目錄ITEMTOC\o"1-3"\h\zHYPERLINK\l"_Toc57366414"一、工程概況Generalsituationofplant.2HYPERLINK\l"_Toc57366415"二、編制依據(jù)Datafororganizing2HYPERLINK\l"_Toc57366416"1、中國(guó)石化蘭州設(shè)計(jì)院資料BaseonLDIdocuments2HYPERLINK\l"_Toc57366417"2、上海SECCO有關(guān)技術(shù)文件ShanghaiSECCOrelatedtechnicaldocuments2HYPERLINK\l"_Toc57366418"3、中國(guó)石化第五建設(shè)公司有關(guān)資料文件BaseonFCCdocuments2HYPERLINK\l"_Toc57366419"4、施工方案編制所依據(jù)的標(biāo)準(zhǔn)、規(guī)范的名稱及編號(hào)Nameandcodeofstandards3HYPERLINK\l"_Toc57366420"三、施工部署Constructiondispose3HYPERLINK\l"_Toc57366421"四、管道施工、檢驗(yàn)程序programofpipingconstructionchecking4HYPERLINK\l"_Toc57366422"五、施工進(jìn)度計(jì)劃Constructionscheduleplan6HYPERLINK\l"_Toc57366423"六、施工技術(shù)及要求Constructiontechniqueandrequirement7HYPERLINK\l"_Toc57366424"1、管子、管件及閥門(mén)的檢驗(yàn)Examinationofpipe,pipingfittingsandvalve7HYPERLINK\l"_Toc57366425"2、配管材料的保管及發(fā)放Storageanddistributionofpipingmaterial9HYPERLINK\l"_Toc57366426"3、管道加工Pipingfabrication10HYPERLINK\l"_Toc57366427"4、管道組對(duì)要求combinationrequirements11HYPERLINK\l"_Toc57366428"5、管道預(yù)制和安裝Pipingprefabricationanderection11HYPERLINK\l"_Toc57366429"6、管道焊接及熱處理Pipingweldingandheattreatment14HYPERLINK\l"_Toc57366430"7、管道系統(tǒng)試驗(yàn)、吹洗與氣密Testandblowingofpipingsystem20HYPERLINK\l"_Toc57366431"七、施工機(jī)具、措施用料及人力資源配置ConstructionMachine、measurematerialAndpower23HYPERLINK\l"_Toc57366432"1、施工機(jī)械和用具Constructionmachineandtools23HYPERLINK\l"_Toc57366433"2、措施用料measurematerial25HYPERLINK\l"_Toc57366434"3、人力資源的配制Distributionofmanpowerresource25HYPERLINK\l"_Toc57366435"八、冬、雨季施工技術(shù)措施Technicalmeasuresinwinterandrainyseasons；26HYPERLINK\l"_Toc57366436"九、工程質(zhì)量保證措施projectqualityassurancemeasure28HYPERLINK\l"_Toc57366437"1、質(zhì)量保證體系的組成Conpositionofqualityassurancesystem28HYPERLINK\l"_Toc57366438"2、材料質(zhì)量保證措施materialqualityassurancemeasure30HYPERLINK\l"_Toc57366439"3、施工質(zhì)量保證措施constructionmeasuresofqualityassurance.30HYPERLINK\l"_Toc57366440"十、工程安全保證措施31HYPERLINK\l"_Toc57366441"1、項(xiàng)目HSE保證體系ProjectHSEassurancesystem31HYPERLINK\l"_Toc57366442"2、安全施工措施Constructionsafetymeasures32HYPERLINK\l"_Toc57366443"3、施工作業(yè)危險(xiǎn)性分析Dangeranalyzingofconstruction33HYPERLINK\l"_Toc57366444"十一、施工平面示意圖Sketchmapofconstructionplane35一、工程概況Generalsituationofplant.賽科90萬(wàn)噸／年乙烯工程26萬(wàn)噸／年丙烯腈裝置，由SECCO投資興建，中國(guó)石化集團(tuán)蘭州設(shè)計(jì)院是EPC總承包，安裝部分由中國(guó)石化第五建設(shè)公司負(fù)責(zé)施工。該裝置包括丙烯腈單元、稀硫銨液濃縮單元、乙腈精制單元及界區(qū)內(nèi)公用工程部分等四部分組成。工藝管道共約94259米（延長(zhǎng)米），其中材質(zhì)為：碳鋼管(20＃)，焊接鋼管(Q235B)，不銹鋼管(304、304L、316及316L)，鉻鉬鋼管(15CrMo)等。各類閥門(mén)共有8614個(gè)，工作量比較大，且本裝置內(nèi)大多數(shù)管道的物料為劇毒介質(zhì)，因此施工質(zhì)量要求很高，故施工時(shí)必須嚴(yán)格執(zhí)行本方案。具體工作量如下表所示：Thereareabout94259mpipinglinesincludingcarbonsteel(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.Workscopecanseefollowing:序號(hào)No.名稱namee材質(zhì)materiall單位unit數(shù)量amount備注remark1無(wú)縫鋼管Seammlesssteellpipee20#m72531.24452鉻鉬鋼管Welddingssteelpipe15CrMo/115CrMooRm293.3其中15CrMoR管管55.7米3不銹鋼管Staiinlessspipee304/304SSS/3044L/316Lm21433.4994各類閥門(mén)Valvve個(gè)8614合計(jì)totalm94258.0335二、編制依據(jù)Datafororganizing1、中國(guó)石化蘭州設(shè)計(jì)院資料BaseonLDIdocuments1.1中國(guó)石化蘭州設(shè)計(jì)院《上海賽科26萬(wàn)噸／年丙烯腈裝置基礎(chǔ)設(shè)計(jì)》0184－00000－00026LonghopDesignInstituteofSINOPEC《ShanghaiSECCO260,000t/yANPlantFoundationEngineering》1.2工藝管道施工圖紙processpipingconstructiondrawing2、上海SECCO有關(guān)技術(shù)文件ShanghaiSECCOrelatedtechnicaldocuments2.1工程質(zhì)量管理規(guī)定PR-00-CIJ-QU-0001SpecificationforConstructionqualitymanagement2.2IPMT施工管理細(xì)則PR-00-CIJ-CN-0001PMTConstructionManagementDetailRules2.3管道工程施工質(zhì)量管理工作細(xì)則PR-00-CIJ-PP-0001Pipingconstructionqualitymanagementdetailrules2.4施工質(zhì)量規(guī)則PR-00-CIJ-QU-0002Constructionqualityrules2.5上海賽科90萬(wàn)噸/年乙烯工程單位工程劃分規(guī)則PR-00-CIJ-QU-00032.6現(xiàn)場(chǎng)條件與現(xiàn)場(chǎng)管理PR-00-CIJ-CN-0002SiteConditionsandSiteManagement2.7無(wú)損探傷和檢測(cè)實(shí)施管理辦法PH-00-CIJ-IN-0001ManagementmethodofNDTinspection3、中國(guó)石化第五建設(shè)公司有關(guān)資料文件BaseonFCCdocuments3.1中國(guó)石化第五建設(shè)公司《質(zhì)量手冊(cè)》FCC《QualityManual》3.2中國(guó)石化第五建設(shè)公司《質(zhì)量體系程序文件》TheFifthConstructionCompanyofSINOPEC《QualitySystemProcedureDocuments》3.3中國(guó)石化第五建設(shè)公司企業(yè)管理標(biāo)準(zhǔn)FCCEnterpriseManagementStandard3.4中國(guó)石化第五建設(shè)公司《HSE體系程序文件》FCC《HSESystemProcedureDocuments》4、施工方案編制所依據(jù)的標(biāo)準(zhǔn)、規(guī)范的名稱及編號(hào)Nameandcodeofstandards4.1《工業(yè)金屬管道工程施工及驗(yàn)收規(guī)范》GB50235-97《CodeforConstructionandAcceptanceofIndustrialMetalPipingWork》4.2《石油化工劇毒、可燃介質(zhì)管道工程施工及驗(yàn)收規(guī)范》SH3501-2002《CodeforConstructionandAcceptanceofPetrochemicalPoisonousandCombustibleMediaPipingWork》4.3《石油化工鋼制管道工程施工工藝標(biāo)準(zhǔn)》SH/T3517-2001《StandardforConstructionTechnologyofPetrochemicalSteelPipingWork》4.4《現(xiàn)場(chǎng)設(shè)備、工業(yè)管道焊接工程施工及驗(yàn)收規(guī)范》GB50236-98《CodeforConstructionandAcceptanceofFieldEquipmentandIndustrialPipingWeldingEngineering》4.5《石油化工異種鋼焊接規(guī)程》SH3526-92《WeldingSpecificationofPetrochemicalSteelofSpecialKinds》4.6《石油化工工程鉻鉬耐熱鋼管道焊接技術(shù)規(guī)程》SHJ520-91《TechnicalSpecificationforWeldingofPetrochemicalEngineeringHeat-resistingCrMoSteelPiping》4.7《石油化工工程高溫管道焊接規(guī)程》SH3523-92《WeldingSpecificationforPetrochemicalEngineeringHighTemperaturePiping》4.8《石油化工設(shè)備和管道涂料防腐蝕技術(shù)規(guī)范》SH30022-99《TechnicalCodeforPetrochemicalEquipmentandPipingAnticorrosionwithCoatings》4.9《石油化工工程建設(shè)交工技術(shù)文件規(guī)定》SH3503-2001《RegulationsforTechnicalAs-builtDocumentsofPetrochemicalEngineeringConstruction》5.0SECCO標(biāo)準(zhǔn)SECCO’sstandards說(shuō)明Note：當(dāng)在項(xiàng)目執(zhí)行過(guò)程中，中國(guó)政府法規(guī)、SECCO項(xiàng)目規(guī)定及標(biāo)準(zhǔn)、規(guī)范間有矛盾時(shí)，執(zhí)行的順序應(yīng)當(dāng)是：中國(guó)政府法規(guī)、SECCO項(xiàng)目規(guī)定、標(biāo)準(zhǔn)和規(guī)范要求。方案內(nèi)容中英文間有矛盾時(shí)，以中文為主。Duringtheprojectexecution,incaseofanyconflictbetweenChinesegovernmentallawsandregulations,SECCO’sprojectspecification,andcodes,thefollowingsequenceisfollowed：Chinesegovernmentallawsandregulations,SECCO’sprojectspecification,standardsandcodes.IfthedifferencebetweenChineseandEnglishcontentinprogramisbeing,Chinesecontentwillbegood.三、施工部署Constructiondispose根據(jù)目前現(xiàn)場(chǎng)實(shí)際情況，40、50和80單元施工圖紙已到位，但材料剛訂貨；界區(qū)管廊框架（除伸向20單元反應(yīng)區(qū)的管廊框架受大件吊裝影響未施工外）已基本安裝完畢，管廊管道材料已到貨，但施工圖紙還沒(méi)出來(lái)。介于以上圖紙和現(xiàn)場(chǎng)施工的具體情況，我們準(zhǔn)備工藝管道施工以管廊管道敷設(shè)為龍頭，緊接著根據(jù)材料的到貨情況，40、50和80單元管道施工逐步展開(kāi)，等這幾個(gè)單元施工末期，其它單元的圖紙和材料等已準(zhǔn)備就緒，管道施工就開(kāi)始全面輻射安裝。Accordingtothepracticeonsite,theconstructiondrawingfor40、50andunithavebeencompleted,butthematerialwasorderedjustnow.thepipegalleryframeofANareahavebeencompletedbasically(exceptthatthepipegalleryextendingtothe20unitreactareaisnotconstructionbecauseofbigliftingaffection)andthematerialissite,butthedesigneddrawingisnotcompleted.Astheabovepractices,wepreparetostartfromlayingpipegallerypiping,andthengraduallyperformtowork40、50and80unitpipinginaccordancewiththematerialonsite.bytheconstructionendoftheaboveseveralunitsthedrawingandmaterialforotherunitshavealreadybeenprepared,thepipingconstructionwouldstartoninstallationfully.