某气相二氧化硅项目管道与焊接中英文工程施工设计方案

.PAGE.某气相二氧化硅项目的管道施工方案ConstructionMethodforPiping2.1概述General本工程是xxxxx新建的4800吨/年气相二氧化硅项目,主要分为18个部分,管道的材料有20#钢、20/PP、0Cr18Ni9、RPM、FRP,镀锌钢管〔Q235-A。由于施工周期短,与土建交叉作业多,因此要合理安排施工任务,质量、安全、进度三者都必须保证。CabotBlueStarChemical<Jiangxi>Co.,Ltd.4,800t/afumedsilicaprojectincludes18sections,pipematerialmanlycontains20#steel,20/PP,0Cr18Ni9,RPM,FRP,galvanizedsteelpipe<Q235-A>.Duetoconstructiontimeistight,installationworksalwayscrosscivilwork,soitisnecessarytoarrangeconstructionreasonably,toensuresafety,qualityandprogressreachedprojecttarget.2.1编制依据CompilationBasis2．1设计公司的招标图drawingforbidissuedbyxxx.GB50235-97、GB50236-982.3主要实物工作量Majorworkquantity不锈钢管S.Spipe150m碳钢管C.Spipe4,900m铝合金管Aluminumalloypipe370mFRP/PP1,670m镀锌管galvanizedsteelpipe2,300m阀门valves680pcs.2.4施工技术措施ConstructionMethod2.4.1管道安装工作程序Pipinginstallationprocedure管道安装程序示意图pipinginstallationflow管道预制管道预制管道支架预制管道清洁度检查管道支架安装质量检验射线探伤试压、冲洗、吹扫复位油漆、保温交工验收材料检验、除锈、涂底漆材料进场管道安装管道组装施工准备PPipingfabricateSupportfabricateCheckcleannessofpipingErectsupportQualityinspectionNDTtestingTestpressure,flushing,blowing&recoverPainting&insulationCompletion&acceptanceInspect,removerust,primecoatingMat’lentersitePipingerectionPipingfit-upPreparation施工准备技术交底：开工之前对所有参加施工的重点人员进行技术交底,使施工人员了解工程概况、工程工期、质量要求、施工程序、施工难度及技术要求,明确自己在施工过程中所承担任务的工作责任,对需持证上岗的人员进行检查。要求参加施工的人员认真阅读图纸,领会设计意图,并在进场施工之前,对所有施工人员一次全面系统的安全教育,通过技术交底,使施工人员对工程有较深的认识,加强施工人员的质量、安全意识。机具检查：对施工所需要的机具进行清点核实,查看施工设备、机具是否完好,各种电动机具及电焊机是否运转正常,安全可靠。检测工具是否齐全、完好,发现问题应及时更换或维修。所有的管材、管件、阀门、焊材等必须有材料质量证明书,其内容、形式必须符合相应材料制造标准的要求。所有的管材、管件、阀门、焊材等必须按规范要求进行外观检查,合格后做好合格标识；阀门应按要求进行强度及严密性试验,合格后作铅封,安全阀应按要求检验与调整开启压力,调试合格后,在技术监督局进行铅封；填写阀门试验记录及安全阀调试记录。不锈钢管道及组成件储存期间不得与碳钢接触,采取有效的隔离措施。ConstructionPreparationTechnicalclarificationmeeting:Allkeyemployeesinvolvedintheinstallationshallparticipateintheinstallationmeetingwhichisheldpriortotheactualinstallationsothattheywillhaveathoroughunderstandingoftheprojectintroduction,schedule,qualityrequirements,installationdifficultyandTechnicalrequirements.Checkallpersonsinvolvingcertifications.Allinstallationpersonnelshallstudythedrawingscarefully.Propertrainingshallbeconductedforallpersonsbeforeenteringthesite.Adeeperunderstandingshallbeachievedthroughthetechnicalmeetings.Qualityandsafetyshallalwaysbekeptinmind.Checkmachines&tools:countallmachinesandtoolsinvolvedintheinstallation.Checkconditionsofinstallationequipment,machinesandtools.Checkelectricalmachinesandseeiftheyarerunningnormallyandreliably.Checkconditionsoftestingtools.Unqualifiedonesshallbereplacedorrepairedinatimelymanner.Allpipes,pipefittings,valvesandweldingmaterials,etc.shallbearmaterialqualitycertificates,thecontentandformofwhichshallbeinaccordancewithfabricationstandardrequirementsforcorrespondingmaterials.Allpipematerials,fittings,valvesandweldingmaterials,etc.shallbevisuallyinspectedaspercoderequirementsandbemarkedifqualified.Valvesshallbetestedforstrengthandairtightnessasperrequirementsandbeleadsealedifqualified.Safetyvalvesshallbeinspectedandadjustedforopeningpressureandshallbeleadsealedifqualified.Finishvalvetestingrecordsandsafetyvalveadjustingrecords.Stainlesssteelpipes,alloysteelpipesandtheircomponentsshallnotcomeintocontactwithcarbonsteelduringstorage.