上海万吨丙烯腈装置工艺管道施工方案

上海SECCO90万吨/年乙烯工程26万吨/年丙烯腈装置工艺管道施工方案中国石化集团第五建设公司--PAGE35--上海SECCO项目部目录ITEMTOC\o"1-3"\h\z一、工程概况Generalsituationofplant. 2二、编制依据Datafororganizing 21、中国石化兰州设计院资料BaseonLDIdocuments 22、上海SECCO有关技术文件ShanghaiSECCOrelatedtechnicaldocuments 23、中国石化第五建设公司有关资料文件BaseonFCCdocuments 24、施工方案编制所依据的标准、规范的名称及编号Nameandcodeofstandards 3三、施工部署Constructiondispose 3四、管道施工、检验程序programofpipingconstructionchecking 4五、施工进度计划Constructionscheduleplan 6六、施工技术及要求Constructiontechniqueandrequirement 71、管子、管件及阀门的检验Examinationofpipe,pipingfittingsandvalve 72、配管材料的保管及发放Storageanddistributionofpipingmaterial 93、管道加工Pipingfabrication 104、管道组对要求combinationrequirements 115、管道预制和安装Pipingprefabricationanderection 116、管道焊接及热处理Pipingweldingandheattreatment 147、管道系统试验、吹洗与气密Testandblowingofpipingsystem 20七、施工机具、措施用料及人力资源配置ConstructionMachine、measurematerialAndpower 231、施工机械和用具Constructionmachineandtools 232、措施用料measurematerial 253、人力资源的配制Distributionofmanpowerresource 25八、冬、雨季施工技术措施Technicalmeasuresinwinterandrainyseasons； 26九、工程质量保证措施projectqualityassurancemeasure 281、质量保证体系的组成Conpositionofqualityassurancesystem 282、材料质量保证措施materialqualityassurancemeasure 303、施工质量保证措施constructionmeasuresofqualityassurance. 30十、工程安全保证措施 311、项目HSE保证体系ProjectHSEassurancesystem 312、安全施工措施Constructionsafetymeasures 323、施工作业危险性分析Dangeranalyzingofconstruction 33十一、施工平面示意图Sketchmapofconstructionplane 35一、工程概况Generalsituationofplant.赛科90万吨／年乙烯工程26万吨／年丙烯腈装置，由SECCO投资兴建，中国石化集团兰州设计院是EPC总承包，安装部分由中国石化第五建设公司负责施工。该装置包括丙烯腈单元、稀硫铵液浓缩单元、乙腈精制单元及界区内公用工程部分等四部分组成。工艺管道共约94259米（延长米），其中材质为：碳钢管(20＃)，焊接钢管(Q235B)，不锈钢管(304、304L、316及31Thereareabout94259mpipinglinesincludingcarbonsteel(20#),weldingsteelpiping(Q235B),seamlessstainlesspiping(304、304L、316/316L),seamlesspiping(15CrMo)heplant-260,000T/Yacrylonitrileplant,900,000T/Yethyleneproject,isinvestedbySECCO,EPCcontractorisLDIandtheconstructionsubcontractorisTheFifthConstructionCompany(FCC).SECCOthatiscomposedofacrylonitrileunitthinthiaminecondensationunit,ethylicextractionunit,commonworkwithinsection.Thereare8614valvesinthisplant.Andthematerialforthemostpipingoftheplanthavestrongpoison,sotherequirementofconstructionqualityisveryhigh.itisnecessarytostrictlycarryouttheprograminconstruction.序号No.名称name材质material单位unit数量amount备注remark1无缝钢管Seamlesssteelpipe20#m72531.2452铬钼钢管Weldingsteelpipe15CrMo/15CrMoRm293.3其中15CrMoR管55.7米3不锈钢管Stainlesspipe304/304SS/304L/316Lm21433.494各类阀门Valve个8614合计totalm94258.035二、编制依据Datafororganizing1、中国石化兰州设计院资料BaseonLDIdocuments1.1中国石化兰州设计院《上海赛科26万吨／年丙烯腈装置基础设计》0184－00000－00026LonghopDesignInstituteofSINOPEC《ShanghaiSECCO260,000t/yANPlantFoundationEngineering》1.2工艺管道施工图纸processpipingconstructiondrawing2、上海SECCO有关技术文件ShanghaiSECCOrelatedtechnicaldocuments2.1工程质量管理规定PR-00-CIJ-QU-0001SpecificationforConstructionqualitymanagement2.2IPMT施工管理细则PR-00-CIJ-CN-0001PMTConstructionManagementDetailRules2.3管道工程施工质量管理工作细则PR-00-CIJ-PP-0001Pipingconstructionqualitymanagementdetailrules2.4施工质量规则PR-00-CIJ-QU-0002Constructionqualityrules2.5上海赛科90万吨/年乙烯工程单位工程划分规则PR-00-CIJ-QU-00032.6现场条件与现场管理PR-00-CIJ-CN-0002SiteConditionsandSiteManagement2.7无损探伤和检测实施管理办法PH-00-CIJ-IN-0001ManagementmethodofNDTinspection3、中国石化第五建设公司有关资料文件BaseonFCCdocuments3.1中国石化第五建设公司《质量手册》FCC《QualityManual》3.2中国石化第五建设公司《质量体系程序文件》TheFifthConstructionCompanyofSINOPEC《QualitySystemProcedureDocuments》3.3中国石化第五建设公司企业管理标准FCCEnterpriseManagementStandard3.4中国石化第五建设公司《HSE体系程序文件》FCC《HSESystemProcedureDocuments》4、施工方案编制所依据的标准、规范的名称及编号Nameandcodeofstandards4.1《工业金属管道工程施工及验收规范》GB50235-97《CodeforConstructionandAcceptanceofIndustrialMetalPipingWork》4.2《石油化工剧毒、可燃介质管道工程施工及验收规范》SH3501-2002《CodeforConstructionandAcceptanceofPetrochemicalPoisonousandCombustibleMediaPipingWork》4.3《石油化工钢制管道工程施工工艺标准》SH/T3517-2001《StandardforConstructionTechnologyofPetrochemicalSteelPipingWork》4.4《现场设备、工业管道焊接工程施工及验收规范》GB50236-98《CodeforConstructionandAcceptanceofFieldEquipmentandIndustrialPipingWeldingEngineering》4.5《石油化工异种钢焊接规程》SH3526-92《WeldingSpecificationofPetrochemicalSteelofSpecialKinds》4.6《石油化工工程铬钼耐热钢管道焊接技术规程》SHJ520-91《TechnicalSpecificationforWeldingofPetrochemicalEngineeringHeat-resistingCrMoSteelPiping》4.7《石油化工工程高温管道焊接规程》SH3523-92《WeldingSpecificationforPetrochemicalEngineeringHighTemperaturePiping》4.8《石油化工设备和管道涂料防腐蚀技术规范》SH30022-99《TechnicalCodeforPetrochemicalEquipmentandPipingAnticorrosionwithCoatings》4.9《石油化工工程建设交工技术文件规定》SH3503-2001《RegulationsforTechnicalAs-builtDocumentsofPetrochemicalEngineeringConstruction》5.0SECCO标准SECCO’sstandards说明Note：当在项目执行过程中，中国政府法规、SECCO项目规定及标准、规范间有矛盾时，执行的顺序应当是：中国政府法规、SECCO项目规定、标准和规范要求。方案内容中英文间有矛盾时，以中文为主。Duringtheprojectexecution,incaseofanyconflictbetweenChinesegovernmentallawsandregulations,SECCO’sprojectspecification,andcodes,thefollowingsequenceisfollowed：Chinesegovernmentallawsandregulations,SECCO’sprojectspecification,standardsandcodes.IfthedifferencebetweenChineseandEnglishcontentinprogramisbeing,Chinesecontentwillbegood.三、施工部署Constructiondispose根据目前现场实际情况，40、50和80单元施工图纸已到位，但材料刚订货；界区管廊框架（除伸向20单元反应区的管廊框架受大件吊装影响未施工外）已基本安装完毕，管廊管道材料已到货，但施工图纸还没出来。介于以上图纸和现场施工的具体情况，我们准备工艺管道施工以管廊管道敷设为龙头，紧接着根据材料的到货情况，40、50和80单元管道施工逐步展开，等这几个单元施工末期，其它单元的图纸和材料等已准备就绪，管道施工就开始全面辐射安装。Accordingtothepracticeonsite,theconstructiondrawingfor40、50andunithavebeencompleted,butthematerialwasorderedjustnow.thepipegalleryframeofANareahavebeencompletedbasically(exceptthatthepipegalleryextendingtothe20unitreactareaisnotconstructionbecauseofbigliftingaffection)andthematerialissite,butthedesigneddrawingisnotcompleted.Astheabovepractices,wepreparetostartfromlayingpipegallerypiping,andthengraduallyperformtowork40、50and80unitpipinginaccordancewiththematerialonsite.bytheconstructionendoftheaboveseveralunitsthedrawingandmaterialforotherunitshavealreadybeenprepared,thepipingconstructionwouldstartoninstallationfully.四、管道施工、检验程序programofpipingconstructionchecking编号编号施工项目3.2阀门试验编号施工项目5.2标准支架弯管制作编号施工项目6.2焊缝返修编号施工项目8.2焊缝热处理检查C检查B检查B检查C检查C检查A检查A检查B编号施工项目2.2技术交底检查B编号施工项目7.2支吊架安装编号施工项目9.2气密试验编号施工项目1.1开工准备11编号施工项目2.1工方案编制21编号施工项目3.1材料检验31编号施工项目4.1管道内部清洁度检查（针对SHA级管道）41编号施工项目5.1管道预制51编号施工项目6.1无损检测61编号施工项目7.1管道安装71编号施工项目8.1完整性检查确认81编号施工项目9.1系统试验（强度/严密性）91编号施工项目10.1吹洗101编号施工项目11.1质量评定111注：检查Ａ指由施工单位、监理单位、总包代表共同检查；Note：CheckingAmeanscheckingbyconstructionparty,supervisingparty,andowner;检查B指由施工单位、监理单位共同检查；CheckingBmeanscheckingbyconstructionside,supervisingside;检查C指由施工单位技术人员、检查人员共同检查。CheckingCmeanscheckingbytechnicalpersonnel/inspectorofconstructionside.ItemItemNoProject3.2valvetestingItemNoProject5.2pipebracketprefabricateItemNoProject6.2weldinglinereturnItemNoProject8.2weldinglineSR检查C检查B检查B检查C检查C检查A检查A检查BItemNoProject2.2technicalexplanation检查BItemNoProject7.2pipebracketinstallationItemNoProject9.2tightnesstestItemNoProject1.1startworkprepar11ItemNoProject2.1methodstatement21ItemNoProject3.1pipingcheckup31ItemNoProject4.1insidecleancheckofpiping(SHA)41ItemNoProject5.1pipeprefabricate51ItemNoProject6.1NDT61ItemNoProject7.1pipeinstallation71ItemNoProject8.1flowcheck81ItemNoProject9.1systemtesting91ItemNoProject10.1waterwashing101ItemNoProject11.1QCassess111五、施工进度计划Constructionscheduleplan六、施工技术及要求Constructiontechniqueandrequirement1、管子、管件及阀门的检验Examinationofpipe,pipingfittingsandvalve1.1检验一般要求Generalrequirementsofexam..管子、管件、阀门等材料必须具有制造厂的质量证明文件。无质量证明文件的产品不得使用。Pipeetc.materialshallbeprovidedwithqualitycertificateofmanufacture.Producthavingnothecertificatecan’tbeadopted.产品在入库前，应对质量证明文件进行审查，并与实物核对。若到货的管道组成件实物标识不清或与质量证明文件不符或对产品质量证明文件中的特性数据或检验结果有异议，供货方应按相应标准作验证性检验或追溯到产品制造单位。异议未解决前，该批产品不得使用。Certificateofqualificationofproductsshallbecheckedbeforecomeintostoreroom.Ifmarksoftheconstituentelementsareunclear,ornotconformtocertificateofqualification,orthereisobjectionaboutperformancedataorinspectionresultincertificateofqualification,theSuppliershallcarryoutexperimentalverificationbaseduponrelatedstandardortrackbacktothemanufacture.Beforesettlementofobjection,theproductscan’tbeused.输送毒性程度为极度危害和高度危害介质管子的质量证明文件中应有超声波检测结果，否则应按GB5777的规定，逐根进行检验。Ultrasonicdetectionresultforpipeconveyingutmosthazardorhighhazardmediumshallbewrittenincertificateofqualification;otherwise,eachpipeshallbedetectedaccordingtoGB5777.管子、管件、阀门在使用前按设计要求核对其规格、材质、型号和定购单代号。Beforeuseofpipeetc.,size,material,orderNo.shallbecheckedaccordingtodesign.