巴斯夫工藝管道施工方案

目錄Contents

一、工程概況General....................................................................................................2

二、編制依據(jù)Reference................................................................................................3

三、施工準(zhǔn)備ConstructionPreparation.........................................................................3

四、施工管理ConstructionManagement........................................................................4

五、管道安裝Pipeinstallation.......................................................................................10

六、材料管理Materialmanagement..............................................................................39

七、施工進(jìn)度控制與管理ControlandManagementofConstructionProgress............41

八、人力計(jì)劃ManpowerPlan........................................................................................42

九、機(jī)具動(dòng)員計(jì)戈IMobilizationplanofequipmentsandtools......................................43

十、安全文明施工Safetyandhousekeeping................................................................44

H—、安全分析Safetyanalysis.....................................................................................47

一、工程概況General

本工程位于馬來西亞關(guān)丹吉本工業(yè)園的檸檬香精項(xiàng)目。業(yè)主方為巴斯夫馬來西亞國油化學(xué)公

司(簡稱BPC),管理公司由FLOUR負(fù)責(zé)，綜合專業(yè)工程C420區(qū)域由中國化學(xué)工程馬來西亞公司

(以下簡稱“CCEM")承建。

TheprojectisBPCLemongrassProjectwhichislocatedinGebengIndustrialParkof

KuantanMalaysia.TheOwneristheBASFPETRONASChemicalsSDNBHD(BPC).Owner

representativeisFLUOR.Multi-disciplinework(AreaC420Citralplant)iscontractedand

constructedbyChinaChemicalEngineering(M)SDNBHD.(HereinafterreferredtoasCCEM)

㈠、工程簡介Projectdescription

1、本項(xiàng)目地上工藝管道主要由管廊管道和裝置區(qū)域管道工程組成。管道總長約42.5KM,約

22.0萬DB,主要材質(zhì)有碳鋼A材6-B、A53?B、A312-TP316/316L,A312-TP304/304L、合金鋼

及非金屬管道HDPE等。

TheA/Gprocesspipesoftheprojectaremainlyforthepiperackandtheplantarea.The

totallengthofthepipesisabout42.5km,whichconsistsofabout120,000DBintotal.Andthe

majorspecificationsarecarbonsteelA106-B,A53-B,A312-TP316/316L,A312-TP304/304L,

Alloyandnon-metalpipe,suchasHDPE,etc.

2、管道的主要連接形式有焊接、法蘭連接以及螺紋連接和卡套連接等。

Themainconnectionwaysforthepipeincludewelding,flangeconnectingandthread

connectingandjacketconnecting.

3、從管道輸送的介質(zhì)及操作溫度、壓力等級劃分為常壓及壓力管道。

Thepipesaredividedintoatmosphericpressurepipeandpressurepipebyservicemedia,

operationtemperatureandpressurerating.

㈡、工程特點(diǎn)Projectfeaturesandchallenges

1、本管道工程材質(zhì)多樣，管徑跨度范圍大，溫度、壓力范圍廣，這給施工方面帶來較大難度。

Therearevarioustypesofpipematerials,whichhavewiderangeofpipediameters,

temperaturesandpressures,bringingmuchdifficultytoconstruction.

2、本工程有易燃、有毒介質(zhì)管線，施工質(zhì)量要求高，特別對焊接質(zhì)量更為嚴(yán)格。

Theprojecthaspipesservicinginflammableandtoxicmedia,whichdemandshigh

standardonconstructionquality,especiallyonweldingquality.

3、該工程的設(shè)備較多，增加配管難度；閥組、儀表調(diào)節(jié)元件多且要求配管質(zhì)量高，增加管道

施工的復(fù)雜性及難度。

Theprojecthaslargeamountofmechanicalequipment,whichmakestubingmoredifficult.

Valvesetsandinstrumentshavemanyregulatingelements,whichdemandshighstandardson

pipeworkquality,andmeanwhilemakesitmorecomplicatedanddifficult.

4、管道的總DB量較大，走向復(fù)雜，管線密集，加大施工工作量；工作任務(wù)重，施工人員多，

加大管道施工管理工作難度。

ThepiperoutesarecomplicatedandconcentratedwithlargeDiameterBorequantity,which

makesworkquantitymorewhileheavyworkloadandlargeamountofconstructors,andmakes

pipeconstruction&managementworkmoredifficult.

