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1、工艺管线施工技术方案Construction Technique Scheme for Process Pipelines1 工程概况 我公司承建的中海壳牌石油化工有限公司南海石化项目苯乙烯、环氧丙烷及丙烯乙二醇装置位于广东省惠州市大亚湾区海畔.该项目由德悉尼布天辰化学工程（天津）有限公司设计，所处地区环境干燥温度最高38.5，最低2.3，湿润温度28.1，空气湿度大，雨期较长。2 编制依据2.1 德悉尼布天辰化学工程（天津）有限公司提供的工艺管道施工图；2.2 工艺管道设计技术交底（会议纪要）；2.4石油化工剧毒、可燃介质管道工程施工及验收规范（SH3501-1997）；2.5工业金属管道工
2、程施工及验收规范（GB50235-97）；2.6现场设备、工业管道焊接工程施工及验收规范（GB50236-98）；2.7埋地钢质管道环氧煤沥青防腐技术标准（SY/T0447-96）；2.8石油化工钢制通用阀门选用、检验及验收规范（SH3064-94）；2.9石油化工设备和管道隔热技术规范（SH3010-2000）；2.10工业设备、管道防腐蚀工程施工及验收规范（HGJ229-91）；2.11工业设备及管道绝热工程施工及验收规范（GBJ126-89）；2.12石油化工工程铬钼耐热钢管道焊接技术规程（SHJ520-91）；2.13电力建设施工及验收技术规范(管道篇)DL5031-942.14电力建
3、设施工及验收技术规范（火力发电厂焊接篇）DL5007-922.15石油化工企业设备管道表面色和标志SH3043-19912.16石油化工异种钢焊接规程SH3526-19922.17石油化工铬镍奥氏体钢、铁镍合金和镍合金管道焊接规程SH3523-19992.18压力容器无损检测（JB4730-94）；2.19石油化工施工安全技术规程（SH3505-99）；2.20工程建设交工技术文件规定（SH3503-93）；2.2150万吨/年延迟装置施工组织设计；2.22压力管道安装质量保证手册（QG/M4441.50.00-1999）；2.23压力管道安装质量程序文件(QG/P4443.50.00-199
4、9)；2.24压力管道安装工艺标准（QG/4441.52.00-1999）；2.25压力管道安装竣工技术文件规定（QG/M4441.53.00-1999）。3 工艺配管的特点： The character of pipe erection3.1 PTA装置中易燃，易爆及腐蚀性介质的管道较多，且物料大多为浆料和粉料，有强烈腐蚀性，故配管材料选用要求严格。本装置中大量使用超低碳不锈钢，包括304L、316L、317L等，并有少量钛管、海氏合金管及塑料管。IN PTA installation, there are many pipes with inflammable, explosive and
5、 corrosive medium, most of which are slurry and powder with strong corrosion. Therefore the required material of pipe erection is very strict. In this installation, we not only use a lot of low carbon stainless steel with specification of 304L,316L and 317L.but also some titanium pipe, alloy pipe an
6、d plastic pipe.3.2本装置动设备较多，必须保证无应力配管，不得对设备施加外力。配管应从设备开始向设备外配管，配管过程中应及时设置管道支吊架，不得让设备承受管道系统的重力。 There are many movable equipments in the installation, we need ensure pipe erection without stressing, and cannot impose external force on the equipments, In the pipe erection, we need start from the equipm
7、ent inside, and then the outside of the equipments. We need set up the pipe rack in time to avoid the gravity from the pipe system.3.3本工程管道焊接量大，需要投入大批量的优秀焊工。我公司目前有压力管道持证焊工685名，能够保证焊接要求。如我公司中标本项目，将派出具有行业及国家级先进水平的优秀焊工来承担本工程的焊接任务，能够确保装置的长期有效地运行。 The pipe welding quantities is very heavy in the project.