管子、管件、阀门在使用前进行外观检查，其表面要求如下：Beforeuseofpipeetc.,appearanceshallbecheckedandrequirementsarefollows：1）无裂纹、缩孔、夹渣、折迭、重皮等缺陷；Nosuchdefaultsascrack,hole,slugetc.;2）没有超过壁厚负偏差的锈蚀及凹陷；Norustandhollowwhichexceedminuswarpofwallthickness.3）合金钢管道及管道组件应有材质标记，并采用光谱分析复验其关键合金成份，对于外观检查有怀疑的应取样进行化学成份的复验。Alloysteelpipeanditsassemblyshallbemarkedandcheckedtheirkeyalloysteel.Foruncertainappearanceexam.,theirchemicalcomponentsshallbechecked.SHA级管道中，设计压力小于10MPa的输送极度危害介质（苯除外）的管子，每批（指同批号、同炉罐号、同材质、同规格）应抽5%且不少于一根，按（SHA级管道中，设计压力等于或大于10MPa管子，外表面应按下列方法逐根进行无损检测，检测方法和缺陷评定应符合JB4730的规定，检验结果以I级为合格。非导磁性钢管，应采用渗透检测。）规定的方法和评定标准进行外表面磁粉检测或渗透检测，检验结果以II级为合格。Exteriorsurfacemagnetic-particleinspectionorpenetrationtestshallbedonefor5%(atleastonepiece)ofeachbatch(ofthesamelotnumber,stovenumber,materialandspecification)ofpipesconveyingutmosthazardmedium(exceptbenzene)withdesignpressurelessthan10MPaaccordingtomethodsandcriteriafor（Nondestructivetestshallbedoneforsurfaceofeachpipewhosedesignpressure≧10MPaamongSHAlevelpipelines.TestmethodsandevaluationofdefectshallmeetspecificationsofJB4730.GradeⅠwillbequalified.Penetrationtestshallbedoneformagneticimpermeablesteelpipe.）.GradeⅡwillbequalified.SHA级管道中，凡按规定作抽样检查或检验的样品中，若有一件不合格，必须按原规定数加倍抽检，若仍有不合格，则该批管道组成件不得使用，并应作好标识和隔离。Ifoneofsamplesisunqualifiedduringsamplinginspection,certainamount(specifiedintheSpecification)ofproductsshallbeinspected.Iftherestillisunqualifiedproduct,thebatchofproductscan’tbeused.Andtheyshallbemarkedandseparatedwithotherproducts.SHA级管道中，管子经磁粉检测或渗透检测发现的表面缺陷允许修磨，修磨后的实际壁厚不得小于管子公称壁厚的90%，且不得小于设计文件规定的最小壁厚。Surfacedefectfoundbymagnetic-particleinspectionorpenetrationtestcanbegrinded.Butthewallthicknessaftergrindingcan’tbelessthan90%ofnominalthicknessofthepipeandmin.thicknessspecifiedindesigndocument.SHA级管道及管件应在到货管道上用油漆书写“SHA级”字样，其它的管道及管件标识见LDI标识规定。TheclassSHApipingandpipingfittingsshallmakeouttheclassSHAsamplewithpaintonpiping,themarksofotherpipingandfittingseethesignspecification.1.2阀门检验、试验Testofvalve1）阀门必须具有出厂合格证和制造厂的铭牌，铭牌上应注明公称压力，公称通径，工作温度和工作介质。Qualitycertificateandnameplateofvalveshallbeprovidedandmarkednominalpressure/dia./worktemperature/medium.2）铸件应表面平整光滑、无缩孔、毛刺、粘砂、夹砂及裂纹等缺陷。Castsshallbeofflatandsmoothsurface,withoutanydefaultssuchasholes,burr,sand,cracketc.3）锻制加工表面应无夹层、重皮、裂纹、斑疤、缺肩等缺陷。Machinedsurfaceofforgingsshallbefreefromsuchdefaultsasinterlayer,crack,spot,lackofshoulderetc..4）阀门的手柄或手轮操作应灵活轻便，开闭时不得有卡塞现象，阀杆的全开和全闭位置应相符合，主要零件不得有严重缺陷。Handleorwheelofvalveshallbeagileandnoclipinopeningandclosing.Fullopeningandclosingpositionshallbeidentical.Itsmainpartsshallbenoseveredefaults.5）用于SHA级管道的通用阀门，其焊缝或阀体、阀盖的铸钢件，应有符合SH3064规定的无损检测合格证明书。Certificateofqualification(meetSH3064)fornondestructivetestofweldjointandsteelcastingofbodyandcoverofuniversalvalveforSHAlevelpipelineshallbeprovided.6）装置所用阀门100％进行强度和严密性试验。Thevalveforinstallationshallbeexamined100%.7）阀门的强度和严密性试验应用洁净水进行。Pressureandtightnesstestsofvalveshallbeperformedusingcleanwater.8）阀门的强度试验压力为公称压力的1.5倍，试验时间不少于5分钟，以壳体、填料无渗漏为合格。