二、編制依據(jù)Reference

1、施工設(shè)計(jì)圖紙及技術(shù)要求；

Constructiondesigndrawingandspecifications&code;

2、本項(xiàng)目的施工合同；

ProjectConstructionContract

3、國際通用標(biāo)準(zhǔn)：

InternationalStandards

a.ASMEb.ASTMc.ANSI

4、馬來西亞香精項(xiàng)目管道工程相關(guān)標(biāo)準(zhǔn)和技術(shù)文件：

RelatedpipingspecificationsofLemongrassProject

9355-C400-EPSP-ACC-001REV.O-PipingmaterialspecificationLineClass-processof

liftingpiping

9355-C400-EMSP-ACC-0022REV.1-Generalmaterialrequirement

9355-C400-EMSP-ACC-0004REV.O-pipesupport

9355-C400-EMSP-ACC-0009REV.1Specificationforpositivematerialidentification

9355-C400-EMSD-ACC-0001REV.O-jackedpipingdetail

9355-C400-EMSP-ACC-0014REV.O-shopandfieldfabrication/installationand

Handingprocess/utilizingpiping

9355-C400-EMSP-ACC-0017REV.O-PipePressureTesting

9355-C400-EMSP-ACC-0006REV.1-SpecificationforweldingandNDEfor

equipment/fieldfabricatedpiping

JB-9-O17-Rev.O-Fieldmaterialmanagementcontrolprocedure

JB-15-003-Rev.0-LemongrasssiteNonDestructiveTestExecutionPlan

JB-15-004LemongrasswelderTestcenterPlan

5、我公司企業(yè)標(biāo)準(zhǔn)

CompanyStandards

a.壓力管道安裝《質(zhì)量手冊》(QG/CC?7.PP.0501?00)

QualityHandbookforPressurePipeInstallation

b.壓力管道安裝《質(zhì)量體系文件》(QG/CC?7.PP.0502?00)

QualitySystemDocumentforPressurePipeInstallation

c.壓力管道安裝《作業(yè)指導(dǎo)書》(QG/CC?7.PP.0503?00)

WorkGuidebookforPressurePipeInstallation

三、施工準(zhǔn)備ConstructionPreparation

3.1.標(biāo)準(zhǔn)、規(guī)范準(zhǔn)備PreparationofStandardandSpecification

3.1.1,收集管道施工要求的規(guī)范、標(biāo)準(zhǔn)。Topreparestandardandspecificationofpipe

construction

3.12收集施工記錄和交工資料表格。Toprepareconstructionrecordandhandoverdocument.

3.1.3.熟悉業(yè)主關(guān)于管道施工的特殊要求。Toknowthespecialrequirementofpipeconstruction

32技術(shù)準(zhǔn)備TechnicalPreparation

3.2.1.圖紙會(huì)審Drawingjointreview；

322管道預(yù)制、安裝方案的編制與審批

MethodstatementcompilationandApprovedforpipefabricationandinstallation；

3.2.3根據(jù)管道單線圖、平面圖、流程圖組織技術(shù)交底.Technicaldisclosureworkshallbedoneas

perpipeisometricdrawing,elevationplanandworkflowchart.

3.3.其他Others

3.3.1.施工計(jì)劃編制ConstructionMethodStatementPreparation

根據(jù)工程實(shí)際及工期要求，編制施工計(jì)劃°Theplanshallbecompiledaspersitecondition

andrequiredconstructionduration.

3.32施工人員準(zhǔn)備ManpowerPreparation

根據(jù)現(xiàn)場施工條件，合理組織管道安裝人員(人力計(jì)劃詳見附表)；Thepersonnelforpipe

installationshallbemobilizedsuitablyaccordingtositecondition,(seeattachmentofmanpower

plan)

3.3.3.施工機(jī)具準(zhǔn)備EquipmentandToolsPreparation

根據(jù)現(xiàn)場施工條件，合理組織管道安裝的施工機(jī)具(施工機(jī)具詳見附表)。Theequipmentand

toolsforpipeinstallationshallbemobilizedsuitablyaccordingtositecondition.(Seeattachment

ofequipmentandtools)

四、施工管理ConstructionManagement

4.1.建立健全質(zhì)量保證體系Toestablishqualityassurancesystem

4.1.1.建立以項(xiàng)目經(jīng)理為第一質(zhì)量責(zé)任人，各專業(yè)質(zhì)量工程師、質(zhì)檢人員為主導(dǎo)的質(zhì)量控制體系。

質(zhì)量文件的建立和管理要細(xì)化到每個(gè)環(huán)節(jié)，分工明確、責(zé)任分明。

TheprojectmanagerisfirstresponsibilitypersonandeachdisciplineengineerandQA/QC

inspectorsareleadingrolesforQA/QCcontrolsystem.

4.1.2.建立明確的質(zhì)量責(zé)任制度，質(zhì)量責(zé)任分解到各個(gè)崗位、各個(gè)環(huán)節(jié)、各個(gè)工種。從制度上落實(shí)

誰管生產(chǎn)誰管質(zhì)量，誰施工誰負(fù)責(zé)質(zhì)量，誰操作誰保證質(zhì)量。

Toestablishqualitysystemdefined,whichshallbeappliedtoeachposition,eachstepand

eachdisciplinetoensurequalitycontrolduringconstruction.