8、 It needs provide a large number of qualified welders. Now our company has 685 welders with certificates, which can comply with the welding requirements. Once tendered, we will send qualified welders to bear the welding task of the project, All the welders have much experience and advance technique,
9、 which can ensure the erection in good quality in a long time.3.4 本装置工艺配管工程量大，共有各类管道132km。为提高劳动效率，加快施工进度，我们将大力推进管道自动焊，实行管道预制工厂化、产品化。我公司有各种型号的自动化焊机多台，在管道预制过程中，配以高纯度氩气（99.99%）的气体保护管道自动焊，可以极大地提高劳动效率，有效地抑制焊接接头部位的氧化，保证接头内部平整、外型美观。.6.3.1.4 The quantities of Process pipe erection is heavy, It includes all
10、kinds of pipeof 132km.In order to enhance the work efficiency and speed the construction progress, we will try our best to push pipe automatic welding and perform pipe prefabrication in market. There are many automatic welding machines with models in our company. In the process of pipe erection, the
11、 application of arc protection automatic welding machine with high purity of argon can improve the work efficiency, hold back the oxidization of the location of welding joint, and ensure the inside of joint flat and on good look outside.4 管道安装工程量The quantities of pipe erection类别Type材质Material 规格（mm）
12、Specification 质量（t）Quality 数量（m）Quantity管材Piping +material CS 1/254 878.04 62813 SS 1/280 315.1 38850 钛材Titanium 3/480 38.53 650 合金钢Alloy steel 3/436 13.53 630 铜管Copper pipe 1/23/4 17.27 28403 塑料管Plastic Pipe 3/456 1.49 706 法兰Flange 114.92 配件Fittings 255.3 阀门Valve 273.21 弹簧支撑Spring Supporting 11.88
13、其它支撑Other supporting 157.45、 管道材料检验Pipe material inspection管道施工材料的质量保证是施工质量的基础。我公司具有一套成熟可行的原材料检验管理制度，我们将按照具体工程特点建立健全切实可行的材料检验管理体系以提供质量保证。The quality assurance of pipe construction material is the basis of the construction quality. Our company owns a available and mature management system of material
14、 inspection and we will adjust it according to the actual project character for quality ensure.5.1 成立专门的检验小组实施统一的管材管件检验，并按照相应标准组织检验。 Setting up a inspection group for pipe material and fittings check, and inspecting with relative standard.5.2 材料检验设有独立的检验场地，并划分出待检区、检验区、合格品区和不合格品区。 Setting up a indepe
15、ndent inspection area for material examination, and divide it into waiting inspection area ,inspection area, qualified production area and unqualified production area.5.3训练有素的检验人员将严格按照以下检验工艺进行检验： The trained person will strictly inspect material complying with the following procedure: 管材、管件接收Pipe ma
16、terial, fittings acceptance 品种、规格、数量检查Brand ,specification and quantities inspection 外观质量检查Configuration quality inspection 材质检查Material quality inspection 质量验证Erection quality inspection 产品标识和检验状态标识Production identification and inspection in situation identification5.4管道组成件的检验 Piping fitting inspec
17、tion5.4.1不锈钢管子、管件（包括螺栓、螺母），应用光谱分析仪对材质的主要化学成份进行复查，并作好检验状态标识。 Stainless piping and fittings (including bolts and screw nuts) shall be rechecked chemical combinations by spectrum analyzer, and located in inspection situation.5.4.2螺栓、螺母的螺纹应完整、无划痕、毛刺等缺陷，并应配合良好，无松动或卡刺现象。 The screw thread shall be free fro
18、m defects such as deformities , scratches and irregular of distance between thread to thread, and shall be in good quality without loosening and jamming .5.4.3法兰密封面、缠绕垫不得有径向划痕、松散、翘曲等缺陷，石棉垫表面应平整光滑，不得有气泡、分层、折皱等缺陷。 The area between flange to flange and circle pad shall be protected from scratches loose
19、ning, twisting and so on. The surface of asbestos shall be flat and smooth , and be free from bubbles ,multi-layers ,crease and so on.5.4.4阀门检验 Valve inspection5.4.4.1阀门试验、检验前，专门成立阀门检验、试验小组，其成员应由施工班组、相关技术人员和质量检查人员组成。同时必须进行专门的技术交底，并配置相应的工装设备。 We will set up a valve check and test group before valve i
20、nspection, which include construction team, relative technique personnel, quality inspector. Meanwhile We will transfer necessary technique information and assemble proper work equipment.5.4.4.2阀门检验、试验程序见图3-1。 The valve inspection and test procedure see drawing 3-15.4.4.3阀门试验应从每批中抽查10%，且不少于1个，进行壳体压力
