巴斯夫工艺管道施工方案

目录Contents一、工程概况General 2二、编制依据Reference 3三、施工准备ConstructionPreparation 3四、施工管理ConstructionManagement 4五、管道安装Pipeinstallation 10六、材料管理Materialmanagement 40七、施工进度控制与管理ControlandManagementofConstructionProgress 42八、人力计划ManpowerPlan 42九、机具动员计划Mobilizationplanofequipmentsandtools 44十、安全文明施工Safetyandhousekeeping 45十一、安全分析Safetyanalysis 48

一、工程概况General本工程位于马来西亚关丹吉本工业园的柠檬香精项目。业主方为巴斯夫马来西亚国油化学公司(简称BPC)，管理公司由FLOUR负责，综合专业工程C420区域由中国化学工程马来西亚公司（以下简称“CCEM”）承建。The

project

isBPC

LemongrassProjectwhichislocatedinGebengIndustrialParkofKuantanMalaysia.TheOwneristheBASFPETRONASChemicalsSDNBHD(BPC).OwnerrepresentativeisFLUOR.Multi-disciplinework(AreaC420Citralplant)iscontractedandconstructedbyChinaChemicalEngineering(M)SDNBHD.(HereinafterreferredtoasCCEM)㈠、工程简介Projectdescription 1、本项目地上工艺管道主要由管廊管道和装置区域管道工程组成。管道总长约42.5KM，约22.0万DB，主要材质有碳钢A106-B、A53-B、A312-TP316/316L、A312-TP304/304L、合金钢及非金属管道HDPE等。TheA/Gprocesspipesoftheprojectaremainlyforthepiperackandtheplantarea.Thetotallengthofthepipesisabout42.5km,whichconsistsofabout120,000DBintotal.AndthemajorspecificationsarecarbonsteelA106-B,A53-B,A312-TP316/316L,A312-TP304/304L,Alloyandnon-metalpipe,suchasHDPE,etc.2、管道的主要连接形式有焊接、法兰连接以及螺纹连接和卡套连接等。Themainconnectionwaysforthepipeincludewelding,flangeconnectingandthreadconnectingandjacketconnecting.3、从管道输送的介质及操作温度、压力等级划分为常压及压力管道。Thepipesaredividedintoatmosphericpressurepipeandpressurepipebyservicemedia,operationtemperatureandpressurerating.㈡、工程特点Projectfeaturesandchallenges1、本管道工程材质多样，管径跨度范围大，温度、压力范围广，这给施工方面带来较大难度。Therearevarioustypesofpipematerials,whichhavewiderangeofpipediameters,temperaturesandpressures,bringingmuchdifficultytoconstruction.2、本工程有易燃、有毒介质管线，施工质量要求高，特别对焊接质量更为严格。Theprojecthaspipesservicinginflammableandtoxicmedia,whichdemandshighstandardonconstructionquality,especiallyonweldingquality.3、该工程的设备较多，增加配管难度；阀组、仪表调节元件多且要求配管质量高，增加管道施工的复杂性及难度。Theprojecthaslargeamountofmechanicalequipment,whichmakestubingmoredifficult.Valvesetsandinstrumentshavemanyregulatingelements,whichdemandshighstandardsonpipeworkquality,andmeanwhilemakesitmorecomplicatedanddifficult.4、管道的总DB量较大，走向复杂，管线密集，加大施工工作量；工作任务重，施工人员多，加大管道施工管理工作难度。ThepiperoutesarecomplicatedandconcentratedwithlargeDiameterBorequantity,whichmakesworkquantitymorewhileheavyworkloadandlargeamountofconstructors,andmakespipeconstruction&managementworkmoredifficult.二、编制依据Reference 1、施工设计图纸及技术要求；Constructiondesigndrawingandspecifications&code;2、本项目的施工合同；ProjectConstructionContract3、国际通用标准：InternationalStandardsa．ASMEb．ASTMc．ANSI4、马来西亚香精项目管道工程相关标准和技术文件:RelatedpipingspecificationsofLemongrassProject9355-C400-EPSP-ACC-001REV.0-PipingmaterialspecificationLineClass–processofliftingpiping9355-C400-EMSP-ACC-0022REV.1-Generalmaterialrequirement9355-C400-EMSP-ACC-0004REV.0-pipesupport9355-C400-EMSP-ACC-0009REV.1Specificationforpositivematerialidentification9355-C400-EMSD-ACC-0001REV.0-jackedpipingdetail9355-C400-EMSP-ACC-0014REV.0-shopandfieldfabrication/installationandHandingprocess/utilizingpiping9355-C400-EMSP-ACC-0017REV.0-PipePressureTesting9355-C400-EMSP-ACC-0006REV.1-SpecificationforweldingandNDEforequipment/fieldfabricatedpipingJB-9-017-Rev.0-FieldmaterialmanagementcontrolprocedureJB-15-003-Rev.0-LemongrasssiteNonDestructiveTestExecutionPlanJB-15-004LemongrasswelderTestcenterPlan5、我公司企业标准CompanyStandards压力管道安装《质量手册》（QG/CC-7.PP.0501-00）QualityHandbookforPressurePipeInstallation压力管道安装《质量体系文件》（QG/CC-7.PP.0502-00）QualitySystemDocumentforPressurePipeInstallation压力管道安装《作业指导书》（QG/CC-7.PP.0503-00）WorkGuidebookforPressurePipeInstallation三、施工准备ConstructionPreparation.标准、规范准备PreparationofStandardandSpecification3.1.1.收集管道施工要求的规范、标准。Topreparestandardandspecificationofpipeconstruction3.1.2.收集施工记录和交工资料表格。