity inspection of fabrication piece 预制件的符合性检查 Conformity inspection (as per proportion)is conducted to pipe fabr

45、ication piece according to design document requirement, main content is as follows: 应根据设计文件要求，对管道预制件进展符合性检查按比例 ，主 要容如下：2.8.1 Ensure the material specification, type and material is correct. 确认使用材料的规格、型号、材质正确无误。2.8.2 Ensure pipe fabrication spool size is conformed to drawing requirement. 确. z.-认管道预制段

46、的尺寸符合图纸要求。2.8.3 Ensureweld appearance quality and non destruction inspection is conformed to design documentrequirement. 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

47、 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 fabrication 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. Ifpipe cap is loosening, use adhesive tape to fi* on pipe. 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

48、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 adhesive tape to fi* for pipe end of big bore pipe fabrication 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 wi

49、re) 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 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 pack. z.-the 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

50、 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 technique measure (JHA Appendi* 3)平安技术措施JHA 分析附录 3 All workers entering fabrication shop must wear uniform work clothes, helmetand crash-proofshoes. 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 toindicatedp