4.1.3.積極主動(dòng)配合業(yè)主、管理機(jī)構(gòu)的工作，認(rèn)真和嚴(yán)格地執(zhí)行其發(fā)出的指令、意見和建議。

Toassistandexecutetheinstruction,suggestionandcommentbyOwnerand

managementagency.

4.1.4.對有特殊資格要求的管理人員和操作人員須經(jīng)資格審查和確認(rèn)，持證上崗。

Formanagementpersonandoperatorwithspecialrequirement,thequalification

certificatesshallbeexaminedandconfirmed.

42壓力管道施工質(zhì)量保證體系QA/QCSystemofPressurePipe

壓駛朝量艇盧4

項(xiàng)目質(zhì)保工程師

各

專

業(yè)

質(zhì)

檢

員

圖（1）

QASystemofPressurePipe

ProjectQAEngineer

PW

rle

cod

eni

sg

prp

iri

ncn

ici

plp

ele

Sketch1

4.2.1.壓力管道安裝時(shí)，為確保其安裝質(zhì)量其處于受控狀態(tài)，應(yīng)建立如圖(1)的壓力管道安裝質(zhì)量保

證體系。

Wheninstallingthepressurepipe,QA/QCsystem(seesketch1)ofpressurepipe

installationshallbesettedforcontrollinginstallationquality.

4.2.建立健全安全管理體系Tosetintegralsafetymanagementsystem

421,建立以項(xiàng)目經(jīng)理為第安全責(zé)任人，專、業(yè)安全工程師、安全人員為主導(dǎo)的安全控制體系。

BuiltaHSEcontrolsystem,whichshallincludeprojectmanagerasafirstresponsibility

personandHSEengineerandsupervisoraskeypersons.

422.落實(shí)安全責(zé)任到施工班組、到施工責(zé)任人。

Safetyresponsibilityshallbeputintoworkteam/groupandpersonal.

4.2.3.現(xiàn)場施工人員必須遵守現(xiàn)場的安全規(guī)定，定期進(jìn)行安全學(xué)習(xí)與培訓(xùn)。

Constructionstuffshallcomplywiththesafetyrequirement,andcarryoutsafetytraining

regularly.

4.2.4嚴(yán)格執(zhí)行各安全制度與操作規(guī)程，做到安全、文明、環(huán)保施工。

Safetysystemandoperationspecificationshallbecarriedoutstrictlyforsafety,healthand

environmentalprotectionconstruction.

4.3工藝管道檢驗(yàn)與試驗(yàn)計(jì)劃Inspectionandtestplanofprocesspipe

在工藝管道的施工過程，全方位的質(zhì)量監(jiān)督。并極力配合業(yè)主、管理公司、監(jiān)理、質(zhì)檢站對

各檢查點(diǎn)的監(jiān)督檢查工作；嚴(yán)格執(zhí)行停檢點(diǎn)、必檢點(diǎn)的監(jiān)督檢查。在管道施工過程中，應(yīng)切實(shí)重

點(diǎn)做好質(zhì)量監(jiān)督檢查控制工作，以便更好地控制管道施工的質(zhì)量，執(zhí)行相關(guān)ITP計(jì)劃。During

processpipeconstruction,WellcooperatedwithBPC/FLOUR,supervisionandrelative

governmentbureauforsupervisionofeachinspectionpoint.Strictlycomplywithsupervisionand

inspectionrequirementsonholdpointandwitnesspoint.Duringpipeconstruction,thefollowing

issuesshallbefocusedonforbetterfabricationquality.

4.4.工序交接Workprocedurehandover

4.4.1.做好各道工序之間的交接工作，確保上道工序不合格的產(chǎn)品嚴(yán)禁進(jìn)入下道工序。

Handoverbetweeneachprocessshallbewellperformedtoensurenounqualifiedproduct

beingusedinthenextprocess.

441.1?管件、閥門、管材等工程材料經(jīng)檢驗(yàn)不合格者，禁止用于本工程施工；同時(shí)臨時(shí)管道，

管件和閥門材料需要合格。

Itisforbiddentousenon-conformingconstructionmaterial,suchaspipefitting,valveand

pipematerial,inthisproject；Thetemporarymaterialsshouldbequalifiedtoo.

4.4.12管道除銹、防腐檢查及管件組對不合格，不得進(jìn)行焊接工作。

Poorfit-uppipefittingscannotbewelded.