Toprepareconstructionrecordandhandoverdocument.3.1.3.熟悉业主关于管道施工的特殊要求。Toknowthespecialrequirementofpipeconstruction3.2.技术准备TechnicalPreparation3.2.1.图纸会审Drawingjointreview；管道预制、安装方案的编制与审批MethodstatementcompilationandApprovedforpipefabricationandinstallation；根据管道单线图、平面图、流程图组织技术交底.Technicaldisclosureworkshallbedoneasperpipeisometricdrawing,elevationplanandworkflowchart.3.3.其他Others3.3.1.施工计划编制ConstructionMethodStatementPreparation根据工程实际及工期要求，编制施工计划。Theplanshallbecompiledaspersiteconditionandrequiredconstructionduration.3.3.2.施工人员准备ManpowerPreparation根据现场施工条件，合理组织管道安装人员（人力计划详见附表）；Thepersonnelforpipeinstallationshallbemobilizedsuitablyaccordingtositecondition.(seeattachmentofmanpowerplan)3.3.3.施工机具准备EquipmentandToolsPreparation根据现场施工条件，合理组织管道安装的施工机具（施工机具详见附表）。Theequipmentandtoolsforpipeinstallationshallbemobilizedsuitablyaccordingtositecondition.(Seeattachmentofequipmentandtools)四、施工管理ConstructionManagement4.1.建立健全质量保证体系Toestablishqualityassurancesystem4.1.1.建立以项目经理为第一质量责任人，各专业质量工程师、质检人员为主导的质量控制体系。质量文件的建立和管理要细化到每个环节，分工明确、责任分明。TheprojectmanagerisfirstresponsibilitypersonandeachdisciplineengineerandQA/QCinspectorsareleadingrolesforQA/QCcontrolsystem.4.1.2.建立明确的质量责任制度，质量责任分解到各个岗位、各个环节、各个工种。从制度上落实谁管生产谁管质量，谁施工谁负责质量，谁操作谁保证质量。Toestablishqualitysystemdefined,whichshallbeappliedtoeachposition,eachstepandeachdisciplinetoensurequalitycontrolduringconstruction.4.1.3.积极主动配合业主、管理机构的工作，认真和严格地执行其发出的指令、意见和建议。Toassistandexecutetheinstruction,suggestionandcommentbyOwnerandmanagementagency.4.1.4.对有特殊资格要求的管理人员和操作人员须经资格审查和确认，持证上岗。Formanagementpersonandoperatorwithspecialrequirement,thequalificationcertificatesshallbeexaminedandconfirmed.4.2.压力管道施工质量保证体系QA/QCSystemofPressurePipe防腐保温施工队防腐保温施工队质检责任师工艺责任师焊接责任师设材责任师计量责任师项目质保工程师专业技术人员管道施工队压力管道质量保证体系理化责任师各专业质检员无损检测责任师图（1）图（1）QASystemofPressurePipeQASystemofPressurePipeProjectQAEngineerProjectQAEngineerWeldingprincipleProcessprincipleQualitycheckupWeldingprincipleProcessprincipleQualitycheckupprincipleMeasurementprincipleMeasurementprincipleMaterialprinciplePhysicalandchemicalprincipleNDEprinciplePhysicalandchemicalprincipleNDEprincipleQualityinspectorQualityinspectorDisciplinetechniciansPipingteamsAPipingteamsAnti-corrosionteamSketch1Sketch14.2.1.压力管道安装时，为确保其安装质量其处于受控状态,应建立如图(1)的压力管道安装质量保证体系。Wheninstallingthepressurepipe,QA/QCsystem(seesketch1)ofpressurepipeinstallationshallbesettedforcontrollinginstallationquality.4.2.建立健全安全管理体系Tosetintegralsafetymanagementsystem4.2.1.建立以项目经理为第一安全责任人，专业安全工程师、安全人员为主导的安全控制体系。BuiltaHSEcontrolsystem,whichshallincludeprojectmanagerasafirstresponsibilitypersonandHSEengineerandsupervisoraskeypersons.4.2.2.落实安全责任到施工班组、到施工责任人。Safetyresponsibilityshallbeputintoworkteam/groupandpersonal.4.2.3.现场施工人员必须遵守现场的安全规定，定期进行安全学习与培训。Constructionstuffshallcomplywiththesafetyrequirement,andcarryoutsafetytrainingregularly.4.2.4严格执行各安全制度与操作规程，做到安全、文明、环保施工。Safetysystemandoperationspecificationshallbecarriedoutstrictlyforsafety,healthandenvironmentalprotectionconstruction.4.3工艺管道检验与试验计划Inspectionandtestplanofprocesspipe在工艺管道的施工过程，全方位的质量监督。并极力配合业主、管理公司、监理、质检站对各检查点的监督检查工作；严格执行停检点、必检点的监督检查。在管道施工过程中，应切实重点做好质量监督检查控制工作，以便更好地控制管道施工的质量，执行相关ITP计划。Duringprocesspipeconstruction,WellcooperatedwithBPC/FLOUR,supervisionandrelativegovernmentbureauforsupervisionofeachinspectionpoint.Strictlycomplywithsupervisionandinspectionrequirementsonholdpointandwitnesspoint.Duringpipeconstruction,thefollowingissuesshallbefocusedonforbetterfabricationquality.4.4.工序交接Workprocedurehandover4.4.1.做好各道工序之间的交接工作，确保上道工序不合格的产品严禁进入下道工序。Handoverbetweeneachprocessshallbewellperformedtoensurenounqualifiedproductbeingusedinthenextprocess.4.4.1.1.管件、阀门、管材等工程材料经检验不合格者，禁止用于本工程施工；同时临时管道，管件和阀门材料需要合格。