四、管道施工、檢驗(yàn)程序programofpipingconstructionchecking編號(hào)編號(hào)施工項(xiàng)目3.2閥門(mén)試驗(yàn)編號(hào)施工項(xiàng)目5.2標(biāo)準(zhǔn)支架彎管制作編號(hào)施工項(xiàng)目6.2焊縫返修編號(hào)施工項(xiàng)目8.2焊縫熱處理檢查C檢查B檢查B檢查C檢查C檢查A檢查A檢查B編號(hào)施工項(xiàng)目2.2技術(shù)交底檢查B編號(hào)施工項(xiàng)目7.2支吊架安裝編號(hào)施工項(xiàng)目9.2氣密試驗(yàn)編號(hào)施工項(xiàng)目1.1開(kāi)工準(zhǔn)備11編號(hào)施工項(xiàng)目2.1工方案編制21編號(hào)施工項(xiàng)目3.1材料檢驗(yàn)31編號(hào)施工項(xiàng)目4.1管道內(nèi)部清潔度檢查（針對(duì)SHA級(jí)管道）41編號(hào)施工項(xiàng)目5.1管道預(yù)制51編號(hào)施工項(xiàng)目6.1無(wú)損檢測(cè)61編號(hào)施工項(xiàng)目7.1管道安裝71編號(hào)施工項(xiàng)目8.1完整性檢查確認(rèn)81編號(hào)施工項(xiàng)目9.1系統(tǒng)試驗(yàn)（強(qiáng)度/嚴(yán)密性）91編號(hào)施工項(xiàng)目10.1吹洗101編號(hào)施工項(xiàng)目11.1質(zhì)量評(píng)定111注：檢查Ａ指由施工單位、監(jiān)理單位、總包代表共同檢查；Note：CheckingAmeanscheckingbyconstructionparty,supervisingparty,andowner;檢查B指由施工單位、監(jiān)理單位共同檢查；CheckingBmeanscheckingbyconstructionside,supervisingside;檢查C指由施工單位技術(shù)人員、檢查人員共同檢查。CheckingCmeanscheckingbytechnicalpersonnel/inspectorofconstructionside.ItemItemNoProject3.2valvetestingItemNoProject5.2pipebracketprefabricateItemNoProject6.2weldinglinereturnItemNoProject8.2weldinglineSR檢查C檢查B檢查B檢查C檢查C檢查A檢查A檢查BItemNoProject2.2technicalexplanation檢查BItemNoProject7.2pipebracketinstallationItemNoProject9.2tightnesstestItemNoProject1.1startworkprepar11ItemNoProject2.1methodstatement21ItemNoProject3.1pipingcheckup31ItemNoProject4.1insidecleancheckofpiping(SHA)41ItemNoProject5.1pipeprefabricate51ItemNoProject6.1NDT61ItemNoProject7.1pipeinstallation71ItemNoProject8.1flowcheck81ItemNoProject9.1systemtesting91ItemNoProject10.1waterwashing101ItemNoProject11.1QCassess111五、施工進(jìn)度計(jì)劃Constructionscheduleplan六、施工技術(shù)及要求Constructiontechniqueandrequirement1、管子、管件及閥門(mén)的檢驗(yàn)Examinationofpipe,pipingfittingsandvalve1.1檢驗(yàn)一般要求Generalrequirementsofexam..管子、管件、閥門(mén)等材料必須具有制造廠的質(zhì)量證明文件。無(wú)質(zhì)量證明文件的產(chǎn)品不得使用。Pipeetc.materialshallbeprovidedwithqualitycertificateofmanufacture.Producthavingnothecertificatecan’tbeadopted.產(chǎn)品在入庫(kù)前，應(yīng)對(duì)質(zhì)量證明文件進(jìn)行審查，并與實(shí)物核對(duì)。若到貨的管道組成件實(shí)物標(biāo)識(shí)不清或與質(zhì)量證明文件不符或?qū)Ξa(chǎn)品質(zhì)量證明文件中的特性數(shù)據(jù)或檢驗(yàn)結(jié)果有異議，供貨方應(yīng)按相應(yīng)標(biāo)準(zhǔn)作驗(yàn)證性檢驗(yàn)或追溯到產(chǎn)品制造單位。異議未解決前，該批產(chǎn)品不得使用。Certificateofqualificationofproductsshallbecheckedbeforecomeintostoreroom.Ifmarksoftheconstituentelementsareunclear,ornotconformtocertificateofqualification,orthereisobjectionaboutperformancedataorinspectionresultincertificateofqualification,theSuppliershallcarryoutexperimentalverificationbaseduponrelatedstandardortrackbacktothemanufacture.Beforesettlementofobjection,theproductscan’tbeused.輸送毒性程度為極度危害和高度危害介質(zhì)管子的質(zhì)量證明文件中應(yīng)有超聲波檢測(cè)結(jié)果，否則應(yīng)按GB5777的規(guī)定，逐根進(jìn)行檢驗(yàn)。Ultrasonicdetectionresultforpipeconveyingutmosthazardorhighhazardmediumshallbewrittenincertificateofqualification;otherwise,eachpipeshallbedetectedaccordingtoGB5777.管子、管件、閥門(mén)在使用前按設(shè)計(jì)要求核對(duì)其規(guī)格、材質(zhì)、型號(hào)和定購(gòu)單代號(hào)。Beforeuseofpipeetc.,size,material,orderNo.shallbecheckedaccordingtodesign.