4.4.1.3預(yù)制產(chǎn)品安裝前，必須經(jīng)相關(guān)的質(zhì)量檢查人員或?qū)I(yè)工程師檢查，確認(rèn)合格后，方可

用于安裝施工。Beforeinstalling,fabricatedproductsmustbeinspectedandapprovedbyrelated

qualityinspectorordisciplineengineer.

4.4.1.4預(yù)制管段安裝前需對管段內(nèi)部垃圾進(jìn)行清理，并組織檢查，檢查合格后才能繼續(xù)安裝。

Theinternalwasteofpre-fabricatedspoolsshouldberemovedbeforeinstallationof

pre-fabricatedspools,theinspectionwillbeperformed,thepre-fabricatedspoolscanbe

installedafterpassingtheinspection.

4.4.1.5預(yù)制管段安裝前需對有法蘭面的管道進(jìn)行保護(hù)，法蘭面安裝時(shí)需安裝臨時(shí)橡膠墊，避

免對法蘭水線照成機(jī)械損壞。

Thepipewithflangefaceshouldbeprotectedbeforeinstallationofpre-fabricatedspools,

thetemporaryrubbergasketneedtobeinstalledwhileflangefaceisbeinginstalled,toavoidthe

mechanicaldamageforflangesealsurface.

4.42施工過程必須加強(qiáng)施工班組的自檢工作，嚴(yán)格“三檢”制度（自檢、互檢、交接檢），確保每道

工序產(chǎn)品合格。

Duringconstruction,internalinspectionofconstructionteamshallbeimproved."Three

Inspections"Regulation(internal-inspection,mutual-inspectionandjointinspection)shallbe

strictlycompliedtoensureproductsusedineachprocessarequalified.

4.5.工藝管道焊接質(zhì)量保證體系QA/QCsystemforProcesspipewelding

4.5.1.現(xiàn)場施焊人員資格審查；Qualificationexaminationforsitewelder

4.52焊接工人上崗前,現(xiàn)場實(shí)際操作考試;Weldershallpassweldingtestinsitebeforeanywork.

4.53焊接過程合格率考核與控制；Testandcontrolofweldingqualificationrate

4.5.4.焊接工程師及焊接質(zhì)量檢查人員現(xiàn)場指導(dǎo)、檢查；Siteguidanceandinspectionactedby

weldingengineerandweldingqualityinspector.

4.6施工技術(shù)及資料管理Constructiontechniqueanddocumentcontrol

4.6.1,施工過程中必須嚴(yán)格執(zhí)行相關(guān)的規(guī)范、標(biāo)準(zhǔn)、要求等。

Relatedspecification,standardandrequirementshallbeperformedstrictlyduring

construction.

4.6.2.嚴(yán)格按照我公司質(zhì)量體系文件運(yùn)行程序進(jìn)行施工和管理。

Relatedspecifications,standardsandrequirements,etc.shallbestrictlycompliedinthe

processofconstruction.

4.63施工圖紙管理Managementofconstructiondrawing(IFCdrawing)

4.6.3.1.施工前，施工圖紙必須經(jīng)專業(yè)工程師審查，并進(jìn)行圖紙會(huì)審。IFCdrawingmustbe

reviewedandjointreviewedbydisciplineengineerbeforeconstruction.

4.6.32圖紙收發(fā)必須進(jìn)行登記，以便核查。圖紙版次更替應(yīng)做到及時(shí)，確保施工圖紙一直處

于最新版次。對于舊版次應(yīng)即刻回收，并做好登記保管，做到無遺漏。Drawingissuancestatus

shallberecordedforeasycheck.Drawingversionshallbeupdatedtimelytomakesurealways

usingthelatestversion.Oldversionshallbereturnedbacktimely,recordshallbemadeaswell

toavoidmissingitems

4.6.3.3?施工圖紙發(fā)放前，必須對施工隊(duì)進(jìn)行技術(shù)交底及圖紙答疑。

Technicaldisclosureanddrawingclarificationshallbedonetoconstructionteamsbefore

issuingIFCdrawing.

4.6.3.4.圖紙?jiān)O(shè)計(jì)變更應(yīng)及時(shí)傳達(dá)到施工隊(duì)，并及時(shí)對圖紙進(jìn)行修改，并及時(shí)執(zhí)行設(shè)計(jì)變更。

Designchangeshallbeinformedtoconstructionteam,drawingshallberevisedtimelyand

designchangeshallbecompliedtimelyaswell.

4.6.4.施工過程記錄應(yīng)做到及時(shí)、準(zhǔn)確，并簽字保存妥當(dāng)。

Constructionprocessrecordsshallbemadetimely,accuratelyandwell-kept.