Intensitytestpressureshallbe1.5timesofnominalpressure,testtimeisnolessthan5min..Noleakageofbodyandfillingisqualified.9）除蝶阀、止回阀、底阀、节流阀外，严密性试验一般按公称压力进行。在能够确定工作压力时，也可以用1.25倍的工作压力进行，以阀瓣密封面不漏为合格。Forvalveexceptbutterflyvalve,checkvalve,bottomvalve,throttle,tightnesstestshallbecarriedouttonominalpressure.Inensuringworkingpressure,alsobe1.25workingpressure.Certificatestandardisnoleakageofpetal..10）对焊阀门的严密性试验应单独进行，强度试验一般可在系统试验时进行。Forbutter-weldingvalve,tightnesstestshallbecarriedoutsolelyanditspressuretestshallbecarriedoutinsystemtest.11）严密性试验不合格的阀门，须解体检查，并重新试验。Fornotqualifiedvalveoftightness,itshallbedisassembledandclosedandtestedagain.13）合金钢阀门应逐个对阀体进行光谱分析，合金钢及高压阀门每批取10％且不少于一个进行解体检查内部零件，如有不合格则需逐个检查。Foralloysteelvalve,itshallbeopticalanalysis.Alloysteelvalveandhighpressurevalveshallbedisassembled10%perbatchandnotlessthanone,andonebyoneifthereisnotdisqualified.14）试验合格的阀门，应及时排净内部积水。密封面应涂防锈油（需脱脂除外），关闭阀门，封闭出入口，并填写试验记录，如有不合格则需逐个检查，试验合格的阀门在阀体上按LDI标示规定做出标识。Forqualifiedvalve,innerwatershallbeejectedintime.Sealingfaceshallbepaintedantirustoil(exceptvalveneededdegreasing)andvalveshallbeclosed,whilemouthshallbeclosed.Testingreportshallbefilledin.Fornotqualifiedvalve,thevalvespassingtestmakeoutthesignonvalvebodyasperthespecificationofLDImark..15）阀门的传动装置和操作机构应进行检查。要求动作灵活可靠，无卡涩现象。Gearingandoperatingunitshallbecheckedandtheyshallbeagileandnoclick.16）安全阀在安装前应按设计要求进行调试。其调试要求如下：Safetyvalveshallbedebuggedbeforeconstructionaccordingtodesign.Requirementsarefollowing：（1）调试安全阀要求制作专用胎具，并保证胎具的清洁，防止胎具内的赃物进入安全阀密封口。Specialtoolshallbeusedindebuggingsafetyvalve.Thereshallbecleanintool.（2）除设计有特殊要求外,介质为气体的安全阀调试介质采用氮气，介质为液体的安全阀调试介质为新鲜水。Safetyvalvewhosemediumisgasshallbeusednitrogenandliquidcleanwater（3）安全阀的起跳次数不得少于3次。Jumpingtimeofsafetyvalveshallnotbelessthan3.（4）安全阀调试必须在甲方代表／监理代表的监督下进行。Debuggingshallbecarriedoutinsupervisoryofrepresentativeofowner/supervisingrepresentative.（5）安全阀经最终调校合格后，应做铅封，并填写“安全阀最终调试记录”Havingpassedthefinaladjustment,thevalveshallbesealedbylead,andthe“RecordsOnTheFinalAdjustmentofSafetyValve”shallbefilled.17）阀门检验或安全阀调试时，甲方代表在现场共同确认。Intestingofvalveanddebuggingofsafetyvalve,representativeofownershallbeaffirmedinsite.18）具有上密封结构的阀门，应逐个对上密封进行试验，试验压力为公称压力的1.1倍。试验时应关闭上密封面，并松开填料压盖，停压4min，无渗漏为合格。Ifthevalvehasuppersealstructure,eachuppersealshallbetested.Uppersealfaceshallbeclosedandcoveroffillershallbeloosened.Maintainthetestpressureat1.1timesofnominalpressurefor4min.Ifthevalveisnotleaky,itisqualified.1.3管件的检验Testingofpipingpiece管件外表面应有制造厂代号（商标）、规格、材料牌号和批号等标识，并与质量证明文件相符，否则不得使用。Exteriorsurfaceofelementsshallhavecodename(trademark),specificationandbrandandlotnumberofmaterialthatareconformtocertificateofqualification.Otherwise,itcan’tbeused.1)管件的表面不得有裂纹，外观应光滑、无氧化皮，表面的其他缺陷不得超过产品标准规定的允许深度。坡口、螺纹加工精度应符合产品标准的要求。