21、试验和密封性试验。当不合格时，应再抽查20%抽查，仍然不合格时，该批阀门不得使用。 10% of valves shall be take for inspection from each batch of it. And no less than 1 piece to shell pressure and densification test. In case it is not qualified, another 20% of it shall be rechecked. If unqualified again, the valves cannot be used. 5.4.4.4阀门
22、的壳体压力性试验和密封性试验必须用洁净水进行。不锈钢阀门试验用水的氯离子含量不得超过25ppm. Clean water should be used in the valve shell pressure and densification test .The content of chlorine used in stainless steel valve should not overpass 25ppm5.4.4.5阀门的壳体试验压力应为公称压力的1.5倍；试验时间不得少于5min，以壳体、填料无渗漏为合格。Valves shell tested pressure should be
23、1.5 times of nominal pressure , and the test should last 5 minutes, It will be qualified in the case of shell and packing be free from leakage.图3-1 阀门检验、试验工艺流程图 Drawing 3-1 Valve Inspection and Test Flow Plan阀门外观质量检查valve configuration quality inspection质量证明文件核查、确认Review and Confirmation of Qualific
24、ation Documentqiquuqq成立阀门检验、试验小组Setting Up valve inspection and test group严密性试验Pressure test强度试验intensity test 不合格unqualified检验、试验状态标识Inspection ,test situation identification工装设计制作检验场地准备Process assembly design and fabrication inspection yard preparation yard 编制技术措施并进行技术交底Prepared Technique and Tran
25、sfer it 不合格品处置Nonqualified production disposal合格交付安装Erection available合格5.4.4.6除止回阀、节流阀外，阀门的密封试验宜以公称压力进行，以阀瓣密封面不泄漏为合格。Except back and throttling valves, valve qualified inspection shall be determined by nominal pressure and no leakage in the densification area of valve petal.5.4.4.7公称压力小于1MPa，且公称直径大
26、于等于600的闸阀，壳体压力试验宜在系统试验时，按系统的试验压力进行试验，闸板密封试验可采用色印等方法进行检验，接合面上色印应连续。 As for the gate valve with nominal diameter more than 600 and nominal pressure less than 1Mpa, When doing the shell pressure test, It is better to examine according to the system testing pressure. Slide plate may use the color papers
27、 for testing and the continuation area should be continued. 5.4.4.8合金钢阀门的壳体材质必须逐件进行快速光谱分析，不合格时该批阀门不得使用。 The shell material of alloy steel valve should be analyzed one by one by high speed spectra. If unqualified valves in it, this batch of valves are forbidden to using.5.4.4.9试验合格的阀门，应及时排净内部积水、吹干密封面
28、上应涂防锈油，关闭阀门，封闭出入口。 Internal water in the valve acceptable should be drained in time and density area should be dried and coated with rust preventive oil. The valve should be closed .The egress and ingress should be closed.5.4.4.10安全阀按设计文件规定的定压值进行调试，允许偏差为3%。调试介质：管道内介质为气体时，优先酇用氮气调试；管道内介质为液体时，应使用液体调试。调
29、压时的压力应稳定，每个安全阀启闭次数为3次。要求起跳压力明显，无前漏、后漏现象。由于安全阀进出口压差较大，不进行壳体压力试验，密封试验时，压力小于定压值，不得泄漏，可在安全阀出口贴纸进行目测。Constant pressure of safety valves should be adjusted according to the document regulations and +/-3% deviation is permitted. We will use different mediums as follows according to the specified conditions
30、: Using nitrogen first in case of air in the piping . Using liquid in case of liquid in the piping. The pressure should be stable when adjusting and every safety valve should be opened and closed three times. The up and down pressure should be clear without internal and external leakage. Because the
31、 pressure deviation between safety valves ingress and egress is relative far ,the pressure is less than its constant pressure in density test .in this condition, the leakage is not permitted and the labels can be made on safety valve ingress and egress for visual check.5.5 质量检验人员均对检验过程做出详实的检验记录，以备随时
32、查证。 Quality inspector shall make detailed inspection record for verifying anytime.5.6 装置区工艺管道材料经检查合格后，均将做出不同色标加以标识。防止施工过程用错材料，并方便检查人员监查确认。各种管道配件在易于辨认处做出两处标识，各种管材、型材均做出通长标识。After checked qualified ,the piping material shall be identified with different color tags ,which can avoid mistake of material
33、utilization and make a convenience for supervisor checking and assurance .Two tags shall be made on the clear area of every kind of piping fittings and general tags shall be made on every kind of tube material and shape steel.6 管道的预制加工 Piping prefabrication and processing 6.1为了减少现场预制带来的技术管理、材料管理、设备管