4.6.5為加強(qiáng)質(zhì)量管理，保證為業(yè)主提供合格的工程項(xiàng)目產(chǎn)品，在施工過程管理工作中，使用公司

開發(fā)的管道施工管理系統(tǒng)軟件，跟蹤、記錄管道的主要施工信息、質(zhì)量II檢信息、無損檢驗(yàn)信息

等，以便施工人員及時(shí)了解相應(yīng)的質(zhì)量進(jìn)度信息，便于質(zhì)量管理和控制，同時(shí)輔助生成主要的交

工資料?，提高交工的質(zhì)量。

lbimprovequalitymanagementandprovidequalifiedproducttotheOwner,company

developedpipeconstructionmanagementsoftwarewillbeusedintheconstructiontotraceand

recordmajorconstructioninformation,dailyqualityinspectioninformation,NDEinformation,etc,

whichmakeconstructorknowrelatedqualityprogressinformationwellandeasytomanagement

andcontrolquality.Mainhandoverdocumentwillbegeneratedasauxiliaryfunction,which

improveshandoverqualityaswell.

4.7.現(xiàn)場安裝管道的標(biāo)識Pipeidentificationforsiteinstallation

4.7.1.管材、管件的追溯檢查Traceabilityofpipematerialandpipefitting

4.7.1.1材料到預(yù)制區(qū)域后按管道預(yù)制過程標(biāo)識和出廠標(biāo)識的要求嚴(yán)格執(zhí)行，以實(shí)現(xiàn)管材鑒定

到管道安裝的全過程可追溯性。

Arrivedatfabricationarea,materialsshallbemarkedasperrequirementsonpipe

installationprocessandmanufacturetomaketraceabilityofwholeprocessfrompipematerial

identificationtopipeinstallationpossible.

4.7.12材料使用前，應(yīng)先確認(rèn)材質(zhì)色標(biāo)是否符合規(guī)定。Ensurethematerialcolorsystem

appliestotherequirementpriortouse.

4.7.1.3.材料分離、分割而使原標(biāo)識不全時(shí)，要進(jìn)行原標(biāo)識的移植；

Originalidentificationshallberelocatedifmaterialisincompletebyseparatingorcutting.

4.72安裝管段的標(biāo)識Pipespoolidentificationforsiteinstallation

4.7.2.1,管段及焊口的編號和標(biāo)識工作貫徹管段安裝全過程。采用在單線圖上標(biāo)明焊口檢驗(yàn)狀

態(tài)，在實(shí)物上用記號筆做標(biāo)識方法進(jìn)行標(biāo)注。Serialnumberandidentificationofpipespooland

weldjointshallbemadeduringwholepipespoolinstallationprocess.Markinspectionstatusof

weldjointintheISOdrawing.Markidentificationonspoolbymarkerpen.

472.2,管端上的焊工號、焊口號及安裝管段號不得用打鋼印，而采用記號筆(不得含鋅、氯

離子等對母材有危害的成分)在距焊縫邊緣50mm處標(biāo)注，字跡清晰工整。WeldersIDnumber,

No.ofweldjointandNo.ofinstallationspool,whichareinthepipeend,shallnotbesteel

stampedbutbemarkedat50mmawayfromweldjointedgebymarkerpen(freeofzinc,and

choirion,whichisharmfultobasemetal)inavisibleandneatlyway.

4.7.2.3.管段及焊口的標(biāo)識方法如下：管道標(biāo)識的責(zé)任：焊工代號由焊工填寫，質(zhì)檢員代號山

質(zhì)檢員檢驗(yàn)后填寫，其余標(biāo)識(預(yù)制管段號、管段長度或爐批號)均由管工填寫。管工和焊工自

檢合格，且所填內(nèi)容齊全后，山管工班長或焊工統(tǒng)一向質(zhì)檢員報(bào)檢，經(jīng)質(zhì)檢員外觀檢查合格后報(bào)

FLOUR檢查，由FLOUR點(diǎn)口確定需檢測的焊口并在焊縫上用記號筆按照要求作為無損檢測的標(biāo)

識(RT、PT等)標(biāo)識內(nèi)容見圖(2)：Identificationmethodofpipespoolandweldjointasfollows:

Responsibilityofpipeidentification:welder*sIDnumberwillbefilledbywelder,quality

inspector'sIDnumberwillbefilledbyqualityinspectorafterinspection,otheridentifications(No.

offabricatedpipespool,lengthofpipespoolorheatNo.)willbefilledbypipefitter.Pipefitter

andweldershallinspectfabricatedpipeandcompleteidentificationsfirstly,thenpipefitterleader

orwelderleadershallreporttoqualityinspectorforinspection.Qualityinspectorwillreportitto

FLOURifvisualinspectionisaccepted.Weldjunctionshouldbedeterminedaccordingto

FLOURspotweldjunction,andmarkedNDE(RT,PT,etc.)ontheweldjointbymarkingpenas

perrequirements.RefertoSketch(2)fordetailedmark.