材料检验所有的管材及管件和其它各种涉及到装置永久性存在的材料都必须有材料合格证,必要时应抽检、化验等。管件、管材、型材、阀门、螺栓、垫片、焊材的质量应符合设计文件、施工图纸的规定。并应按国标进行外观检查,不合格者严禁使用。可燃介质、高温、易爆介质管道阀门需逐个试验,其它管道阀门以每批中抽检10%,且不少于1个进行强度及严密性试验。当试验不合格时,应加倍抽查,仍不合格该批阀门不得使用。阀门壳体的试验压力取公称压力的1.5倍,试验时间10分钟,以壳体填料无渗漏为合格。密封试验以公称压力进行,以阀瓣密封面无泄露为合格。试验合格的阀门及时排尽内部积水,并吹干,密封面涂防锈油,关阀门,封闭出入口,做明标记,并填写"阀门试验记录"。管道组成件及支承件在施工过程中按业主要求妥善保管,不得混淆或损坏,其标记应明显,暂时不能安装的管材应两端封闭,不锈钢材料应特别注意不得与其它碳钢材料堆放,防金相腐蚀〔渗碳。管材、〔管件检验主要参照下述标准:GB2270-80、GB8163-87、HGJ46-91、HGJ20615、GB50235-97。从业主领用的材料或乙方自采购的材料应分门别类堆放,妥善保管,发出的材料应有工程师的签字方可发放。MaterialTest&InspectionAllpipes,fittingsandvalvesandotherinvolvedwithpermanentfacilitiesofthePlantshallbeprovidedwithmanufacturerqualitycertificationsandbecheckedforsize,typeandmaterialbeforeuse.。ForInflammablemedium,hightemperatureorexplosivepipevalves,itisnecessaryfortesttobedoneonebyone;forotherpipevalves,testtobedoneby10%ofeverybatch,andatleast1pieceshallbedonewithstrengthandtightnesstest.Thetestpressureforvalvecaseshallbe1.5timesofitsnominalpressure,whichtesttimeshallbe10minutes,andnoleakfromcasestuffingisaseligible.Sealingtestpressureshallbenominalpressureofit,afternoleakfromsealfaceofvalveclack,itcanberegardedaseligible.Qualifiedvalvesshallbefreewaterintime,anddryitout,sealfaceshallbelaidwithanti-rustoil,thenturnoffvalves,closeinletandoutlet,makeidentification,andfillin"ValvesTestRecord".PipingcomponentsandsupportsshallbeingoodcustodyasperrequirementofTHEOWNER,avoidconfusionanddamage,whichmarksshallbeclear,forpipingerectedlater,whichbothendsshallbeclosed,andforstainlesssteelmaterial,attentionshallbepaidthatshallbeisolatedawayC.S.materialtopreventfromcorrosionofmetallurgicalphase<carburizing>.。test&inspectionofpipematerialandfittingsmainlyrefertofollowingcodesandstandards:GB2270-80、GB8163-87、HGJ46-91、HGJ20615、GB50235-97.Itisnecessaryformaterialtakendeliveryfromtheownerorconstructioncontractorpurchasedmaterialtobestoredingoodorder,andmaterialcannotbeissueduntilengineermakesignature.管道预制管道预制拟定在施工临设规定的管道预制厂的专门的预制平台上进行,这样既改善工作环境,又保证施工质量。Pipefabricationistobeperformedindedicatedprefabricationshopsinsideofbatterylimitoftheplantsoastoimproveworkingenvironmentandensureinstallationquality.管道清洁度检查：预制前对所需用的管道进行内部和外部的清洁程度检查,如果内部有铁锈、碎屑、油污等杂质,应用压缩空气进行清理,直到检查合格后,才能投入使用。Pipecleannesscheck:cleannesscheckshallbeperformedforinternalandexternalofrequiredpipespriortoprefabrication,anyrust,debris,greaseorotherforeignmattersshallberemovedusingcloth,compressedair,ironwireorsandblastandshallbeinspectedbyTHEOWNERpriortouse.钢管切割按提供的管道布置图进行选材下料,并在图上标识管段号。管子下料之前,应将管道上原有标记进行移植；小口径钢管采用切割机切割,然后用坡口机坡口；大口径碳钢管〔6″以上用切割机无法切割时,可采用氧—乙炔切割并打磨坡口。不锈钢管4″以下采用砂轮切割机切割,6″以上不锈钢管道采用等离子切割机切割。在管道预制车间的钢平台上操作时,应用橡胶板铺设在平台上进行隔离；FRP/PP管、铝合金管采用细齿钢锯切割.钢管切割的质量要求是：切口表面应平整,不得有裂纹、重皮、毛刺、凹凸等缺陷,如有应予以清除。切口端面斜偏差△≤外径的1%,且不得超过3mm。切割之后的钢管应及时在每一个管段上用油漆或记号笔标明钢管的材质、规格、管线号,并根据施工图纸标明所使用的位置。