Itisforbiddentousenon-conformingconstructionmaterial,suchaspipefitting,valveandpipematerial,inthisproject；Thetemporarymaterialsshouldbequalifiedtoo.4.4.1.2.管道除锈、防腐检查及管件组对不合格，不得进行焊接工作。Poorfit-uppipefittingscannotbewelded.4.4预制产品安装前，必须经相关的质量检查人员或专业工程师检查，确认合格后，方可用于安装施工。Beforeinstalling,fabricatedproductsmustbeinspectedandapprovedbyrelatedqualityinspectorordisciplineengineer.4.4.1.4预制管段安装前需对管段内部垃圾进行清理，并组织检查，检查合格后才能继续安装。Theinternalwasteofpre-fabricatedspoolsshouldberemovedbeforeinstallationofpre-fabricatedspools,theinspectionwillbeperformed,thepre-fabricatedspoolscanbeinstalledafterpassingtheinspection.4.4.1.5预制管段安装前需对有法兰面的管道进行保护，法兰面安装时需安装临时橡胶垫，避免对法兰水线照成机械损坏。Thepipewithflangefaceshouldbeprotectedbeforeinstallationofpre-fabricatedspools,thetemporaryrubbergasketneedtobeinstalledwhileflangefaceisbeinginstalled,toavoidthemechanicaldamageforflangesealsurface.4.4.2.施工过程必须加强施工班组的自检工作，严格“三检”制度（自检、互检、交接检），确保每道工序产品合格。Duringconstruction,internalinspectionofconstructionteamshallbeimproved.“ThreeInspections”Regulation(internal-inspection,mutual-inspectionandjointinspection)shallbestrictlycompliedtoensureproductsusedineachprocessarequalified.4.5.工艺管道焊接质量保证体系QA/QCsystemforProcesspipewelding4.5.1.现场施焊人员资格审查；Qualificationexaminationforsitewelder4.5.2.焊接工人上岗前，现场实际操作考试；Weldershallpassweldingtestinsitebeforeanywork.4.5.3.焊接过程合格率考核与控制；Testandcontrolofweldingqualificationrate4.5.4.焊接工程师及焊接质量检查人员现场指导、检查；Siteguidanceandinspectionactedbyweldingengineerandweldingqualityinspector.4.6施工技术及资料管理Constructiontechniqueanddocumentcontrol4.6.1.施工过程中必须严格执行相关的规范、标准、要求等。Relatedspecification,standardandrequirementshallbeperformedstrictlyduringconstruction.4.6.2.严格按照我公司质量体系文件运行程序进行施工和管理。Relatedspecifications,standardsandrequirements,etc.shallbestrictlycompliedintheprocessofconstruction.4.6.3.施工图纸管理Managementofconstructiondrawing(IFCdrawing)4.6.3.1.施工前，施工图纸必须经专业工程师审查，并进行图纸会审。IFCdrawingmustbereviewedandjointreviewedbydisciplineengineerbeforeconstruction.4.6.3.2.图纸收发必须进行登记，以便核查。图纸版次更替应做到及时，确保施工图纸一直处于最新版次。对于旧版次应即刻回收，并做好登记保管，做到无遗漏。Drawingissuancestatusshallberecordedforeasycheck.Drawingversionshallbeupdatedtimelytomakesurealwaysusingthelatestversion.Oldversionshallbereturnedbacktimely,recordshallbemadeaswelltoavoidmissingitems4.6.3.3.施工图纸发放前，必须对施工队进行技术交底及图纸答疑。TechnicaldisclosureanddrawingclarificationshallbedonetoconstructionteamsbeforeissuingIFCdrawing.4.6.3.4.图纸设计变更应及时传达到施工队，并及时对图纸进行修改，并及时执行设计变更。Designchangeshallbeinformedtoconstructionteam，drawingshallberevisedtimelyanddesignchangeshallbecompliedtimelyaswell.4.6.4.施工过程记录应做到及时、准确，并签字保存妥当。Constructionprocessrecordsshallbemadetimely,accuratelyandwell-kept.4.6.5为加强质量管理，保证为业主提供合格的工程项目产品，在施工过程管理工作中，使用公司开发的管道施工管理系统软件，跟踪、记录管道的主要施工信息、质量日检信息、无损检验信息等，以便施工人员及时了解相应的质量进度信息，便于质量管理和控制，同时辅助生成主要的交工资料，提高交工的质量。ToimprovequalitymanagementandprovidequalifiedproducttotheOwner,companydevelopedpipeconstructionmanagementsoftwarewillbeusedintheconstructiontotraceandrecordmajorconstructioninformation,dailyqualityinspectioninformation,NDEinformation,etc,whichmakeconstructorknowrelatedqualityprogressinformationwellandeasytomanagementandcontrolquality.Mainhandoverdocumentwillbegeneratedasauxiliaryfunction,whichimproveshandoverqualityaswell.4.7.现场安装管道的标识Pipeidentificationforsiteinstallation4.7.1.管材、管件的追溯检查Traceabilityofpipematerialandpipefitting4.7.1.1材料到预制区域后按管道预制过程标识和出厂标识的要求严格执行，以实现管材鉴定到管道安装的全过程可追溯性。Arrivedatfabricationarea,materialsshallbemarkedasperrequirementsonpipeinstallationprocessandmanufacturetomaketraceabilityofwholeprocessfrompipematerialidentificationtopipeinstallationpossible.4.7..材料使用前，应先确认材质色标是否符合规定。Ensurethematerialcolorsystemappliestotherequirementpriortouse.4.7.1.3.材料分离、分割而使原标识不全时，要进行原标识的移植；Originalidentificationshallberelocatedifmaterialisincompletebyseparatingorcutting.