34、理的工作负担，搞好文明施工，开辟第二现场，设置管道预制场地，进行管道的工厂化、产品化的预制加工，而后再在现场进行安装。管道预制加工厂设有轨道式天车、车床、摇臂钻床、剪板机、坡口加工机、自动焊机等施工机具。We have track crown blocks, lathes, beam drills, plate shears ,groove processing machine and automatic welding machines in the piping prefabrication yard to avoid field work bearing such as techniqu
35、e management ,material management and equipment management, make housekeeping ,develop the second site, set up piping prefabrication yard ,make piping prefabrication process in the market and then erect in the jobsite 6.2 预制前仔细核对单线图与平面图，核对基础、设备、管架、预埋件、预留孔是否正确，对于最后封闭的管段应考虑组焊位置和调节裕量。Before prefabricat
36、ion, We will check the isolated drawings and plans carefully , align the foundations ,equipments, pipe frames ,embedded parts and preformed holes in correct, and consider the welding position and adjust the size under the actual construction condition to the piping sections closed last.6.3 管道预制应按单线图
37、规定的数量、规格、材质选配管道组成件，预制过程中的每一道工序均应核对管子的标记，并做好标记的移植，做到用料正确、尺寸准确、标识明显。 In piping prefabrication progress, We will purchase piping fittings according to the specification, quantities and material quality formed in isolated drawings. We will check the piping tags in every steps and make changed tags in go
38、od consequence for using correct material and size and making clear tags.6.4 钢材的切割及管道坡口的加工应采用以下方法：镀锌钢管和公称直径50的碳钢管，采用机械切割，公称直径大于DN50的碳钢管采用氧乙炔焰法切割；不锈钢管应用机械或等离子的方法切割，304L、316L和317L材质的钢管用砂轮切割或修磨时，应有专用砂轮片。管子切口表面应平整、无裂纹、重皮、毛刺、凸凹、缩口、熔渣、氧化物、铁屑等。 Steel material cutting and piping groove process should use me
39、thods as follows; For galvanized steel tubes and carbon steel tubes with nominal diameter 50 using mechanical cutting .For carbon steel tubes with nominal diameter less than DN50 using oxygen acetylene cutting ,For stainless steel tubes using applied mechanical or plasma cutting ,For steel tubes wit
40、h specification of 304L,314L and 317L using abrasive wheel cutting or another alternative using special emery plate to grind. Tube cutting should be flat and smooth and no cracking, sand crust, fins ,uneven open track ,melted residue ,scrap and oxidization. 6.5 预制好的管段，按单元或区域摆放整齐，以便于运输和安装。管道施焊时，按规定的焊
41、接工艺执行。管道焊接、无损检测工作完成后，应在预制厂内除锈、喷砂和防腐，但焊口两侧各100mm的范围内不允许涂漆，焊工钢印号、管道编号以及管线号不允许涂漆，待系统水压试验合格后再进行防腐涂漆。为保证焊接质量，工艺管道焊接均采用氩电联焊的工艺进行。Prefabricated piping section shall be laid in order to transportation and erection. We will weld complying with regulated welding process. After piping welding and non-destructi
42、ve test. The derusting, blasting and anti-rotting steps should be done in the prefabrication yard. But 100mm away form two sides of welding joints and welders sign, piping number and pipeline number are not permit to paint, it should be done after system water pressure test qualified. In order to en
43、sure welding quality, all the process piping use argon continuation welding .6.6 预制完成的管段进行管线号、预制管段号标识，并用人工或压缩风将管膛内清除干净，用塑料布封闭管口分门别类摆放。不锈钢和碳钢在切割和存放时，严格区分开。We make identification tags for pipeline number and prefabrication piping section number which are completed the prefabrication, clean piping insi
44、de by hand and pressure wind, Classify and lay down them with piping mouth closed by plastic cloth. When cutting and storing ,stainless steel and carbon steel should be divided strictly.7 管道焊接 Piping weldingPTA装置焊接工程中，工艺管道母材的不锈钢比例在60以上，且有钛一类特殊材质的管道，焊接难度大、工艺标准要求高是该工程的主要特点。焊接质量直接决定整个安装工程的质量，因此，我们应从焊接材
45、料、焊接工艺、施焊过程、焊接检验诸方面对焊接质量进行严格控制，确保每个焊接环节都处于受控状态。In PTA assembly welding process, Because there is 60% of stainless steel in process piping parent material and piping has the especial titanium, the main character of the project is the difficult welding and high requirements of process standard. Welding quality determine the overall erection project quality. we will control the welding material, welding process, welding operation ,welding inspection and so on to ensure welding quality and every welding steps in control.焊材型号和规格选用应严格执行焊接工艺评定。焊前检查、修正接缝的间隙、错边量等；焊接作业期间，注意自