SteelPipeCuttingSelectmaterialinaccordancewiththeisometricdrawingprovidedbyTHEOWNER,pipesegmentnumbershouldbemarkedonthedrawing.Transplantexistingmarkingonthepipespriortocutting.Smallsizedsteelpipesshallbecutusingcuttingmachineandbebeveledusingbevelmachine;largesized<above6">carbonsteelpipethatareimpossibletobecutbycuttingmachinecanuseoxyacetyleneforcuttingandthebevelshallbeground.Stainlesssteelpipesizebelow4"willuseabrasivewheelcuttingmachine,andthoseabove6"shalluseplasma-cuttingmachine.Forfabricationonthesteelplatformintheprefabricationshop,rubbersheetsshallbelaidontheplatformforseparation.FRP/PPpipeandaluminumalloypipeshallbecutwithserratinghacksaw.Qualityrequirementsforsteelpipecutting:thecutsurfaceshallbeflatwithoutanycracks,laminations,burrs,pittingorotherdefects,ifexist,theyshallberemoved.Bevelendslopedeviation≤1%ofO.Dofpipe,andnotmorethan3mm.Forsteelpipesthatarealreadycut,usepaintormarkingpentomarkoneachpipesegmentthematerial,specificationandlinenumberforthesteelpipe,theirservicelocationsshallbemarkedonAFCdrawings.坡口加工根据设计院提供的管道施工规范〔GB50235-97中的技术要求,坡口加工应按下列图表进行：管壁厚度小于等于2.5mm坡口形式按下图当管壁厚度为2.5~20mm时坡形式按下图。t>2.5~9>9~20α70°+560°-5b1~22~3p1~22~3不等厚管子、管件组对时,如果内壁错边量大于1.0mm或外壁错过量大于2mm时按下图形式进行修整。BevelchamferingInaccordancewithpipingconstructioncode<GB50235-97>suppliedbydesigninstitute,bevelchamferingshallbeexecutedasperfollowingfigure:Forpipewallthickness≤2.5mm,thebeveltypeasfollowingfigure:Forpipewallthickness≥2.5mm,and≤20mm,thebeveltypeasfollowingfigure:t>2.5~9>9~20α70°+560°-5b1~22~3p1~22~3Whenfitupdifferentthicknesspipesorfittings,ifoffsetofpipeinsideisover1.0mm,oroffsetofpipeoutsideisupper2mm,repairshallbedoneasfollowingfigure:管道的组对管道预制的组对工作,在管道加工平台上进行,组对不锈钢管时平台上应铺设δ＝3mm的橡胶板,同碳钢板进行隔离。不得用碳钢器皿打击不锈钢管。管道组对允许偏差按管道允许偏差进行检查,其检验方法是用角尺、钢板尺、钢卷尺测量。自由管段和封闭管段选配应合理,封闭管段应按现场实测后的安装长度加工。自由管段和封闭管段的加工尺寸允许偏差应符合下表规定：项目允许偏差自由管段封闭管段长度±10±1.5法兰面与管子中心垂直度D＜1000.50.5100≤DN≥3001.01.0DN＞3002.02.0法兰螺栓孔对称水平度±1.6±1.6管支架制作在管道预制的同时可以进行管道支架的制作。管架制作的型式结构、材质、加工尺寸、制作精度应符合设计院提供的管支架标准的要求,外观应平整美观,焊接应牢固,无漏焊、欠焊、裂纹等缺陷,焊接表面应光洁,无飞溅物,焊接变形应予以矫正,制作好的管支架应及时进行防锈处理,并作出标记。Pipingfit-uppipeassemblyshallbedoneonthepipefabricationplatform.Forstainlesssteelassembly,δ＝3mmrubbersheetsshallbefurnishedontheplatformforseparationagainstcarbonsteelplate.Carbonsteeltoolsarenotallowedtostrikestainlesssteelpipes.Assemblytoleranceshallbecheckedagainstallowablepipetolerance.TheinspectionmethodinvolvesmeasurementwithAngleSquare,steelplaterulerandsteeltape.ItshallbereasonableforSelectionandarrangementoffreespoolandclosespool,constructionforclosespoolshallbeasperinstallationlengthmeasuredatsite.Allowableprocesssizedeviationforfreespoolandclosespoolshallbeinconformitywithfollowingtablerequirement:ItemAllowabledeviationFreespoolClosespoollength±10±1.5Centerverticalitybetweenflangeandpiping.D＜1000.50.5100≤DN≥3001.01.0DN＞3002.02.0Symmetricallevelnessofflangebolthole.