焊接管件的焊缝应成形良好，且与母材圆滑过渡，不得有裂纹、未熔合、未焊透、咬边等缺陷。Surfaceofelementsshallbesmoothwithoutcrackandscale.Otherdefectsonsurfacecan’texceedthepermissibledepthspecifiedinproductstandard.Workingaccuracythreadandgrooveatendshallmeettherequirementsinproductstandard.Weldjointofpipesshallbesmoothandwelljoinwiththepipe.Thereshallbenocrack,stick-outweld,faultyfusionandundercut.2)弯头、异径管、三通、法兰、补偿器及紧固件须检查其尺寸、材质、型号及识别号，高压管件及紧固件验收后应填写记录。Elbow,reducer,flange,compensatorandfixershallbecheckedtheirsize,material,marker,andreportshallbefilledinafteracceptanceofhighpressurepipingpieceandfixer.3)法兰密封面应平整光洁，不得有毛刺及径向沟槽，法兰螺纹部分应完整，无损伤。凸凹面应能自动嵌合，凸面的高度不得低于凹槽的深度。Valvesealingfaceshallbeflatandclean,noburrandradialgroove.Screwshallbefull,nodamage.Convexheightshallnotbelessthangroove.4)垫片不能有径向划痕、松散、翘曲等缺陷。密封垫片应按产品标准进行抽样检查验收，每批不得少于一件。缠绕垫片不得有松散、翘曲现象，表面不得有影响密封性能的伤痕、空隙、凹凸不平及锈斑等缺陷。Gasketshallbefreefromradialtrace,relax,warpetc..Samplinginspection(atleastonepieceperbatch)ofgasketsealshallbecarriedoutaccordingtotheproductstandard.Thegasketcan’tbelooseorwarped.Thereshallbenoscar,gap,sag,crestandrustystainthatmayimpactsealingpropertyonsurface.5)弹簧支吊架应有合格证及数据书。Certificateanddatamanualshallbeprovidedforspringsupport.6）螺栓、螺母的螺纹应完整，无划痕、毛刺等缺陷，加工精度符合产品标准的要求。螺栓、螺母应配合良好，无松动或卡涩现象。Threadsofboltandnutshallbecompletewithoutscratchorburr.Workingaccuracyshallmeettheproductstandard.Boltandnutshallfitwitheachotherwithoutlooseorlock2、配管材料的保管及发放Storageanddistributionofpipingmaterial2.1材料的保管Storage1）进库的管子、管件应根据材料清单，按材料编码及部件号存放，核对材质、尺寸、色标、型号及其它识别号，进行验收并分类摆放。Pipe,pipingpiecebestoredshallbestoriedaccordingcodeandcheckingsizeetc..2)管材要放置在支架或临时支墩上，各种材质钢管要分开摆放，并明显标识。Pipingmaterialshallbeplacedonsupportandplacedaccordingtomaterialandmarked.3)凡有保护油的碳钢管子，按需要清洗，并根据清洗要求检查合格后方可入库。Topipehavingprotectingoil,itshallbecleanedandstoriedafterchecking.4)管件应按材质、种类、等级、规格分类放置在货架上，装卸时应避免碰撞，以防擦伤或损伤管件。Pipingpieceshallbeplacedonsupportaccordingtomaterial,sizeandavoidedcollision.2.2材料的发放Distributionofmaterial1)通过“材料限额卡”发放材料。Materialshallbedistributededaccordingtogeneralmaterialrequisitionlist.2)校对所提取材料的规格、型号、材质及材料编码，无误后给予发料，并做好标记的核对和移植工作。Distributionshallbecarriedoutaftercheckingsize,typeetc.andcheckingofmarkerandremarkingshallbecarriedout.3）管道及材料发放管理办法Managementstandardofmaterialdistribution（1）在整个工程中，技术人员按各自分管单元的管线号（管线号与其轴测图及材料相对应）填写“材料限额卡”。Inthewholeproject,thetechnicianfillinthemateriallimitationcardasperpipeNo.managedbyeachone(correspondeachotherbetweenthepipeNo.anditsaxisdrawingandmaterial).（2）“材料限额卡”可手写或用计算机打印，一式四份，专业工程师、计划员、保管员各存一份，分公司领料员拿一份作为领料依据，保管员见其余三人签字后的“材料限额卡”才能依卡发料。Themateriallimitationcardfilledinbyhandwritingorprintedoutbycomputer,havethesimilarfourpiecekeptseparatelybyspecialengineer,planner、keeperandmaterialpersonnelfromsub-company.thekeepercangivematerialafterseeingotherthreepersons’signatureinmateriallimitationcard.