SpoolfabricationWeldseam

五、管道安裝Pipeinstallation

5.1.施工準(zhǔn)備Preparation

5.1.3.3.施工人員準(zhǔn)備Manpowermobilization

根據(jù)現(xiàn)場施工條件，合理組織管道安裝人員（人力計(jì)劃詳見附表）；Pipeinstallationpersonshall

bemobilizedaccordingtositeconstructioncondition.（detailedmanpowerplanisattachedas

bellow）

5.1.3.4.施工機(jī)具準(zhǔn)備Equipmentandtoolspreparation

根據(jù)現(xiàn)場施工條件，合理組織管道安裝的施工機(jī)具（施工機(jī)具詳見附表）。Equipmentandtools

shallbemobilizedaccordingtositeconstructioncondition.（detailedequipmentandtoolsplanis

attachedasbellow）

52管道安裝Pipeinstallation

521.安裝流程Workingprocedure

管道施工安裝流程如圖（圖）Pipeinstallationprocedureisshownassketch1.

5.2.2安裝位置核查Inspectionoflocationforpipeinstallation

管道安裝前，檢查土建基礎(chǔ)、結(jié)構(gòu)、設(shè)備管口的尺寸、標(biāo)高、位置等是否與管道圖紙相符。Before

pipeinstallation,inspectdimension,elevation,positionofcivilfoundation,structureand

equipmentnozzleaccordingtopipedrawing.

523.預(yù)制管段安裝前內(nèi)部清理檢查Checkinginteriorcleaningstatusbeforeinstallingfabricated

spool.

安裝前，通過預(yù)制記錄及預(yù)制管線標(biāo)識找查安裝的管線，檢查預(yù)制管段的管內(nèi)部清潔度。Before

installation,findthepipelineaccordingtofabricationrecordandpipeidentification,andcheck

theinternalclearnessofpipespoolfabricated.

524.管道安裝的允許偏差A(yù)llowableDeviationofpipeinstallation

架空及地溝平面坐標(biāo)：室內(nèi)允許偏差15mm,室外允許偏差25mm。Coordinateofoverhead

layerandtrench:indoorshallbe15mm,outdoorshallbe25mm.

架空及地溝標(biāo)高：室內(nèi)允許偏差±15mm,室外允許偏差±20mm。Elevationofoverheadlayer

andtrench:indoorshallbe±15mm,outdoorshallbe±20mm.

水平管道平直度：DN<100,允許偏差為2L%。，最大50mm。DN>100,允許偏差為3L%。，

最大80mm。Straightnessofhorizontalpipeline:ifDN<100,allowabledeviationshallbe2L%o,

maximumdeviationshallbe50mm.ifDN<100,allowabledeviationshallbe3L%o,maximum

deviationshallbe50mm.

立管鉛垂度：允許偏差為5L%o,最大30mmoTheverticalityofriserpipeline:allowable

deviationshallbe5L%o,maximumallowabledeviationshallbe30mm.

成排管道的間距：允許偏差15mmoTheintervalofpipeinarow:theallowabledeviationshall

be15mm.

交叉管或絕熱層間距：允許偏差20mm。Theintervalofcrosspipelineorthermalinsulation

layer:theallowabledeviationshallbe20mm.

525.管道各類焊縫間距要求intervalspacerequirementofvariousweldjoint

管道各類焊縫間距要求詳見(圖3)及表二

Pleasereferto(sketch3)andform2forintervalspacerequirementofvariousweldjoint

管道焊縫間距要求示意圖(圖3)

Sketchforintervalspace

requirementofpipeweldjoint

(sketch3)

表二(forrr)2)

焊縫最小間距(選最大者)Minimum

焊縫類型DescriptionofWeldTypeDistanceBetweenWeldToes(whichever

isgreater)

A120°or7CDr)or5t<1>

B120°oi■小而or5t⑵

C100mmor2t⑶

D50mmor2t

Dimensionaltolerancesforfabricatedpiping

5.2.6管線鋪設(shè)Pipelinelaying

526.1管廊管道鋪設(shè)Rackpipelaying

A.管廊穿管Pipelaying

對于管廊及管吊架上管線，其為分層排列，給管道鋪設(shè)工作造成極大麻煩，因而必須合理地

安排施工方法。管道敷設(shè)時(shí);從管廊端頭穿入管廊各層，并計(jì)算好各層用料。穿管時(shí)，通過吊車

直接將管道放置于竄管器上。Forthepiperackandpipelineonthebracket,whichshallbe

arrangedreasonablybylayers,topreventpipelayingfrombeingintrouble.DuringPipelaying,

pipeshallbeputonpipeconnector,andpassthroughintoeachlayerofpiperackbylifting.The

amountofpipematerialshallbecalculatedinadvance.