±1.6±1.6Pipesupportfabrication:pipesupportcanbefabricatedasthepipesareprefabricated.Thesupportsshallbefabricatedsuchthattheirform,material,dimension,accuracymeetrequirementsinthepipesupportstandardprovidedbyCO.Thesurfaceshallbeflat.Theweldingshallbefixedwithoutdefectslikemissingweld,insufficientweldorcracks.Theweldingsurfaceshallbesmoothwithoutanyspatters.Anyweldingdistortionshallbecorrected.Rust-proofingtreatmentshallbeperformedforfabricatedsupportsinatimelymanner,andshallbeproperlymarked.管道焊接在管道焊接之前,应具备焊接工艺评定、焊工合格考试并取证、焊接工艺卡、焊接材料根据焊接母材作相应的选定。焊工应根据焊接工程师所提供的工艺卡进行施焊,不允许在雨天、雾天、相对湿度超过90%,风速超过8m/s除非采取相应的保护措施。焊条根据要求,由专门烘烤工实施干燥,不同烘干温度的焊条不得在同一烘箱中烘烤,不同牌号的焊条应作出相应的标记。没有用完的焊条应及时回收,超过烘烤次数的焊条应禁止使用。焊工必须使用正规焊条筒领用焊条。在点焊之前,应仔细检查坡口、表面、并进行相应的清理,管内无杂物,焊接坡口端50mm以内的表面应打磨干净,呈现金属光泽,方可点焊。管道对接焊口的组对应做到内壁平齐,内壁错边量不宜超过壁厚的10%,且不大于2mm,不等壁管道施工时,应注意修整。当焊接完成时,在管道轴测图上标注焊口号,焊工号。预制完成的管线,管口端应用管帽〔塑料封堵,防止脏物进入。本工程各钢种选用的焊丝、焊条如下：Weldrod&wire<appliedinthisproject>asfollows钢号steelNo.手弧焊焊条manualweldingrod氩弧焊argonarcwelding20#J422H08Mn2SiAQ235AJ4220Cr18Ni9A102H0Cr20Ni10TiALSALMg-XPipingweldingWeldingprocedurequalification,welderqualificationexamination,weldingprocesscardandweldingmaterial<choiceasperbasemetal>shallbeconductedpriortopipewelding.Weldersshallcomplywithweldingprocesscardissuedbyengineertoexecuteweldingwork.Noweldingispermittedinraining,foggyweather,orwhenhumidityexceeds90%,orwhenwindspeedexceeds8m/s.Weldingelectrodesshallbedriedasperrequirement<skilledpersonwillbeinchargeofweldingelectrodedryingwork,strictelectrodeissuingrecordsystemshallbecarriedout>.Meanwhile,differentbrandsofelectrodesshallbeidentifiedwithdifferentcolormarkingorothertypesofmarkingattheelectrodeends.Wrongelectrodewilldirectlyaffectweldquality.Therefore,weldersshallrequestforelectrodeswithelectroderequestsheetsissuedbytheinstallationtechnician,andshalluseformalelectrodedryer.Weldersshallcheckassemblyconditionspriortotackwelding.Thebevelangle,buttclearanceandinternalwallunfitnessshallbeasperweldingproceduresheet.Thesurfacewithin50mmoftheweldingbevelendshallbegroundtillsoundmetalpriortotackwelding.Pipeweldingprocedureshallbeinaccordancewiththecorrespondingweldingproceduresheet.Slagandspattershallberemovedimmediatelyafterwelding.Theweldsurfaceshallbecleanedandvisuallyinspected.Whenweldingisfinished,markthewelderNo.,craterNo.,weldingdateonthecorrespondingcrater.Markingshallbedoneaccordinglyonthesingle-linediagram.Fabricatedpipelineshallhavetheirendscoveredwithpipecaps<plastic>toprotectingressofforeignmatters.焊接检查焊缝外观检查不允许有裂纹、未溶合、气孔、夹渣、飞溅存在；咬边度<0.5mm,焊缝两侧咬边总长不大于该焊缝全长的105,且不应大于100mm；焊缝表面不得低于母材表面,焊缝余高应符合GB50236-98提供的焊接规范要求；焊接接头错边量不应大于壁厚的10%,且不大于2mm。焊缝质量：管道焊缝质量检查按设计院提供管道施工规范〔GB50235-97中的有关焊缝检查的标准进行。焊接合格的焊缝应及时填写管道焊接记录,记录应整洁、准确、工整、对不合格片应严格进行返修,然后用原方法作射线无损检测,检查合格的焊口应在单线图或焊接记录上作出相应的标识。