管子、管件、閥門(mén)在使用前進(jìn)行外觀檢查，其表面要求如下：Beforeuseofpipeetc.,appearanceshallbecheckedandrequirementsarefollows：1）無(wú)裂紋、縮孔、夾渣、折迭、重皮等缺陷；Nosuchdefaultsascrack,hole,slugetc.;2）沒(méi)有超過(guò)壁厚負(fù)偏差的銹蝕及凹陷；Norustandhollowwhichexceedminuswarpofwallthickness.3）合金鋼管道及管道組件應(yīng)有材質(zhì)標(biāo)記，并采用光譜分析復(fù)驗(yàn)其關(guān)鍵合金成份，對(duì)于外觀檢查有懷疑的應(yīng)取樣進(jìn)行化學(xué)成份的復(fù)驗(yàn)。Alloysteelpipeanditsassemblyshallbemarkedandcheckedtheirkeyalloysteel.Foruncertainappearanceexam.,theirchemicalcomponentsshallbechecked.SHA級(jí)管道中，設(shè)計(jì)壓力小于10MPa的輸送極度危害介質(zhì)（苯除外）的管子，每批（指同批號(hào)、同爐罐號(hào)、同材質(zhì)、同規(guī)格）應(yīng)抽5%且不少于一根，按（SHA級(jí)管道中，設(shè)計(jì)壓力等于或大于10MPa管子，外表面應(yīng)按下列方法逐根進(jìn)行無(wú)損檢測(cè)，檢測(cè)方法和缺陷評(píng)定應(yīng)符合JB4730的規(guī)定，檢驗(yàn)結(jié)果以I級(jí)為合格。非導(dǎo)磁性鋼管，應(yīng)采用滲透檢測(cè)。）規(guī)定的方法和評(píng)定標(biāo)準(zhǔn)進(jìn)行外表面磁粉檢測(cè)或滲透檢測(cè)，檢驗(yàn)結(jié)果以II級(jí)為合格。Exteriorsurfacemagnetic-particleinspectionorpenetrationtestshallbedonefor5%(atleastonepiece)ofeachbatch(ofthesamelotnumber,stovenumber,materialandspecification)ofpipesconveyingutmosthazardmedium(exceptbenzene)withdesignpressurelessthan10MPaaccordingtomethodsandcriteriafor（Nondestructivetestshallbedoneforsurfaceofeachpipewhosedesignpressure≧10MPaamongSHAlevelpipelines.TestmethodsandevaluationofdefectshallmeetspecificationsofJB4730.GradeⅠwillbequalified.Penetrationtestshallbedoneformagneticimpermeablesteelpipe.）.GradeⅡwillbequalified.SHA級(jí)管道中，凡按規(guī)定作抽樣檢查或檢驗(yàn)的樣品中，若有一件不合格，必須按原規(guī)定數(shù)加倍抽檢，若仍有不合格，則該批管道組成件不得使用，并應(yīng)作好標(biāo)識(shí)和隔離。Ifoneofsamplesisunqualifiedduringsamplinginspection,certainamount(specifiedintheSpecification)ofproductsshallbeinspected.Iftherestillisunqualifiedproduct,thebatchofproductscan’tbeused.Andtheyshallbemarkedandseparatedwithotherproducts.SHA級(jí)管道中，管子經(jīng)磁粉檢測(cè)或滲透檢測(cè)發(fā)現(xiàn)的表面缺陷允許修磨，修磨后的實(shí)際壁厚不得小于管子公稱壁厚的90%，且不得小于設(shè)計(jì)文件規(guī)定的最小壁厚。Surfacedefectfoundbymagnetic-particleinspectionorpenetrationtestcanbegrinded.Butthewallthicknessaftergrindingcan’tbelessthan90%ofnominalthicknessofthepipeandmin.thicknessspecifiedindesigndocument.SHA級(jí)管道及管件應(yīng)在到貨管道上用油漆書(shū)寫(xiě)“SHA級(jí)”字樣，其它的管道及管件標(biāo)識(shí)見(jiàn)LDI標(biāo)識(shí)規(guī)定。TheclassSHApipingandpipingfittingsshallmakeouttheclassSHAsamplewithpaintonpiping,themarksofotherpipingandfittingseethesignspecification.1.2閥門(mén)檢驗(yàn)、試驗(yàn)Testofvalve1）閥門(mén)必須具有出廠合格證和制造廠的銘牌，銘牌上應(yīng)注明公稱壓力，公稱通徑，工作溫度和工作介質(zhì)。Qualitycertificateandnameplateofvalveshallbeprovidedandmarkednominalpressure/dia./worktemperature/medium.2）鑄件應(yīng)表面平整光滑、無(wú)縮孔、毛刺、粘砂、夾砂及裂紋等缺陷。Castsshallbeofflatandsmoothsurface,withoutanydefaultssuchasholes,burr,sand,cracketc.3）鍛制加工表面應(yīng)無(wú)夾層、重皮、裂紋、斑疤、缺肩等缺陷。Machinedsurfaceofforgingsshallbefreefromsuchdefaultsasinterlayer,crack,spot,lackofshoulderetc..4）閥門(mén)的手柄或手輪操作應(yīng)靈活輕便，開(kāi)閉時(shí)不得有卡塞現(xiàn)象，閥桿的全開(kāi)和全閉位置應(yīng)相符合，主要零件不得有嚴(yán)重缺陷。Handleorwheelofvalveshallbeagileandnoclipinopeningandclosing.Fullopeningandclosingpositionshallbeidentical.Itsmainpartsshallbenoseveredefaults.5）用于SHA級(jí)管道的通用閥門(mén)，其焊縫或閥體、閥蓋的鑄鋼件，應(yīng)有符合SH3064規(guī)定的無(wú)損檢測(cè)合格證明書(shū)。Certificateofqualification(meetSH3064)fornondestructivetestofweldjointandsteelcastingofbodyandcoverofuniversalvalveforSHAlevelpipelineshallbeprovided.6）裝置所用閥門(mén)100％進(jìn)行強(qiáng)度和嚴(yán)密性試驗(yàn)。Thevalveforinstallationshallbeexamined100%.7）閥門(mén)的強(qiáng)度和嚴(yán)密性試驗(yàn)應(yīng)用潔凈水進(jìn)行。