(3)管道支吊架材料由各分公司依图做材料预算，直接领用。Supportmaterialwillbereceivedaccordingtobudgetofdrawings.(4)对因设计变更和误操作造成的材料增补，由工艺工程师签发增补材料领用单，保管员见签字后的增补材料领用单才能发料。设计变更部分的材料预算由各项目组做。Formaterialsupplementofchangeddesignandfaultyoperation,keepingpersonshallprovidethematerialinseeingthematerialdrawinglistissuedbypipingengineer.(5)安全阀、调节阀等特殊阀门按施工进度要求适时发放，并造册登记。登记时必须显示其应用部位（单线图号）及领用人。Safetyvalve,regulatingvalveshallbeprovidedintimeandregistered.Positionanddrawershallbeshowed.3、管道加工Pipingfabrication3.1管道清理Cleaning管道预制前对每根管子内部必须进行清理，具体措施按下列要求进行。Clearanceofinnerpipeshallbecarriedoutbeforefabrication,andmeasuresarefollowing;1）公称通径大于或等于600mm的管道，宜进入管内人工清扫或擦拭；Forpipingwhosenominaldiameterismorethanorequalto600mm,clearanceshallbecarriedoutbyinnerclearancemanually.2）公称通径200～550mm的管道，可用弧形板夹破布拖扫，或将管子直立，同时以木锤敲打管壁，使管内的铁锈及污物彻底清理出来；Forpipingwhosenominaldiameteris200~550mm,cloutclampedbyarcplatewillbeused;erectingpipeandknockedbywoodhammer.3）公称通径50～200mm的管道，可用绑有破布、毛刷或钢丝刷的铁丝在管内反复拖拉，直至干净；Forpipingwhosenominaldiameteris50~200mm,clout,brushclampedbywirecanbeused.4）公称通径小于50mm的管道，宜用压缩空气吹净；Forpipingwhosenominaldiameterislessthan50mm,compressedairwillbeused;3.2管道的切割Cutting1)管道加工开始时，管工必须吃透图纸，确定管子、管件材质，核对好尺寸，开始下料。Beforefabrication,pipingfabricationpersonshallensurematerial,sizeetc..2)镀锌管和直径小于等于2"的中低压碳钢管，应用机械方法切割。Galvanizingpipeandmedium/lowpressurecarbonsteelleethan2",mechanicalmethodwillbeused.3)不锈钢管应用机械或等离子方法切割，用砂轮片切割或修磨时，砂轮片应专项专用，严禁不锈钢与碳钢打磨交叉使用，禁止用火焰切割和电弧切割。Mechanicalorplasmamethodwillbeusedincuttingstainlesssteelpipe.Grindingwheelshallbespecialandusedforcarbonsteelpipeandstainlesssteelpipeseparately.Flameandarccuttingarenotallowed.4)管子切割后切口表面应平整，不得有裂纹、重皮、毛刺、凸凹、缩口。熔渣、氧化铁、铁屑应予以清除干净。Cuttingsurfaceshallbeflat,withoutcrack,burr,contractedmouth.Slug,ferricoxide,slagshallbecleanedout.3.3管道开孔Openinghole1)开孔应在管段未成型前或相互组对之前进行，以便除净由于开孔而落入管内的切削物和熔渣等。Holeopeningshallbecarriedoutbeforecombination,whichwillgetrideofcuttingcontentandslagbecauseofopening.2)在管线上开大于1"孔时，碳钢用氧－乙炔焰，不锈钢用等离子或氩弧切割开孔，开孔后必须将热影响区磨去2mm。Whenopeningholemorethan1",oxygen-ethinearcwillbeusedtocarbonsteelandplasmatostainlesssteel.Heatinfluencedzoneshallbegottenrideof2mm.3)在管线上开小于等于1"孔时，必须采用机械钻眼。Whenopeningholelessthan1",mechanicalmethodshallbeused.4)管道开孔应尽量在管道预制时进行，如果在安装后开孔，开孔后必须及时将管内杂物用空气吹扫干净或用布拖净。Openingshallbecarriedoutinfabrication.Ifopeningaftererection,sundriesinpipeshallbeblownclean.4、管道组对要求combinationrequirements1）管子组对前检查坡口的质量、尺寸、角度应符合要求，内外表面不得有裂纹、夹渣、污垢及铁锈等缺陷。Slopeshallbecheckedforquality,size,andnocrack,slag,rust.2）组对前应用手工或机械清理坡口内外表面，在20mm范围内不得有油漆、锈、毛刺等污物，其方法碳钢可用角向磨光机、钢锉等，不锈钢可用不锈钢丝刷等。Manualormechanicalmethodshallbeusedinclearingsurfaceofslope.Therearenopaint,rust,burr.Grindingmachineorfilingtoolwillbeusedtocarbonsteelandstainlesssteelbrushtostainlesssteel.3）对于焊接管要注意纵向焊缝并标出，以便与开孔位置错开，相邻两管纵焊缝应相隔180°，有可能的地方焊缝最小间距150mm。