4.7.2.安装管段的标识Pipespoolidentificationforsiteinstallation

4.7.2.1.管段及焊口的编号和标识工作贯彻管段安装全过程。采用在单线图上标明焊口检验状态，在实物上用记号笔做标识方法进行标注。Serialnumberandidentificationofpipespoolandweldjointshallbemadeduringwholepipespoolinstallationprocess.MarkinspectionstatusofweldjointintheISOdrawing.Markidentificationonspoolbymarkerpen.

4.7.2.2.管端上的焊工号、焊口号及安装管段号不得用打钢印，而采用记号笔（不得含锌、氯离子等对母材有危害的成分）在距焊缝边缘50mm处标注，字迹清晰工整。Welder’sIDnumber,No.ofweldjointandNo.ofinstallationspool,whichareinthepipeend,shallnotbesteelstampedbutbemarkedat50mmawayfromweldjointedgebymarkerpen(freeofzinc,andcholrion,whichisharmfultobasemetal)inavisibleandneatlyway.

.2.3.管段及焊口的标识方法如下：管道标识的责任：焊工代号由焊工填写，质检员代号由质检员检验后填写，其余标识（预制管段号、管段长度或炉批号）均由管工填写。管工和焊工自检合格，且所填内容齐全后，由管工班长或焊工统一向质检员报检，经质检员外观检查合格后报FLOUR检查，由FLOUR点口确定需检测的焊口并在焊缝上用记号笔按照要求作为无损检测的标识（RT、PT等）标识内容见图（2）：Identificationmethodofpipespoolandweldjointasfollows:Responsibilityofpipeidentification:welder’sIDnumberwillbefilledbywelder,qualityinspector’sIDnumberwillbefilledbyqualityinspectorafterinspection,otheridentifications(No.offabricatedpipespool,lengthofpipespoolorheatNo.)willbefilledbypipefitter.Pipefitterandweldershallinspectfabricatedpipeandcompleteidentificationsfirstly,thenpipefitterleaderorwelderleadershallreporttoqualityinspectorforinspection.QualityinspectorwillreportittoFLOURifvisualinspectionisaccepted.WeldjunctionshouldbedeterminedaccordingtoFLOURspotweldjunction,andmarkedNDE(RT,PT,etc.)ontheweldjointbymarkingpenasperrequirements.RefertoSketch(2)fordetailedmark.