Pressureandtightnesstestsofvalveshallbeperformedusingcleanwater.8）閥門(mén)的強(qiáng)度試驗(yàn)壓力為公稱壓力的1.5倍，試驗(yàn)時(shí)間不少于5分鐘，以殼體、填料無(wú)滲漏為合格。Intensitytestpressureshallbe1.5timesofnominalpressure,testtimeisnolessthan5min..Noleakageofbodyandfillingisqualified.9）除蝶閥、止回閥、底閥、節(jié)流閥外，嚴(yán)密性試驗(yàn)一般按公稱壓力進(jìn)行。在能夠確定工作壓力時(shí)，也可以用1.25倍的工作壓力進(jìn)行，以閥瓣密封面不漏為合格。Forvalveexceptbutterflyvalve,checkvalve,bottomvalve,throttle,tightnesstestshallbecarriedouttonominalpressure.Inensuringworkingpressure,alsobe1.25workingpressure.Certificatestandardisnoleakageofpetal..10）對(duì)焊閥門(mén)的嚴(yán)密性試驗(yàn)應(yīng)單獨(dú)進(jìn)行，強(qiáng)度試驗(yàn)一般可在系統(tǒng)試驗(yàn)時(shí)進(jìn)行。Forbutter-weldingvalve,tightnesstestshallbecarriedoutsolelyanditspressuretestshallbecarriedoutinsystemtest.11）嚴(yán)密性試驗(yàn)不合格的閥門(mén)，須解體檢查，并重新試驗(yàn)。Fornotqualifiedvalveoftightness,itshallbedisassembledandclosedandtestedagain.13）合金鋼閥門(mén)應(yīng)逐個(gè)對(duì)閥體進(jìn)行光譜分析，合金鋼及高壓閥門(mén)每批取10％且不少于一個(gè)進(jìn)行解體檢查內(nèi)部零件，如有不合格則需逐個(gè)檢查。Foralloysteelvalve,itshallbeopticalanalysis.Alloysteelvalveandhighpressurevalveshallbedisassembled10%perbatchandnotlessthanone,andonebyoneifthereisnotdisqualified.14）試驗(yàn)合格的閥門(mén)，應(yīng)及時(shí)排凈內(nèi)部積水。密封面應(yīng)涂防銹油（需脫脂除外），關(guān)閉閥門(mén)，封閉出入口，并填寫(xiě)試驗(yàn)記錄，如有不合格則需逐個(gè)檢查，試驗(yàn)合格的閥門(mén)在閥體上按LDI標(biāo)示規(guī)定做出標(biāo)識(shí)。Forqualifiedvalve,innerwatershallbeejectedintime.Sealingfaceshallbepaintedantirustoil(exceptvalveneededdegreasing)andvalveshallbeclosed,whilemouthshallbeclosed.Testingreportshallbefilledin.Fornotqualifiedvalve,thevalvespassingtestmakeoutthesignonvalvebodyasperthespecificationofLDImark..15）閥門(mén)的傳動(dòng)裝置和操作機(jī)構(gòu)應(yīng)進(jìn)行檢查。要求動(dòng)作靈活可靠，無(wú)卡澀現(xiàn)象。Gearingandoperatingunitshallbecheckedandtheyshallbeagileandnoclick.16）安全閥在安裝前應(yīng)按設(shè)計(jì)要求進(jìn)行調(diào)試。其調(diào)試要求如下：Safetyvalveshallbedebuggedbeforeconstructionaccordingtodesign.Requirementsarefollowing：（1）調(diào)試安全閥要求制作專用胎具，并保證胎具的清潔，防止胎具內(nèi)的贓物進(jìn)入安全閥密封口。Specialtoolshallbeusedindebuggingsafetyvalve.Thereshallbecleanintool.（2）除設(shè)計(jì)有特殊要求外,介質(zhì)為氣體的安全閥調(diào)試介質(zhì)采用氮?dú)?，介質(zhì)為液體的安全閥調(diào)試介質(zhì)為新鮮水。Safetyvalvewhosemediumisgasshallbeusednitrogenandliquidcleanwater（3）安全閥的起跳次數(shù)不得少于3次。Jumpingtimeofsafetyvalveshallnotbelessthan3.（4）安全閥調(diào)試必須在甲方代表／監(jiān)理代表的監(jiān)督下進(jìn)行。Debuggingshallbecarriedoutinsupervisoryofrepresentativeofowner/supervisingrepresentative.（5）安全閥經(jīng)最終調(diào)校合格后，應(yīng)做鉛封，并填寫(xiě)“安全閥最終調(diào)試記錄”Havingpassedthefinaladjustment,thevalveshallbesealedbylead,andthe“RecordsOnTheFinalAdjustmentofSafetyValve”shallbefilled.17）閥門(mén)檢驗(yàn)或安全閥調(diào)試時(shí)，甲方代表在現(xiàn)場(chǎng)共同確認(rèn)。Intestingofvalveanddebuggingofsafetyvalve,representativeofownershallbeaffirmedinsite.18）具有上密封結(jié)構(gòu)的閥門(mén)，應(yīng)逐個(gè)對(duì)上密封進(jìn)行試驗(yàn)，試驗(yàn)壓力為公稱壓力的1.1倍。試驗(yàn)時(shí)應(yīng)關(guān)閉上密封面，并松開(kāi)填料壓蓋，停壓4min，無(wú)滲漏為合格。Ifthevalvehasuppersealstructure,eachuppersealshallbetested.Uppersealfaceshallbeclosedandcoveroffillershallbeloosened.Maintainthetestpressureat1.1timesofnominalpressurefor4min.Ifthevalveisnotleaky,itisqualified.1.3管件的檢驗(yàn)Testingofpipingpiece管件外表面應(yīng)有制造廠代號(hào)（商標(biāo)）、規(guī)格、材料牌號(hào)和批號(hào)等標(biāo)識(shí)，并與質(zhì)量證明文件相符，否則不得使用。