WeldinginspectionWeldvisualinspectionNocracks,lackoffusion,porosity,slaginclusionorspatterarepermitted.Undercutshallbelessthan0.5mm,totalundercutlengthonbothsidesoftheweldshallnotbelargerthan10%oftotalweldlength,andshallnotbelargerthan100mm;Theweldsurfaceshallnotbelowerthanthatofbasemetal,excessweldmetalshallbeaspercoderequirementprovidedbydesigninstitute;Weldjointunfitnessshallnotexceed10%ofwallthickness,andshallnotbelargerthan2mm.Weldquality:pipeweldqualityinspectionshallproceedasperrelativeweldinspectionrequirementsinthepipeinstallationcode<GB50235-97>providedbydesigninstitute.Fillinpipeweldingrecordsforqualifiedweldsandenterproperqualificationdataintothecomputer.Therecordshallbetight,accurateandclean.Unqualifiedproductshallberepairedandradiographedbytheoriginalmethod,andshallfollowcode<H-331>requirement.Qualifiedcratershallbeaccordinglymarkedonthesingle-linediagramorweldingrecord.管道安装前应具备的条件与管道安装的土建或钢结构工程已检验合格,满足安装要求,并办理好交接手续；与管道连接的设备已找正合格,固定完毕；管道内部清洁度已检查合格,对管内有特殊要求的管线其质量应符合设计文件的要求；设计需要修改的位置及管道上的开孔应在安装之前完成。ConditionsbeforeinstallationCivilorstructureworksassociatedwithpipeinstallationhavebeencompletedandinspectedtobesatisfactoryforpipeinstallation.Properhandoverhasbeendone;Equipmenttobeconnectedwiththepipesarealignedandfitted;Thepipeinternalcleannesshasbeeninspected.Forpipelineswithspecialrequirementsfortheirinternal,theirqualityshallbeasperrequirementsinthedesigndocuments;Locationmodificationsrequiredbydesignandopeningonthepipeshallbecompletedpriortopipeinstallation.钢制管道安装管道安装时,应检查法兰密封面及密封垫片,不得有影响密封性能的划痕、斑点等缺陷。法兰连接应与管道同心,并应保证螺栓自由穿入。法兰螺栓应跨中安装。法兰间应保持平行,其偏差不得大于法兰外径的1.5%,且不得大于2mm,不得用强紧螺栓的方法消除歪斜。工作温度低于200℃的管道,其螺纹接头密封材料宜选用聚四氟乙烯带。拧紧螺纹时,不得将密封材料挤入管内。法兰连接应使用同一规格的螺栓,安装方向应一致。螺栓紧固后与法兰紧帖,不得有楔缝。需加垫圈时,每个螺栓不应超过一个。紧固后的螺栓与螺母宜齐平。当管道安装处于露天或处于大气腐蚀环境时,螺栓、螺母应涂以二硫化钼油脂、石墨机油或石墨粉。建设单位另有要求时,按建设单位要求进行。管子对口时应在距接口中收200mm处测量平直度〔见下图。当管子公称直径小于100mm时,允许偏差△为1mm,当管子公称直径大于100mm时,允许偏差△为2mm。全长允许偏差≯10mm。管道对口平直度管道连接时,不得用强力对口、加偏垫或加多层垫等方法来消除接口端面的空隙、偏隙、错口或不同心等缺陷。支管与主管连接时,当工艺要求按介质流向倾斜,倾斜度按设计规定。管道安装允许偏差应符合下表规定：〔单位：mm项目允许偏差坐标架空及地沟室外25室内15标高架空及地沟室外±20室内±15水平管道平直度DN≤1002L‰,最大50DN＞1003L‰,最大80立管铅垂度5L‰,最大30成排管道间距15交叉管的外壁或绝热层间距20膨胀节安装时,按设计要求进行予拉伸,允许偏差±10mm,拉前将固定管托焊接牢固。阀门安装阀门安装前,应检查填料,其压盖螺栓应留有调节余量。阀门安装前,应按设计文件核对其型号,并应按介质流向确定其安装方向。当阀门与管道以法兰或螺纹连接时,阀门应在关闭状态下安装。水平管道上的阀门,其手柄方向宜安装在上半周范围内,阀门操作和机构应灵活,指示准确。支架安装管道安装时,应及时固定,高调整支架。支架位置应准确,安装应平整牢固,与管子接触应紧密。有热位移的管道,导向支架或滑动支架的滑动面应洁净平整；不得有歪斜和卡涩现象。其安装位置应从支撑面中心位置向位移反方向偏移,偏移量应为位移量的1/2,或符合设计规定,绝热层不妨碍其位移。固定支架应严格按设计规定执行；在一直管线上不得有两个以上固定支架。管道安装时不宜使用临时管架,当使用临时管架时,支架不得与正式管架位置冲突；并应有明显标记。在管线安装完毕应予拆除。管道安装完毕后,应按设计文件规定逐个核查支架形式和位置。活动架的位移方向及导向性能应符合设计规定。管托不得脱落。固定支架牢固可靠。伴热管安装伴热管应与主管平行安装,多个伴热管在主管圆周上的分布按设计要求布置。不允许将伴热管直接点焊到主管上,伴热管的固定按设计要求进行。伴热管的其他安装同主管的要求相同〔包括伴热管的压力试验吹扫。SteelPipeinstallationForpipesconnectedtostaticequipment,noadditionalstressisallowedwithflangedconnection.Theequipmentopeningsshallbecoveredwithsheetsteelorasbestosrubberplateforseparation;Flangeconnectionshallkeepconcentricwithpiping;ensureboltscanbefreeintoholes.Flangeboltsshallbesetatstridingtocentermethod.Parallelshallbekeptbetweenflanges,whichdeviationshallbenotmorethan1.5%ofO.Dofflange,andnotmorethan2mm.Forpipingwhichtemperatureunder200℃,Teflontapeisapplicableforthethreadjointsealingmaterial.Theflangesealingfacesshallbesmooth,anydamagedfaceshallberepairedorreplaced;duringbolting,theflangefaceshallmaintainaxialityandparallelismtoensureevenforceonthegaskets.Whenpipinginstallationonoutdoororinambientcorrosionenvironment,bolts&nutsshallbesmearedwithsupramolygrease,graphiteengineoilorgraphitepowder.Whenfittinguppipe,theevennessshallbemeasuredat200mmplaceawayfromconnectingjoint<seefollowingfigure>.Whennominaldiameterofpipeislower100mm,allowabledeviationis1mm,whenitisover100mm,allowabledeviationis2mm.Fulllengthallowabledeviationshallbe10mm.Pipingfit-upevennessWhilepiping,extraforcefit-upisforbidden,andbyaddingleanshimormulti-layerpadtoeliminatespace,gap,offsetoreccentric,etcwaysareforbiddenhere.Whenbranchpipeconnectingmainpiping,andprocessrequiresinclineaspermediumflowdirection,theleandegreeshallbeasperdesignspecification.Pipinginstallationallowabledeviationtableasfollows:〔unit:mmitemAllowabledeviationCoordinateInelevationortrenchOutdoor25Indoor15ElevationInelevationortrenchOutdoor±20Indoor±15LevelpipingevennessDN≤1002L‰,Max.50DN＞1003L‰,Max.80Verticalpipingperpendicularity5L‰,Max.30Spacebetweenrowedpipelines15Spacebetweencrosspipelinesorinsulationlayers20Whenexpansionjointinstallation,itshallbestretchedaccordingtodesignrequirement,allowabledeviationis±10mm.ValveerectionPackingofvalveshallbeinspectedpriortoerectionofvalve,whichpresscovershallleaveadjustmentallowance.Beforevalveerected,whichtypeshallbecheckedasperdesigndocument,andinstallationdirectionshallbeconfirmedaccordingtomediumflowingway.Whenflangeorthreadisusedtoconnectvalveandpiping,valvesshallbeerectedunderclosingstatus.Forvalvestobeerectedonhorizontalpiping,whichhandledirectionshallbewithinupperhalf-cyclerange,valvesoperationshallbeagile,andindicationbecorrect.SupportinstallationWhilepiping,pipingsupportshallbefixedandadjustedintime,whichlocationshallbecorrect,installationforitshallbelevelandfirm,thesupportshalltouchedfirmlywithpiping.Forheating-displacementpiping,slidingsurfaceofguidesupportorslidingsupportshallbecleanandlevel,deflectionandblockareforbidden.Itserectionlocationshallbeexcursionfromsupportingcentertoreversedirectionofdisplacement,theexcursionquantityshallbe1/2ofdisplacement,orinaccordancewithdesignspecification,andinsulationlayershallnotdisturbitsdisplacement.Rootsupportshallbeasperdesignspecification;andonsameonepipeline,above2rootsupportsshallbenotallowable.Temporarysupportisnotavailableforpiping,whenhavetousetemporarysupport,itshallnotconflictwithformalpipesupport,whichshallbemarkedobviously.Afterpipingcompleted,temporarysupportsshallbedismantled.Afterpipingerected,supporttypeandlocationshallbeinspectedonebyoneasperdesigndocument.Displacementdirectionandguideperformanceshallbeconformitywithdesignrequirement.Pipingshoesshallbenotfalloff.Rootsupportsshallbefirmandreliable.InstallationoftracingpipeThetracepipeshallbeinstalledinparallelwiththemainpipe,andshallhaveitsowndrain.Horizontaltracepipeispreferablyinstalledunderthemainpipeoronthesideclosetothesupport.Verticaltracepipesshallbeevenedarrangedaroundthemainpipe,thetracepipeshallbefittedonthemainpipebygalvanizedironwire.Tracingpipeotherinstallationmethodisassameasmainpiping<includingpressuretestandblowingoff>.