DiagramDiagram2PipespoollengthL=No.ofpipespoolFabricatedareaWeldseamSpoolfabricationIdentificationPipematerialISODwgNo.No.ofweldWelder’sIDNo.Welddate五、管道安装Pipeinstallation5.1.施工准备Preparation

5.1.3.3.施工人员准备Manpowermobilization

根据现场施工条件，合理组织管道安装人员（人力计划详见附表）；Pipeinstallationpersonshallbemobilizedaccordingtositeconstructioncondition.(detailedmanpowerplanisattachedasbellow)

5.1.3.4.施工机具准备Equipmentandtoolspreparation

根据现场施工条件，合理组织管道安装的施工机具（施工机具详见附表）。Equipmentandtoolsshallbemobilizedaccordingtositeconstructioncondition.(detailedequipmentandtoolsplanisattachedasbellow)

5.2.管道安装Pipeinstallation

5.2.1.安装流程Workingprocedure

管道施工安装流程如图（图一）Pipeinstallationprocedureisshownassketch1.

安装位置核查Inspectionoflocationforpipeinstallation

管道安装前，检查土建基础、结构、设备管口的尺寸、标高、位置等是否与管道图纸相符。Beforepipeinstallation,inspectdimension,elevation,positionofcivilfoundation,structureandequipmentnozzleaccordingtopipedrawing.

5.2.3.预制管段安装前内部清理检查Checkinginteriorcleaningstatusbeforeinstallingfabricatedspool.

安装前，通过预制记录及预制管线标识找查安装的管线，检查预制管段的管内部清洁度。Beforeinstallation,findthepipelineaccordingtofabricationrecordandpipeidentification,andchecktheinternalclearnessofpipespoolfabricated.

管道安装的一般流程（管道安装的一般流程（图一）管线上仪表元件的拆除试压方案确定试压临时管线安装试压装置准备脚手架搭设进度计划编制人力、机具准备设备、结构验收材料、验收施工前准备按PID图检查按支架安装图检查预热、热处理及其他处理支架和一次部件的安装吊装前管内清洁检查按管道图检查不合格气密试验（泄漏性试验）管道油漆现场组对、安装吹扫方案确定管线检查管道压力试验管线吹扫、冲洗管线复位管线复位检查临时管道安装现场焊接管线整改管道调整段预制安装支架安装管线最终检查方案确定管道伴热管道绝热移交方案确定方案确定方案确定试压包资料审查RT、PT等RT、PT等

PT、RTPT、RTetcPipeinsulationHandoverConfirmationofmethodPipepressuretestandgoldjointInspectionaccordingtoworkflowInspectionaccordingtosupportinstallationdrawingInspectionaccordingtoworkflowAirleakagetestPaintingConfirmationofflushingmethodPipelineinspectionPipelineblastingandflushingPipelinereplacementInspectionofpipereplacementTemporarypipeinstallationPipelinemodifySupportinstallationFinalinspectionConfirmationofmethodElectricheattracingConfirmationofmethodConfirmationofmethodTestPackDocumentCheckRemovalofpipeinstrumentonthepipelinePressuremethodconfirmTemporarypipelineinstallationEquipmentpreparationWorkflowofpipeinstallation(sketch3)materialandacceptancePreparationPipePreheating,heattreatmentorothersBracketandon-lineinstrumentcomponentinstallationPipeinternalcleaningbeforeliftingUnqualifiedFitting-upandinstallationonsiteWeldingonsiteAdjustedpipefabricationandinstallationScaffoldingerectionMakeconstructionplanManpowerandequipmentEquipmentandstructureacceptance

5.2.4.管道安装的允许偏差AllowableDeviationofpipeinstallation

架空及地沟平面坐标：室内允许偏差15mm，室外允许偏差25mm。Coordinateofoverheadlayerandtrench:indoorshallbe15mm,outdoorshallbe25mm.

架空及地沟标高：室内允许偏差±15mm，室外允许偏差±20mm。Elevationofoverheadlayerandtrench:indoorshallbe±15mm,outdoorshallbe±20mm.

水平管道平直度：DN≤100，允许偏差为2L‰，最大50mm。DN＞100，允许偏差为3L‰，最大80mm。Straightnessofhorizontalpipeline:ifDN≤100,allowabledeviationshallbe2L‰,maximumdeviationshallbe50mm.ifDN≤100,allowabledeviationshallbe3L‰,maximumdeviationshallbe50mm.