Exteriorsurfaceofelementsshallhavecodename(trademark),specificationandbrandandlotnumberofmaterialthatareconformtocertificateofqualification.Otherwise,itcan’tbeused.1)管件的表面不得有有裂紋，外觀觀應(yīng)光滑、無(wú)無(wú)氧化皮，表表面的其他缺缺陷不得超過(guò)過(guò)產(chǎn)品標(biāo)準(zhǔn)規(guī)規(guī)定的允許深深度。坡口、螺螺紋加工精度度應(yīng)符合產(chǎn)品品標(biāo)準(zhǔn)的要求求。焊接管件件的焊縫應(yīng)成成形良好，且且與母材圓滑滑過(guò)渡，不得得有裂紋、未未熔合、未焊焊透、咬邊等等缺陷。Surfaceofellementtsshaallbeesmooothwiithouttcracckanddscalle.Ottherddefecttsonsurfaacecaan’texcceedtthepeermisssibledepthhspeccifieddinpproducctstaandardd.Worrkingaccurracytthreaddandgroovveatendsshallmeettherrequirrementtsinproduuctsttandarrd.Weeldjoointoofpippesshhallbbesmooothaandweelljooinwiiththhepippe.Thheresshallbenoocracck,sttick-ooutweeld,faulltyfuusionanduunderccut.2)彎頭、異徑徑管、三通、法法蘭、補(bǔ)償器器及緊固件須須檢查其尺寸寸、材質(zhì)、型型號(hào)及識(shí)別號(hào)號(hào)，高壓管件件及緊固件驗(yàn)驗(yàn)收后應(yīng)填寫(xiě)寫(xiě)記錄。Elbow,reduccer,fflangee,commpensaatoraandfiixersshallbechheckeddtheiirsizze,maateriaal,maarker,,andreporrtshaallbeefillledinnafteeraccceptannceoffhighhpresssurepipinngpieeceanndfixxer.3)法蘭密封面面應(yīng)平整光潔潔，不得有毛毛刺及徑向溝溝槽，法蘭螺螺紋部分應(yīng)完完整，無(wú)損傷傷。凸凹面應(yīng)應(yīng)能自動(dòng)嵌合合，凸面的高高度不得低于于凹槽的深度度。Valveseealinggfaceeshalllbeflatandcclean,,nobburraandraadialgroovve.Sccrewsshallbefuull,nnodammage.Conveexheiightsshallnotbbelesssthaangrooove.4)墊片不能有有徑向劃痕、松松散、翹曲等等缺陷。密封封墊片應(yīng)按產(chǎn)產(chǎn)品標(biāo)準(zhǔn)進(jìn)行行抽樣檢查驗(yàn)驗(yàn)收，每批不不得少于一件件。纏繞墊片片不得有松散散、翹曲現(xiàn)象象，表面不得得有影響密封封性能的傷痕痕、空隙、凹凹凸不平及銹銹斑等缺陷。Gasketsshallbefrreefrromraadialtracee,rellax,wwarpeetc..SSampliinginnspecttion((atleeastoonepiiecepperbaatch)ofgaasketsealshalllbeccarrieedouttaccoordinggtottheprroducttstanndard..Thegaskeetcann’tbelooseeorwwarpedd.Theereshhallbbenoscar,,gap,,sag,cresstanddrusttystaainthhatmaayimppactssealinngproopertyyonssurfacce.5)彈簧支吊架架應(yīng)有合格證證及數(shù)據(jù)書(shū)。Certificateanddatamanualshallbeprovidedforspringsupport.6）螺栓、螺母的螺螺紋應(yīng)完整，無(wú)無(wú)劃痕、毛刺刺等缺陷，加加工精度符合合產(chǎn)品標(biāo)準(zhǔn)的的要求。螺栓栓、螺母應(yīng)配配合良好，無(wú)無(wú)松動(dòng)或卡澀澀現(xiàn)象。Threadsofbooltanndnuttshalllbecomplletewwithouutscrratchorbuurr.WWorkinngacccuracyyshalllmeeettheeprodductsstandaard.BBoltaandnuutshaallfiitwittheacchothherwiithouttloosseorlock2、配管材料的保管管及發(fā)放Storaageannddisstribuutionofpiipingmaterrial2.1材料的保管管Storrage1）進(jìn)庫(kù)的管子、管管件應(yīng)根據(jù)材材料清單，按按材料編碼及及部件號(hào)存放放，核對(duì)材質(zhì)質(zhì)、尺寸、色色標(biāo)、型號(hào)及及其它識(shí)別號(hào)號(hào)，進(jìn)行驗(yàn)收收并分類擺放放。Pipe,piipingpieceebesstoreddshalllbestoriiedacccordiingcoodeanndcheeckinggsizeeetc...2)管材要放置在支架架或臨時(shí)支墩墩上，各種材材質(zhì)鋼管要分分開(kāi)擺放，并并明顯標(biāo)識(shí)。Pipinggmateerialshalllbepplaceddonssupporrtanddplaccedacccordiingtoomateerialandmmarkedd.3)凡有保護(hù)油的碳鋼鋼管子，按需需要清洗，并并根據(jù)清洗要要求檢查合格格后方可入庫(kù)庫(kù)。Topippehavvingpprotecctingoil,itshhallbbecleeanedandsstorieedaftterchheckinng.4)管件應(yīng)按材質(zhì)、種種類、等級(jí)、規(guī)規(guī)格分類放置置在貨架上，裝裝卸時(shí)應(yīng)避免免碰撞，以防防擦傷或損傷傷管件。Pipingpieceeshalllbeplaceedonsuppoortacccordiingtoomateerial,,sizeeandavoiddedcoollisiion.2.2材料的發(fā)放放Disstribuutionofmaateriaal1)通過(guò)“材料限額卡”發(fā)放放材料。Materiialshhallbbedisstribuutededdaccoordinggtoggeneraalmatteriallrequuisitiionliist.2)校對(duì)所提取材料的的規(guī)格、型號(hào)號(hào)、材質(zhì)及材材料編碼，無(wú)無(wú)誤后給予發(fā)發(fā)料，并做好好標(biāo)記的核對(duì)對(duì)和移植工作作。Distriibutioonshaallbeecarrriedooutaffterccheckiingsiize,ttypeeetc.aandchheckinngofmarkeeranddremaarkinggshalllbecarriiedouut.3）管道及材料發(fā)放放管理辦法Managgementtstanndardofmaateriaaldisstribuution（1）在整個(gè)工程中，技技術(shù)人員按各各自分管單元元的管線號(hào)（管管線號(hào)與其軸軸測(cè)圖及材料料相對(duì)應(yīng)）填填寫(xiě)“材料限額卡卡”。