Longitudinalseamshallbemarkedandnearseamsshallbeatadistanceof180°,leastdistanceshallbe150mmpossibly.5、管道预制和安装Pipingprefabricationanderection5.1管道预制Pipingprefabrication1)为了满足施工进度的要求，减少现场的工作量，所以要充分提高工厂预制的深度。Inordertosatisfyconstructionprogress,reduceworkinsite,itshallimproveprefabricationdepth.2)管道预制应考虑运输和安装的方便，并留有调整活口，对已就位的设备，有必要实测时，应先实测后预制。Transportationanderectionshallbeconsideredtopipingprefabrication.Settingendshallbeleaved.Tosettledequipment,prefabricationshallbecarriedoutaftermeasuringindemandingmeasuring.3)管道预制加工应按现场审查确认的设计单线图或依据管道平、剖面图绘制的单线图进行，预制加工图上应标注管线编号、现场组焊位置和调节裕量。Prefabricationofpipelineshallbecarriedoutaccordingtodesignedsinglelinediagram,orsinglelinediagramdrawnbaseduponplaneandsectionofpipelinethatareapprovedonsite.Numberofpipeline,positionofgangweldingandovermeasureshallbeindicatedintheworkingdiagram.4)管道预制过程中的每一道工序，均应核对管子的标识，并做好标识的移植。不锈钢管道、低温钢管道，不得使用钢印作标识。Duringeachsequenceofprefabrication,marksofpipelineshallbechecked.Transferofmarksshallbedonewell.Steelmarkcan’tbeusedforstainlesssteelpipeandlowtemperaturesteelpipe.5)管道预制时自由段和封闭段的加工尺寸允许偏差应符合规定。Freesectionandclosingsectionshallhaveprescribedsizeallowance.6)预制管道组合件应具有足够的刚性，否则应有临时加固措施，必要时应标出吊装索具捆绑点的位置，摆放要注意支撑好，不得产生永久变形。Combinationofpiecesshallhaveadequaterigidity,otherwiseitshallbereinforced.Puttingshallbegoodandavoidpermanentdistortionmoment.7)弯管制作后，弯管处的最小壁厚不得小于管子公称壁厚的90%，且不得小于设计文件规定的最小壁厚。弯管处的最大外径与最小外径之差，应符合下列规定：Afterfabricationofelbowpipe,min.wallthicknessatelbowcan’tbelessthan90%ofthenominalthicknessandmin.thicknessspecifiedinthedesigndocument.Differencebetweenmax.exteriordiameterandmin.exteriordiameteratelbowshallmeetthefollowingspecifications:(1)SHA级管道应小于弯制前管子外径的5%；ForSHAlevelpipeline,thedifferenceshallbelessthan5%ofexteriordiameterofpipebeforefabrication.(2)SHB、SHC及SHD级管道应小于弯制前管子外径的8%。ForSHB,SHCandSHDlevelpipelines,itshallbelessthan8%ofexteriordiameterofpipebeforefabrication.8)SHA级管道弯制后，应进行磁粉检测或渗透检测。若有缺陷应予以修磨，修磨后的壁厚不得小于管子公称壁厚的90%，且不得小于设计文件规定的最小壁厚。Afterbending,magnetic-particleinspectionorpenetrationtestofSHAlevelpipelineshallbecarriedout.Ifthereisdefect,itcanbegrinded.Afterthat,thewallthicknesscan’tbelessthan90%ofthenominalthicknessandmin.thicknessindesigndocument.9)SHA级管道弯管加工、检测合格后，应填写SHA级管道弯管加工记录。Afterbendingandinspection,BendingrecordforSHAlevelpipelineshallbemade10)夹套管内的主管必须使用无缝钢管。当主管上有环焊缝时，该焊缝应经100%射线检测，经试压合格后方可进行隐蔽作业。套管与主管间的间隙应均匀，并按设计文件要求焊接支承块。Mainpipeinsleeveshallbeseamlesssteelpipe.Ifthereisgirthjointonthesteelpipe,thejointshallbecheckedwith100%radial.Ifitisqualified,concealedworkscanbecarriedout.Gapbetweensleeveandmainpipeshallbeuniform.Restpadshallbeweldedaccordingthedesigndocument.11)管道预制完后，一切检验工作均应合格。出厂管道一律写明区号、图号、分段号，不锈钢管道用记号笔书写；碳钢管道用白油漆刷底，记号笔书写，最后全部用透明胶带包上，以防雨淋日晒字迹不清。Allcheck