立管铅垂度：允许偏差为5L‰，最大30mm。Theverticalityofriserpipeline:allowabledeviationshallbe5L‰,maximumallowabledeviationshallbe30mm.

成排管道的间距：允许偏差15mm。Theintervalofpipeinarow:theallowabledeviationshallbe15mm.

交叉管或绝热层间距：允许偏差20mm。Theintervalofcrosspipelineorthermalinsulationlayer:theallowabledeviationshallbe20mm.

5.2.5.管道各类焊缝间距要求intervalspacerequirementofvariousweldjoint

管道各类焊缝间距要求详见（图3）及表二Pleasereferto(sketch3)andform2forintervalspacerequirementofvariousweldjoint

t(mm)t(mm)D(mm)ACDBBBBB管道焊缝间距要求示意图（图3）Sketchforintervalspacerequirementofpipeweldjoint(sketch3)表二(form2)

cipionofWTpe焊缝最小间距（选最大者）MinimumDistanceBetweenWeldToes(whicheverisgreater)A120°oror5t（1）B120°oror5t（2）C100mmor2t（3）D50mmor2tDimensionaltolerancesforfabricatedpiping采用气体乌弧焊和气体金属弧焊预制的焊口错边量不得超过2.4mm(0.8mm)MISALIGNMENTACROSSANYDIAMETERATWELD采用气体乌弧焊和气体金属弧焊预制的焊口错边量不得超过2.4mm(0.8mm)MISALIGNMENTACROSSANYDIAMETERATWELDPREPARATIONSSHALLNOTEXCEED2.4mm(0.8mm)FORGTAW/GMAWWELDS偏离中心线不得超过+/-+/-3.2mmMAXOFFCENTRELINEROTATIONOFFLANGESFROMTHEINDICATEDPOSITIONMEASUREDASSHOWN1.6mmMAXIMUM法兰/100mm直径。MISALIGNMENTACROSSANYDIAMETERATFLANGEFACESSHALLNOTEXCEED0.25mmPER100mmDIAMETER，FORTOLERANCESONBENDPROFILESSEE4滚筒rollor支撑架bracket管架梁beam固定板fixedplate图(4)1000窜管器管线铺设Pipelinelaying

管廊管道铺设Rackpipelaying

A.管廊穿管Pipelaying

滚筒rollor支撑架bracket管架梁beam固定板fixedplate图(4)1000窜管器C.管道牵引Pipetrailing管廊在窜管器上牵引一般采取人工形式或采用倒链牵引。对于同层管道数量大且直径相对较大时，可采用卷扬机牵引，如图（5）。Piperackshallbetrailedbymanualorchainblock.Foralargequantityanddiameterofpipeinthesame,itshallbetrailedbywindlass.Seesketch(5)

窜管器窜管器Pipeconnector卷扬机windlass工艺管道Processpipe图（5）

5.2.6.2.设备间管线铺设与安装Pipelinelayingandinstallationbetweenequipments安装时，首先测量好现场已安装完成的管线连接设备间距离、标高等参数，预制管段。将连接设备两端法兰固定在设备口，螺栓拧紧，数量不得低于4颗。Pipespoolshallbefabricatedaccordingtothedistance,elevationetc.betweenpipeinstalledandequipment.Fixtheflangeontheendofequipment,tighteningthebolt,andshouldbenotlessthan4.

然后采用吊车将预制管段吊装就位，组对，点焊好。LiftPipespoolfabricatedtothecorrectpositionbyhoist,fitupandspotweld。

点焊好后，应采用临时措施加固避免变形（防变形的临时加固件，应在焊接工作彻底完成后才能拆卸）。待焊口根部焊缝完成后，拆卸组对管线，在地面完成剩余的焊接、探伤、试压、清洗等工作，然后复位安装。Afterspotwelding,pipespoolshallbestrengthenedbytemporarymeasurestopreventdeforming(Thetemporarymeasurescan’tberemoveduntilweldingcompletefinish).Afterfinishrootweldingofweldjoint,removethepipespoolfittedup,whichshallbetreatedbywelding,crackdetection,cleaningontheground,andberepositedandinstalledatlast.

5.2.7.管道对口Pipefittingup

5.2.7.1.管道对口连接时，不得用强力进行组对，亦不得通过松或强紧连接螺栓或添加法兰连接垫片来调整组对间隙及管口平直度。Duringfittingupwork,pipecannotbejointedbytheactionofastrongforce,alsonotbeadjustedtheintervalandstraightnessbyflangegasket.

5.2.7.2.管口组对时，应符合图（6）要求.