Inthewwholeprojeect,thhetecchniciianfiillinnthematerrialllimitaationcardaspeerpippeNo..manaagedbbyeacchonee(corrrespoondeaachottherbbetweeentheepipeeNo.andiitsaxxisdrrawinggandmaterrial).（2）“材料限額卡”可手手寫(xiě)或用計(jì)算算機(jī)打印，一一式四份，專專業(yè)工程師、計(jì)計(jì)劃員、保管管員各存一份份，分公司領(lǐng)料員拿一份作為為領(lǐng)料依據(jù)，保保管員見(jiàn)其余余三人簽字后后的“材料限額卡卡”才能依卡發(fā)發(fā)料。Themateeriallimittationncarddfillledinnbyhhandwrritinggorpprinteedouttbyccomputter,haavethhesimmilarfourpieceekepttsepaaratellybyspeciialenngineeer,plaanner、keepeeranddmateerialpersoonnelfromsub-ccompanny.theekeeppercaangivvematteriallafteerseeeingootherthreeeperssons’signnatureeinmmateriialliimitattionccard.(3)管道支吊架架材料由各分分公司依圖做做材料預(yù)算，直直接領(lǐng)用。Supporrtmatteriallwilllberreceivvedacccordiingtoobudggetoffdrawwings..(4)對(duì)因設(shè)計(jì)變變更和誤操作作造成的材料料增補(bǔ)，由工工藝工程師簽簽發(fā)增補(bǔ)材料料領(lǐng)用單，保保管員見(jiàn)簽字字后的增補(bǔ)材材料領(lǐng)用單才才能發(fā)料。設(shè)設(shè)計(jì)變更部分分的材料預(yù)算算由各項(xiàng)目組組做。Formatteriallsuppplemenntofchanggeddeesignandffaultyyoperrationn,keeepingpersoonshaallprrovideethematerrialiinseeeingtthemaateriaaldraawinglistissueedbypipinngenggineerr.(5)安全閥、調(diào)調(diào)節(jié)閥等特殊殊閥門(mén)按施工工進(jìn)度要求適適時(shí)發(fā)放，并并造冊(cè)登記。登登記時(shí)必須顯顯示其應(yīng)用部部位（單線圖圖號(hào)）及領(lǐng)用用人。Safetyyvalvve,reegulattingvvalveshalllbepproviddedinntimeeandregissteredd.Possitionnanddraweershaallbeeshowwed.3、管道加工Piipingfabriicatioon3.1管道清理Cleaaning管道預(yù)制前對(duì)每根根管子內(nèi)部必必須進(jìn)行清理理，具體措施施按下列要求求進(jìn)行。Clearancceofinnerrpipeeshalllbecarriiedouutbefforeffabriccationn,anddmeassuresareffollowwing;1）公稱通徑大于或或等于6000mm的管道道，宜進(jìn)入管管內(nèi)人工清掃掃或擦拭；Forpippingwwhosenominnaldiiameteerismorethanoreqqualtto6000mm,clearranceshalllbeccarrieedouttbyiinnerclearrancemanuaally.2）公稱通徑2000～550mmm的管道，可可用弧形板夾夾破布拖掃，或或?qū)⒐茏又绷⒘ⅲ瑫r(shí)以木木錘敲打管壁壁，使管內(nèi)的的鐵銹及污物物徹底清理出出來(lái)；Forpippingwwhosenominnaldiiameteeris200~5550mmm,clooutcllampeddbyaarcpllatewwillbbeuseed;errectinngpippeanddknocckedbbywooodhammmer.3）公稱通徑50～～200mmm的管道，可可用綁有破布布、毛刷或鋼鋼絲刷的鐵絲絲在管內(nèi)反復(fù)復(fù)拖拉，直至至干凈；Forpiipingwhoseenomiinalddiametteriss50~2200mmm,cloout,bbrushclamppedbyywireecanbeussed.4）公稱通徑小于550mm的管管道，宜用壓壓縮空氣吹凈凈；Forpiipingwhoseenomiinalddiametterisslesssthann50mmm,coompresssedaairwiillbeeusedd;3.2管道的切割割Cuttiing1)管道加工開(kāi)始時(shí)，管管工必須吃透透圖紙，確定定管子、管件件材質(zhì)，核對(duì)對(duì)好尺寸，開(kāi)開(kāi)始下料。Beforefabriicatioon,piipingfabriicatioonperrsonsshallensurrematteriall,sizzeetcc..2)鍍鋅管和直徑小于于等于2"的中低壓碳碳鋼管，應(yīng)用用機(jī)械方法切切割。Galvaniizingpipeandmmediumm/lowpresssureccarbonnsteeelleeethann2",mecchaniccalmeethodwillbeussed.3)不銹鋼管應(yīng)用機(jī)械械或等離子方方法切割，用用砂輪片切割割或修磨時(shí)，砂砂輪片應(yīng)專項(xiàng)項(xiàng)專用，嚴(yán)禁禁不銹鋼與碳碳鋼打磨交叉叉使用，禁止止用火焰切割割和電弧切割割。Mechannicalorpllasmamethoodwilllbeusedincuuttinggstaiinlessssteeelpippe.Grrindinngwheeelshhallbbespeecialanduusedfforcaarbonsteellpipeeandstainnlesssteellpipeesepparateely.FFlameandaarccuuttinggarenotaalloweed.4)管子切割后切口表表面應(yīng)平整，不不得有裂紋、重重皮、毛刺、凸凸凹、縮口。熔熔渣、氧化鐵鐵、鐵屑應(yīng)予予以清除干凈凈。Cutttingssurfacceshaallbeeflatt,witthoutcrackk,burrr,coontracctedmmouth..Slugg,ferrricooxide,,slaggshalllbecleannedouut.3.3管道開(kāi)孔Openninghhole1)開(kāi)孔應(yīng)在管管段未成型前前或相互組對(duì)對(duì)之前進(jìn)行，以以便除凈由于于開(kāi)孔而落入入管內(nèi)的切削削物和熔渣等等。Holeopeeningshalllbeccarrieedouttbefoorecoombinaation,,whicchwilllgettrideeofccuttinngconntentandsslagbbecausseofopeniing.2)在管線上開(kāi)開(kāi)大于1"孔時(shí)，碳鋼鋼用氧－乙炔炔焰，不銹鋼鋼用等離子或或氬弧切割開(kāi)開(kāi)孔，開(kāi)孔后后必須將熱影影響區(qū)磨去22mm。