不锈钢管安装材料检验与保管不锈钢管及管件必须具有制造厂的合格证书、化学成分和机械性能等资料。不锈钢管子及管件使用前应按规范要求进行外观检查,表面不得有裂缝、重皮等缺陷。搬运不锈钢管时,应避免与碳钢管相互摩擦、碰撞,堆放时应与碳钢管用橡胶板分开隔离,并防止雨水、铁锈等腐蚀。不同材质的不锈钢管要进行标记,并分别堆放,以免混用。对材质有疑问时,可进行光普分析材料成分。管子切割和坡口不锈钢管管径≤100的采用砂轮机切割。不锈钢管管径＞100的采用等离子切割。不锈钢管坡口采用砂轮机进行坡口。管道焊接不锈钢管及低合金钢管焊接采用氩弧焊打底,手工电弧焊盖面的方法。管道材质焊接材料牌号焊丝牌号备注304LA002H00Cr21Ni10316LA002H0Cr20Ni14Mo3A335P11/P22R507H1Cr5Mo采用氩弧焊时,所焊接管道内应充氩保护,氩气纯度宜在99.9%以上,钨极可选用钍钨棒或纯钨棒。焊接前应将坡口极其两侧20mm宽度范围内的油污清除干净,并在坡口两侧各100mm宽度内涂上白垩粉,防止焊接飞溅物粘附在管壁上。焊后应对焊缝极其附近的管子表面进行酸洗,然后用热水冲洗干净,再进行钝化处理。预制好的管子应进行标记,防止不同材质的管子混装。管道安装不锈钢管道安装应在支架全部固定好之后进行,安装时不得用铁质工具敲击。不锈钢法兰用的非金属垫片,其氯离子含量不得超过50ppm。不锈钢管不准直接与碳钢支架接触,应在管道与支架之间垫入石棉橡胶板或橡胶皮。管子穿墙壁或楼板时,均应加装套管,管子与套管之间的间隙应不小于10mm,并在空隙里填加绝缘物,绝缘物内不得有铁屑等杂物,绝缘物一般为石棉绳。不锈钢管焊缝表面清洗不锈钢管道焊接完毕后,应用砂轮磨光机对焊缝表面的飞溅物进行打磨,然后涂上酸洗膏浸泡,用钢丝刷进行焊缝清洗,最后用水进行冲洗,焊缝表面呈现金属亮光色泽,通过THEOWNER质检人员检查确认后为合格。InstallationofstainlesssteelpipingMaterialinspection&testandcustodyItisnecessaryforS.S.pipeandS.S.fittingstohavequalificationcertificate,chemicalcontentandmechanicalperformance,rmation.VisualobservationisnecessaryforS.S.pipeandS.S.fittingspriortousageasperrelevantcodesandstandards,whichsurfaceshallnotexistcracks,overlap,etc.defects.WhenhandlingS.S.pipe,itshallavoidfrictioninmutual,andwhenliftingS.S.pipe,nylonstripisnecessary,andrubbersheetisapplicabletoseparateS.S.pipe,andpreventfromrain,rustcorrosion,etc.ItisnecessarytomakeidentificationfordifferentmaterialS.S.pipe,whichshallbestoreseparately,toavoidconfusion.Whendoubtingmaterial,spectralanalysisisavailableformaterialcontent.CuttingandbevelingS.Spipesize≤100mm,itshallbecutwithgrinder.S.S.Pipesize＞100mm,itshallbecutwithplasmacutter.GrinderisavailabletochamferbevelofS.S.pipe.S.S.pipingweldingArgonarcweldingforjointrootandmanualelectricalarcweldingforcoveringareapplicableforS.S.pipeandlowalloysteelpipe.<pipesize≤2’’,argonarcweldingisutilized.>PipematerialWeldingmaterialbrandWeldingwirebrandremarks304LA002H00Cr21Ni10316LA002H0Cr20Ni14Mo3A335P11/P22R507H1Cr5MoWhenusingargonarcwelding,pipinginsideshallbefilledwithargontobeshielded,andargonpurenessshallbe99.9%andabove,tungstenelectrodecanusethoriumtungstenbarortungstenbar.Beforewelding,bevelanditsbothsideswith50mmshallbecleanedandfreeoil,andchalkpowdershallbesmearedtopreventfromspattersattachingpipe.Afterwelding,picklingshallbeexecutedforweldingjointandpipesurfacenearbyjoint,thenusewaterwashingit,finally,passivationcanbeperformed.Fabricatedpipeshallbemarkedtopreventfromdifferentmaterialspipesintermixed.PipinginstallationAllsupportsshallbefixedpriortoinstallstainlesssteelpiping,othersteelorirontoolsareforbiddentoknockS.S.pipe.FornonmetalgasketusedforS.S.flange,itschlorineioncontentshallbenotover50ppm.S.S.pipeisforbiddentotouchC.S.support;asbestosrubbersheetorrubbersheetshallbeputbetweenpipingandsupport.Pipingthroughwallorfloor,jacketpipeshallcovermainpiping,andanyweldisnotallowableforthemainpipinginsideofjacketpipe.Spacebetweenpipingandjacketpipingshallbenotover10mm,whichshallbefilledwithinsulationmaterial;thematerialgenerallyusesasbestosrope.WeldsurfacecleaningofstainlesssteelpipeAfterS.S.pipewelded,spattersontheweldssurfaceshallbegrindedwithgrinder,thensmearpicklingpasteonit,andbrushthesurfacewithsteelwirebrush,flushitwithwater,tilltheweldssurfaceappearmetalbasebrightcolor.WhenTHEOWNERinspecterconfirmsit,itcanbeaseligible.FRP/PP管的安装InstallationforFRP/PPPiping所有聚丙烯/玻璃钢管的开口必须用塑料护套保护,以防止碰伤或外物进入管中。Allopeningsofpolypropylene/glass-reinforcedplasticpipeshallbeprotectedwithplasticcover,toavoiddamagedorotherarticlesintopipe.存放粘结剂的箱子,应加以保护,避免太阳直晒。Toprotectbondagentbox,inordertoavoidsunlight.调配完成的粘结剂,未使用完必须妥善处理,不要随意抛弃,以免造成污染。Totreatproperlyremainingbondingagent<alreadyprepared>,withoutleaveitinanyplace,toavoidpollution.施工时每一道涂层必须硬化后,方可进行下一道施工。包覆的玻璃布必须完全浸透,两道玻璃布间的纹路必须交叉。Aftereachcoatinghardened,nextprocedurecanbedone,wrappedglassclothshallbesaturatedfully,andlinesbetweentwolayersofglassclothshallbecrossed.所有原料在使用前必须先查验其有效的存放期限,过期则不可使用,如果没有标识,树脂存放超过两个月则不可以使用。环氧树脂则存放不可超过一年,树脂若涂刷不易或已开始胶化,均不可使用。Validdateshallbecheckedbeforeallmaterialused,ifinvalid,materialshallbeuseless,ifnoanymarkidentification,resinstoragebeyond2monthsshallbeuseless.Epoxyresinstoragetimeshallbenotover1year,ifresinbrushingisdifficultorgohardened,itshallbeuseless.在工作接头接合的两个小时前,所有要进行接合包覆的已硬化端口必须彻底且均匀地加以研磨,然后将此端口的氧化物与污物清除干净,加工面必须比欲包覆面积大。Before2hoursthatjointsbonded,allhardenedjoint<needtobewrapped>shallbegrindeduniformlyandentirely,thencleanoutoxideandcontainmentofthisjoint,preparedfaceshallbemorethanwrappedarea.已处理完毕准备包覆的端口表面,若再遭到污染,或超过两个小时沿未进行包覆,则此端口表面须再作研磨加工才能所覆。Forjointwaitingforwrapped,ifpollutionagain,ornotwrappedmorethan2hours,itshallbegrindedagain,thenwrappingit.经过研磨后,将要包覆的端口必须是一个粗糙的表面,在包覆前保持干净且干燥。Aftergrinded,jointtobewrappedshallbecomecoarse,keepitcleananddrybeforewrapping.在接合端口的间隙,必须用树脂填平,以保持表面的平整。Clearancebetweenjointsshallbefilledwithresintokeepflatface.在接头完成包覆后,任何已经过研磨的外露表面均必须加上一层树脂保护。Afterjointwrapped,anyexposedface<alreadygrinded>shallbeprotectedwith1layerofresin.须作多层包覆加强的接头,每层加强材的端缘要互相交错,避免在同一切面上。接头包覆完毕后要等到完全硬化后才能移动。Forjointneedtobestrengthenedwithmulti-layerwrapping,edgeofeverystrengtheningmaterialshallbecrossed,toavoidtheminthesameonetangentplane.Afterwrappedandhardened,theycanbemoved.下料后的管子切断面,必须涂上树脂保护,不可让纤维外露,且任何空隙都要用树脂填满,若端口出现绽开,则视为不合格品,不可使用。Cuttingfaceofpipeneedtobeprotectedwithresin,fibershallbenotexposed,andanygapshallbefilledwithresin,ifendcracked,itcanberegardedasunqualifiedproduct.PP管的施工ConstructionmethodforPPpipingPP管道连接以承插方式为主。SockedtypeisappliedforPPpipingconnection.FRP/PP管连接时,先清除PP管插口处的油脂污物,涂上粘贴胶后再插入承口,承插口外接合面进行电热空气熔化焊接封口,施焊过程中,为防止过热,应不断的摆动焊枪喷嘴,使焊条和焊枪均匀受热,焊条排列均匀,以使焊缝饱满平整无皱纹和凹瘪。WhenconnectingFRP/PPpiping,oil&containmentshallbecleanedforPPpipingfaucet,afteritbondedwithbondingmaterial,itcanbeplacedintofaucet,socketoutsidebondingfaceshallbeclosedinelectricalheatingairfusionweldingway,duringwelding,inordertoavoidpostheating,weldinggunshallbeswungcontinuously,keepweldrodandgun