当管子公称直径小于100mm时，允许偏差值α为1mm；当管子公称直径大于或等于100mm时，允许偏差值α为2mm；但全长的偏差值不得超过10mm。管道坡口加工时，壁厚＜3mm采用I型坡口，壁厚≥3mm采用V型坡口；组对间隙应控制在2~4mm；允许最大错边量为壁厚的10%且不大于2mm。Pipefittingupshallmeettherequirementofsketch(6).Whenthenominaldiameterofpipe<100mm,allowabledeviationvalueαshallbe1mm.Whenthenominaldiameterofpipe≥100mm,allowabledeviationvalueαshallbe2mm,butthewholedeviationshouldnotexceeds10mm.Forthepipefit-up,adoptItypegrooveforthethicknesslessthan3mm,andadoptVtypegrooveforthethickness≥3mm;thespaceofthefit-upshouldbecontrolledwithin2~4mm;permittedmaximumunfitnessvalueis10timesofthewallthicknessbutnotexceed2mm.图（6）Sketch6图（6）Sketch6钢板尺steelruler200α5.2.7.3.作为封闭管段组对时，其首先应根据现场实测的安装长度进行下料加工，其偏差不得超过1.5mm，确保焊口间隙，保障焊接质量。Sealpipespoolshallbefabricatedaspersurveyedinstallationlengthwithallowancenomorethan1.5mm,tokeepaintervalbetweenweldjointswithahighqualityofwelding.

5.2.8.法兰安装Flangeinstallation

5.2.8.1.法兰连接应与管道同心，并确保螺栓自由穿过螺栓孔；Connectedflangeshallbeasamecenterwithpipe.

5.2.8.2.垂直或倾斜法兰面螺栓孔应垂直跨中安装，其连线水平度不得大于1.5mm；水平法兰面螺栓孔安装应跨装置南北或东西方向；Allboltholesofflangeshallstraddleverticalandhorizontalcentrelinesofthepipe.Levelnessshallbenomorethan1.5mm.Flangeboltholesonhorizontalpipeshallstraddlethesitesystemlines,i.e.sitePlantNorth/SouthorPlantEast/West.

5.2.8.3.水平法兰水平度及垂直法兰的铅锤度不得大于法兰外径的1‰，且不得大于2mm。Theverticalityofhorizontalandverticalflangeshallbenomorethanouterdiameter1‰(2mm).

5.2.8.4.当法兰采取螺纹连接时，管端应低于法兰密封面1.5mm.Iftreadedconnectionisusedtoflanges,theendofpipeshallbelowerthanthesealingface1.5mm.

5.2.8.5.不得用强紧螺栓的方法或松螺栓方法来消除歪斜。同时，不得加偏垫或多层垫等方法来消除法兰接口端面的间隙、偏斜、错口或不同心等缺陷。Itisnotallowedtotightenorlooseboltforadjusttiltedsurfaceofbolt,meanwhilenotallowedtoaddpartialpadorcushionstoeliminatedefectsofclearance,deviations,mismatchanddisalignment.

5.2.8.6.动设备法兰口最终连接时，必须在联轴器上架设百分表监视动设备的位移。

当动设备额定转速大于6000r/min时，其位移值应小于0.02mm；当额定转速小于或等于6000r/min时，其位移值应小于0.05mm。Flangeconnectionofrotaryequipmentmustbetestedwithdialgauge.installingthedialindicatoroncouplertomonitorequipment'sdislocation.Whenratedspeedismorethan6000r/min,thedislocationvalueshouldbelessthan0.02mm,whenratedspeedisnotmorethan6000r/min,it'sdislocationvalueshouldbelessthan0.05mm.

5.2.9.垫片安装Gasketinstallation

5.2.9.1.垫片安装前，应按图确认其型号规格是否满足设计要求。法兰安装前，应检查法兰密封面及密封垫片，不得有影响密封性能的径向划痕、斑点、破损、皱折等缺陷。同时，配对法兰环槽密封面与金属环垫还应作接触线检查，当金属环垫在密封面上转动45°检查接触线不得有间断现象。Beforegasketinstallation,thetypeandspecificationshallbeconfirmedtomeettherequirementofdesign.Beforeflangeinstallation,checkthesealingfaceandsealinggasketwhichfreeofscratch,stain,damagedandwrinkledetc..Contactinglinecheckbetweenflangeringsealfaceandmetalringgasketshallbedoneinthemannerthatnodiscontinuouslineexistingwhenrotatemetalringgasketfor45°.

5.2.9.2.安装时，必须确保垫片安装位置应在法兰密封面中心，1个密封面只安装1块垫片，禁止安装多层垫。Duringgasketinstallation,gasketmustbeplacedinthecenterofflangesurface,only1piecegasketcanbeusedforflangesurfaceinsteadofmulti-piece.

阀门安装Valveinstallation

5.2.10.1.阀门安装前应检查阀门的规格型号是否与设计一致，并检查填料其压盖螺栓应留有调节余量。Thetypeandspecificationofvalveshallbecheckedformeetingtherequirementofdesign,asuitablespaceshallberemainedbetweenglandboltandfillingmaterial.