Whenopeeningholemorethan1",oxyygen-eethineearcwillbeussedtoocarbbonstteelaandpllasmatosttainleessstteel.Heatinfluuenceddzoneeshalllbegotteenriddeof2mm.3)在管線上開(kāi)開(kāi)小于等于1"孔時(shí)，必須須采用機(jī)械鉆鉆眼。Whenopeeningholelessthan1",mecchaniccalmeethodshalllbeuused.4)管道開(kāi)孔應(yīng)應(yīng)盡量在管道道預(yù)制時(shí)進(jìn)行行，如果在安安裝后開(kāi)孔，開(kāi)開(kāi)孔后必須及及時(shí)將管內(nèi)雜雜物用空氣吹吹掃干凈或用用布拖凈。Openingshalllbeccarrieedouttinffabriccationn.Ifopeniingafftereerectiion,ssundriiesinnpipeeshalllbeblownncleaan.4、管道組對(duì)要求combbinatiionreequireementss1）管子組對(duì)前檢查坡坡口的質(zhì)量、尺尺寸、角度應(yīng)應(yīng)符合要求，內(nèi)內(nèi)外表面不得得有裂紋、夾夾渣、污垢及及鐵銹等缺陷陷。Sloppeshaallbeechecckedfforquualityy,sizze,anndnocrackk,slaag,ruust.2）組對(duì)前應(yīng)用手工或或機(jī)械清理坡坡口內(nèi)外表面面，在20mmm范圍內(nèi)不不得有油漆、銹銹、毛刺等污污物，其方法法碳鋼可用角角向磨光機(jī)、鋼鋼銼等，不銹銹鋼可用不銹銹鋼絲刷等。Manualoormecchaniccalmeethodshalllbeuusediincleearinggsurffaceoofsloope.Thereearenopaaint,rust,,burrr.Griindinggmachhineoorfillingttoolwwillbbeuseedtocarboonsteeelanndstaainlessssteeelbrrushttostaainlessssteeel.3）對(duì)于焊接管要注注意縱向焊縫縫并標(biāo)出，以以便與開(kāi)孔位位置錯(cuò)開(kāi)，相相鄰兩管縱焊焊縫應(yīng)相隔180°，有可能的的地方焊縫最最小間距1550mm。Longituddinalseamshalllbemmarkeddandnearseamssshalllbeatadistaanceoof1880°,leaastdiistancceshaallbee150mmpoossiblly.5、管道預(yù)制和安裝裝Pippingpprefabbricattionaanderrectioon5.1管道預(yù)制Pipiingprrefabrricatiion1)為了滿足施施工進(jìn)度的要要求，減少現(xiàn)現(xiàn)場(chǎng)的工作量量，所以要充充分提高工廠廠預(yù)制的深度度。Inorderrtossatisffyconnstrucctionprogrress,reducceworrkinsite,,itsshallimproovepprefabbricattionddepth..2)管道預(yù)制應(yīng)應(yīng)考慮運(yùn)輸和和安裝的方便便，并留有調(diào)調(diào)整活口，對(duì)對(duì)已就位的設(shè)設(shè)備，有必要要實(shí)測(cè)時(shí)，應(yīng)應(yīng)先實(shí)測(cè)后預(yù)預(yù)制。Transporrtatioonandderecctionshalllbecconsidderedtopiipingprefaabricaation..Setttingeendshhallbbeleaaved.Toseettleddequiipmentt,preefabriicatioonshaallbeecarrriedooutafftermmeasurringiindemmandinngmeaasurinng.3)管道預(yù)制加工工應(yīng)按現(xiàn)場(chǎng)審審查確認(rèn)的設(shè)設(shè)計(jì)單線圖或或依據(jù)管道平平、剖面圖繪繪制的單線圖圖進(jìn)行，預(yù)制制加工圖上應(yīng)應(yīng)標(biāo)注管線編編號(hào)、現(xiàn)場(chǎng)組組焊位置和調(diào)調(diào)節(jié)裕量。Prefabriicatioonofpipellinesshallbecaarrieddoutaccorrdingtodeesigneedsinnglellineddiagraam,orrsinggleliinediiagrammdrawwnbassedupponpllaneaandseectionnofppipeliinethhatarreappproveddonssite.Numbeerofpipelline,posittionoofganngwelldingandoovermeeasureeshalllbeindiccatedinthheworrkingdiagrram.4)管道預(yù)制過(guò)程程中的每一道道工序，均應(yīng)應(yīng)核對(duì)管子的的標(biāo)識(shí)，并做做好標(biāo)識(shí)的移移植。不銹鋼鋼管道、低溫溫鋼管道，不不得使用鋼印印作標(biāo)識(shí)。Duringeeachssequennceoffpreffabriccationn,marrksoffpipeelineshalllbeccheckeed.Trransfeerofmarkssshalllbedonewell..Steeelmarrkcann’tbeusedforsstainllessssteelpipeandllowteemperaaturesteellpipee.5)管道預(yù)制時(shí)時(shí)自由段和封封閉段的加工工尺寸允許偏偏差應(yīng)符合規(guī)規(guī)定。Freesecctionandcclosinngsecctionshalllhaveepresscribeedsizzealllowancce.6)預(yù)制管道組組合件應(yīng)具有有足夠的剛性性，否則應(yīng)有有臨時(shí)加固措措施，必要時(shí)時(shí)應(yīng)標(biāo)出吊裝裝索具捆綁點(diǎn)點(diǎn)的位置，擺擺放要注意支支撐好，不得得產(chǎn)生永久變變形。Combinattionoofpieecessshallhaveadequuaterrigidiity,ootherwiseitshhallbbereiinforcced.PPuttinngshaallbeegooddandavoiddpermmanenttdisttortioonmomment.7)彎管制作后后，彎管處的的最小壁厚不不得小于管子子公稱壁厚的的90%，且不得小小于設(shè)計(jì)文件件規(guī)定的最小小壁厚。彎管管處的最大外外徑與最小外外徑之差，應(yīng)應(yīng)符合下列規(guī)規(guī)定：Afterfaabricaationofellbowppipe,min.wallthickknessatellbowccan’