B.管廊傳管Pipedelivery

管道穿入管廊各層后，應(yīng)即刻組織人力將管道傳輸?shù)桨惭b位置，調(diào)整好各管線間間距，并臨時(shí)固

定好。管廊傳管必須使用竄管器（如圖4）進(jìn)行。竄管器應(yīng)牢固地安裝在管廊橫梁上，竄管器滾筒必

須采用橡膠皮等纏好，以保護(hù)管線油漆及不銹鋼管避免污染。竄管器宜每3米間隔距離安裝1件,

這樣管子竄起來就容易得多。Pipeshallbedeliveredtothepositionofinstallation,adjustedthe

intervalofeachpipe,andfixedforthepresent.Thepipeconnectorshallbefixedfirmlyonthe

beam.Wrappedtherollerwithrubberskintoprotectpaintingandstainlesssteelpipeis

preventedfrompollution.Pipeconnectorshallbeinstalledatintervalsof3M,itiseasytopipe

connectio

C.管道牽引Pipetrailing

管廊在竄管器匕牽引一般采取人工形式或采用倒鏈牽弓I。對于同層管道數(shù)量大且直徑相對較

大時(shí)，可采用卷揚(yáng)機(jī)牽引，如圖（5）。Piperackshallbetrailedbymanualorchainblock.Fora

largequantityanddiameterofpipeinthesame,itshallbetrailedbywindlass.Seesketch（5）

5.2.62設(shè)備間管線鋪設(shè)與安裝Pipelinelayingandinstallationbetweenequipments

安裝時(shí)，首先測量好現(xiàn)場已安裝完成的管線連接設(shè)備間距離、標(biāo)高等參數(shù)，預(yù)制管段。將連

接設(shè)備兩端法蘭固定在設(shè)備口，螺栓擰緊，數(shù)量不得低于4顆。Pipespoolshallbefabricated

accordingtothedistance,elevationetc.betweenpipeinstalledandequipment.Fixtheflangeon

theendofequipment,tighteningthebolt,andshouldbenotlessthan4.

然后采用吊車將預(yù)制管段吊裝就位，組對，點(diǎn)焊好。LiftPipespoolfabricatedtothecorrect

positionbyhoist,fitupandspotweldo

點(diǎn)焊好后，應(yīng)采用臨時(shí)措施加固避免變形（防變形的臨時(shí)加固件，應(yīng)在焊接工作徹底完成后

才能拆卸）。待焊口根部焊縫完成后，拆卸組對管線，在地面完成剩余的焊接、探傷、試壓、清洗

等工作，然后復(fù)位安裝。Afterspotwelding,pipespoolshallbestrengthenedbytemporary

measurestopreventdeforming（Thetemporarymeasurescan*tberemoveduntilwelding

completefinish）.Afterfinishrootweldingofweldjoint,removethepipespoolfittedup,which

shallbetreatedbywelding,crackdetection,cleaningontheground,andberepositedand

installedatlast.

527.管道對口Pipefittingup

527.1.管道對口連接時(shí)，不得用強(qiáng)力進(jìn)行組對，亦不得通過松或強(qiáng)緊連接螺栓或添加法蘭連

接墊片來調(diào)整組對間隙及管口平直度。Duringfittingupwork,pipecannotbejointedbytheaction

ofastrongforce,alsonotbeadjustedtheintervalandstraightnessbyflangegasket.

5272管口組對時(shí)，應(yīng)符合圖(6)要求.

當(dāng)管子公稱直徑小于100mm時(shí)，允許偏差值。為1mm；當(dāng)管子公稱直徑大于或等于100mm時(shí),

允許偏差值a為2mm；但全長的偏差值不得超過10mm。管道坡口加工時(shí)，壁厚V3mm采用I

型坡口，壁厚N3mm采用V型坡口；組對間隙應(yīng)控制在2~4mm；允許最大錯(cuò)邊量為壁厚的10%

且不大于2mm。Pipefittingupshallmeettherequirementofsketch(6).Whenthenominal

diameterofpipe<100mm,allowabledeviationvalueashallbe1mm.Whenthenominal

diameterofpipe>100mm,allowabledeviationvalueashallbe2mm,butthewholedeviation

shouldnotexceeds10mm.Forthepipefit-up,adoptItypegrooveforthethicknesslessthan

3mm,andadoptVtypegrooveforthethickness>3mm;thespaceofthefit-upshouldbe

controlledwithin2~4mm;permittedmaximumunfitnessvalueis10timesofthewallthickness

butnotexceed2mm.