5.2.10.2.当阀门与管道以法兰或螺纹方式连接时，阀门应以关闭状态安装。当阀门与管道以焊接方式连接时，必须将阀芯打开焊接；承插焊阀门安装时，应确保管段光滑，并与阀门内凸台留出1-1.5mm间隙。Whenvalveisconnectedtopipebythreading,itshallbeinclosedstatus.Whenvalveisconnectedtopipebywelding,itshallbeinopenedstatus.Whenvalveisinstalledbysocketwelding,pipespoolshallbesmoothandkeepadistanceof1-1.5mmwithvalveboss.

5.2.10.3.水平管线闸阀安装时，应水平斜45°以上范围，以图纸为基准，以避免阀芯因重力而脱落或发生故障。Forhorizontalpipelinegatevalveinstallation,whichshallbeanangleof45degreetopreventvalvecoredropofforgowrongduetogravity.

5.2.10.4.如无特殊要求，对于截止阀应按阀体标识方向安装，低进高出的原则。Globevalveshallbeinstalledaccordingtodirectionofinstructiononthevalvebody,baseontheprincipleoflowtohigh.

5.2.10.5.对止回阀安装方向，阀体标识方向必须与工艺管道流向一致。Forinstallationdirectionofcheckvalve,thedirectionofinstructiononthevalvebodymustaccordwithflowdirectionofprocesspipeline.

5.2.10.6.安全阀的安装应符合以下规定：Safetyvalveinstallationshallcomplywithregulationisshownasbellow.

A.安全阀应垂直安装；Safetyvalveshallbeinstalledvertically.

B.管道投入运行前，安全阀必须经具有资质的专业机构进行调校，安全阀经最终调校合格后，应进行铅封并作好相应的资料；Beforepipelineusing,safetyvalveshallberegulatedbyqualifiedorganization,andthenbesealedwithlead.Makerelevantdocument.

5.2.10.7.调节阀、流量计安装，必须在其两端增设临时盲板，以防止异物进入阀体内，其安装方向应按阀体标识方向与介质流向保持一致。孔板、流量计前后直管段的长度应符合图纸和规范要求。孔板、连接流量计的法兰内壁焊缝必须打磨平整。Forcontrolvalveandflowmeterinstallation,theblankplateshallbesetontheendsofthemtopreventforeignmatterformentering.Thedirectionofinstallationshallbethesamewithflowdirectionofprocesspipeinaccordwithvalvebodysign.Thestraightpipelengthconnectingtheorificeandflowmetershouldapplywiththerequirementofthedrawingandspecification.Theinnerwallofflangefortheorificeandflowmetermustbegroundflatly.

5.2.10.8.取样阀安装，其位置应符合图纸，且便于操作。Thelocationofsamplevalveshallmeetthedrawingandbeeasytowork.

5.2.10.9.对于球阀、蝶阀等，一般无方向要求，为便于检修，安装时应按阀体标识进行安装。Forballvalveandbutterflyvalveinstallation,whichshallbeinstalledaccordingtovalvebodysign,shallbeeasytomaintainandrepair,andnorequirementofdirection.

5.2.10.10.所有的阀门安装时，必须确保操作方便、安全可靠。所有碳钢阀门丝杆在阀门安装必须涂抹好油脂进行保护。Allvalveinstallationmustbesafetyandeasytooperation.Oilgreaseshallbeusedforprotectcarbonsteelvalverod.

5.2.11.螺栓安装Boltinstallation

5.2.11.1.法兰连接螺栓应使用同一规格，安装方向一致。螺栓紧固后应与法兰紧贴，不得有楔缝。需安装垫圈时，每颗螺栓不得超过1只。紧固后，螺栓应与螺母保持齐平或1～2个螺距。为拆卸方便，一般地应使用双头螺栓。Thesametypeboltshallbeuseforflangeconnection,andkeepthesameinstallationdirection.Tightenboltandkeepclosetoflange,freeofinterval.Whengasketisinstalled,thereshallbenotmorethan1piece.Afterbolttightening,thedistanceof0-5mmshallbekeptfrombolttonutinordertotaketheboltdowneasily.Threadedstudshallbeusedingeneral.5.2.11.2.所有不锈钢螺栓、合金钢螺栓安装时，必须涂抹二硫化钼油脂，以防止紧固过程中发生过烧，致使螺栓不能拆卸；所有露天装置和用于设计温度高于100℃或低于0℃的碳钢螺栓安装时，必须涂抹黄油。Wheninstallingstainlesssteelbolt,alloysteelbolts,Molybdenumdisulfidegreaseshallbecoveredtoavoidboltistoohot,whichaffecttheboltremoval,Fordeviceinopenair,andcarbonsteelboltinstallation,whichthedesigntempratureismorethan100℃o