5.2.73作為封閉管段組對時(shí)，其首先應(yīng)根據(jù)現(xiàn)場實(shí)測的安裝長度進(jìn)行下料加工，其偏差

不得超過1.5mm,確保焊口間隙，保障焊接質(zhì)量。Sealpipespoolshallbefabricatedasper

surveyedinstallationlengthwithallowancenomorethan1.5mm,tokeepaintervalbetween

weldjointswithahighqualityofwelding.

5.2.8.法蘭安裝Flangeinstallation

528.1.法蘭連接應(yīng)與管道同心，并確保螺栓自由穿過螺栓孔；Connectedflangeshallbea

samecenterwithpipe.

5282垂直或傾斜法蘭面螺栓孔應(yīng)垂直跨中安裝，其連線水平度不得大于1.5mm；水平法蘭

面螺栓孔安裝應(yīng)跨裝置南北或東西方向；Allboltholesofflangeshallstraddleverticaland

horizontalcentrelinesofthepipe.Levelnessshallbenomorethan1.5mm.Flangeboltholeson

horizontalpipeshallstraddlethesitesystemlines,i.e.sitePlantNorth/SouthorPlantEast/West.

528.3.水平法蘭水平度及垂直法蘭的鉛錘度不得大于法蘭外徑的1%。,且不得大于2mmcThe

verticalityofhorizontalandverticalflangeshallbenomorethanouterdiameter1%o(2mm).

528.4.當(dāng)法蘭采取螺紋連接時(shí)，管端應(yīng)低于法蘭密封面1.5mm.Iftreadedconnectionisused

toflanges,theendofpipeshallbelowerthanthesealingface1.5mm.

528.5.不得用強(qiáng)緊螺栓的方法或松螺栓方法來消除歪斜。同時(shí)、不得加偏墊或多層墊等方法

來消除法蘭接口端面的間隙、偏斜、錯(cuò)口或不同心等缺陷。Itisnotallowedtotightenorloosebolt

foradjusttiltedsurfaceofbolt,meanwhilenotallowedtoaddpartialpadorcushionstoeliminate

defectsofclearance,deviations,mismatchanddisalignment.

5286動(dòng)設(shè)備法蘭口最終連接時(shí)，必須在聯(lián)軸器上架設(shè)百分表監(jiān)視動(dòng)設(shè)備的位移。

當(dāng)動(dòng)設(shè)備額定轉(zhuǎn)速大于6000r/min時(shí)，其位移值應(yīng)小于0.02mm；當(dāng)額定轉(zhuǎn)速小于或等于

6000r/min時(shí)，其位移值應(yīng)小于0.05mm。Flangeconnectionofrotaryequipmentmustbetested

withdialgauge.installingthedialindicatoroncouplertomonitorequipment'sdislocation.When

ratedspeedismorethan6000r/min,thedislocationvalueshouldbelessthan0.02mm,when

ratedspeedisnotmorethan6000r/min,it'sdislocationvalueshouldbelessthan0.05mm.

529.墊片安裝Gasketinstallation

529.1.墊片安裝前，應(yīng)按圖確認(rèn)其型號規(guī)格是否滿足設(shè)計(jì)要求。法蘭安裝前，應(yīng)檢查法蘭密

封面及密封墊片，不得有影響密封性能的徑向劃痕、斑點(diǎn)、破損、皺折等缺陷。同時(shí):配對法蘭

環(huán)槽密封面與金屬環(huán)墊還應(yīng)作接觸線檢查，當(dāng)金屬環(huán)墊在密封面上轉(zhuǎn)動(dòng)45。檢查接觸線不得有間斷

現(xiàn)象。Beforegasketinstallation,thetypeandspecificationshallbeconfirmedtomeetthe

requirementofdesign.Beforeflangeinstallation,checkthesealingfaceandsealinggasket

whichfreeofscratch,stain,damagedandwrinkledetc..Contactinglinecheckbetweenflange

ringsealfaceandmetalringgasketshallbedoneinthemannerthatnodiscontinuousline

existingwhenrotatemetalringgasketfor45°.

5.2.92安裝時(shí)，必須確保墊片安裝位置應(yīng)在法蘭密封面中心，1個(gè)密封面只安裝1塊墊片，

禁止安裝多層墊。Duringgasketinstallation,gasketmustbeplacedinthecenterofflange

surface,only1piecegasketcanbeusedforflangesurfaceinsteadofmulti-piece.

5210閥門安裝Valveinstallation

5210.1,閥門安裝前應(yīng)檢查閥門的規(guī)格型號是否與設(shè)計(jì)一致，并檢查填料其壓蓋螺栓應(yīng)留有

調(diào)節(jié)余量。Thetypeandspecificationofvalveshallbecheckedformeetingtherequirementof

design,asuitablespaceshallberemainedbetweenglandboltandfillingmaterial.

5210.2,當(dāng)閥門與管道以法蘭或螺紋方