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1、5200DWT化学船5200DWT Chemical Tanker施 工 设 计working design标记mark数量NO修改单号modification签字 SIGN日期 DATE管系原则工艺Piping technics in principle编 制designed校对checked标 检chk.of stand共 9 页第 1 页批 准approved 江 州 造 船 厂JiangZhou shipyard描 图tracing本工艺适用于5200DWT化学船管系布置,加工,安装。本工艺参考了CB/Z345-85船舶管系布置和安装通用技术条件、CB/T3790-97船舶管子加工技术
2、条件、CB/T3626-94舱室风管及附件安装质量要求和经BV船级社认可的5200DWT化学船主要管系原理图中有关技术要求编制而成，本工艺未表述的内容，可参照上述标准。希望各施工部门严格执行本工艺有关要求。1. 管系布置原则1.1管子的排列应尽可能的平直, 成束排列, 整齐美观,. 避免不必要的迂回和交叉, 并优先布置大通径管子.1.2 管子的间距1.2.1 并列或交叉管子(包括管子附件)的间距应20mm. 对于需要绝缘包扎的管子, 包好绝缘后, 其外部与相邻的管子,附件或船体结构的间距应20mm.1.2.2 下列管子与电缆的间距应在100mm上:a 加热管子绝缘层外表b 排气管子绝缘层外表c
3、 压缩空气管子(压力1.0Mpa以上) 1.3 布管位置应便于安装和操作,各种管子应尽量沿着船体结构或箱柜附近布置. 不得防碍走道, 通道, 逃口, 门, 人孔和舱口盖. 1.4 在通道,拆检的空间内不应设置管路. 并保证设备拆装,维修,检查等的必要空间. 检查时管子的拆卸工作量要最小. 1.5 管系布置要尽可能远离配电板, 控制箱和电缆. 1.6 燃油舱的空气,溢流,测量和注入管应避免通过居住舱室, 并避开通道，如不可避免，应用套管连接。 1.7 监视室, 电气设备上方及后面应避免设置油管,水管和排气管.如不可避免，应用套管连接。1.8 烟道,排气管及消音器应尽量避开油管,油柜.1.9 测量
4、管布置应与甲板垂直。1. 10粪便管,水池排水接头下方要设S弯头;居住舱室采用水封式地漏，它们的排水管路斜度不小于30mm/1000mm., 在居住舱室外优先考虑法兰连接, 并安装疏通接头；在居住舱室内采用套管连接，避免可拆接头。1.11 货油管应尽可能采用对焊形式连接，减少可拆式连接。1.12 较大管的管子马脚尽可能焊在船体结构上。1.13 下列管路要采用弯头或膨胀补偿的措施来避免管路膨胀时引起船体结构的破坏a 舱内压载管, 舱底水管b 贯穿两水密壁之间的管子c 连接震动较大设备的管子2. 管系附件布置原则2.1 阀, 旋塞及滤器应安装在便于操作的地方, 手轮的操作方向应保证水平布置.2.2
5、 阀和阀并排布置时, 手轮之间的间距应在30mm以上.2.3 连接在箱柜的进出管应按系统集中布置.2.4 当阀件布置在花钢板下时, 其手轮与花钢板平行, 且在花钢板上对应的位置开孔装活络盖板.2.5 泥箱,滤器和舱底水管路的阀原则上在花钢板下并考虑拆装清洁的可能.2.6 加热盘管绕吸口布置。.3 管子通过船体接构的安装要求 3.1 管子通过甲板,水密舱壁,双层底和机舱围壁的船体结构时,均采用通舱管件或法兰焊接坐板.3.2 通舱管件形式选用:QJ/XG02.028-94套管式焊接通舱管件, 法兰式通舱管件参考CBM1093-81、CBM1094-81, 焊接固定式通舱管件参考CB/T3480-9
6、2。4 管子加工 4.1 管子弯制一般采用冷弯的方法, 如不可避免也可适当选用成形弯头，外径大于100mm的管子用成形弯头；货油管管子弯制均采用316L不锈钢管成形弯头，开支管采用焊接式三通。 4.2 管子的弯曲半径一般为管子外径的23倍. 4.3 管子焊接制造完毕后按图纸进行强度试验, 船上进行密性试验. 如内厂强度试验无法进行, 则在船上进行管系的强度(密性)试验(附件除外). 4.4 管子清洗:燃油、滑油、液压管子、压缩空气管制造完毕后进行化学清洗, 内部涂油, 外部底漆.封闭管子开口上船安装. 安装完善后方可拆除封口. 投入使用前进行投油清洗. 4.5 海水, 淡水, 压载, 舱底,
7、空气, 疏排和生活管按图纸进行热镀锌. 镀锌层应光滑,不应有明显的漏镀, 流挂,剥落和起泡等现象.4.6 高、低温淡水管制造完毕后进行化学清洗和磷化处理，外部底漆.4.7 镀锌管在现场焊接时受到损伤,应及时用富锌漆补涂.4.8 货油管均采用316L不锈钢管，法兰采用316L对焊法兰。焊丝采用管材厂推荐的焊丝，或订管材时，要求配套供应。5. 管系和附件的安装要求 5.1 管系安装前确定管子安装的基准. 5.2 所有上船安装的管子应是报检合格的管子, 注意内壁的清洁. 5.3 管系安装首先确定安装起点, 如海水总管, 吸口等, 再按系统安装. 5.4 系统垫片选择:生活供水系统 无毒硅橡胶垫片燃、
8、滑油、压缩空气、蒸气系统 非石棉垫片压载, 舱底, 冷却水, 疏排水 非石棉垫片排气 石墨垫片货油管系 聚四氟乙烯 5.5 管子吊架 CB/T3780-97 U形镀锌(在油舱内，不镀锌)。 5.6 货油区316L不锈钢管的安装，应尽可能在舱室内的焊接和除锈打磨工作完工后，否则必须用石棉布/三防布包扎保护。6 检验 6.1 管系安装结束后,应检查其完整性符合图纸要求. 附件安装正确. 螺栓完全紧固. 6.2 按图纸要求进行密性试验或强度试验.This workmanship is applicable for the piping arrangement, processing and inst
9、allation of 5200DWT chemical product tanker. It is written with reference to CB/Z345-85 “The general rules for marine pipes arrangement and installation technology”CB/T3790-97 “Rules for marine pipes processing technology” CB/T3626-94 “The quality requirements for vent ducts and fittings installatio
10、n in cabins” as well as the relevant technical requirements in the main piping principle diagrams of 5200DWT approved by BV classification society. The other details, which are not specified in this workmanship, can be consulted from the a.m. standards. Each working department must carry out the rel
11、ative requirements of this workmanship strictly.1. The principle of piping arrangement1.1 The pipeline to be laid as levelly as possible and be arranged in bundles in order to have a good appearance. To avoid unnecessary bypass and cross and to prefer arranging those pipelines with big diameters.1.2
12、 The space between pipelines1.2.1 The space between parallel or cross pipes (including pipe fittings):20mm. For those pipes needing insulation, the space between their outer surfaces and the neighboring pipes, fittings or the hull structure20mm after being insulated.1.2.2 The spaces between the foll
13、owing pipes and cables to be over 100mm.a. The insulation surface of heating pipeb. The insulation surface of exhaust pipec. Compressed air pipe (The pressure is over 1.0Mpa)1.3 The arrangement of pipelines must consider easy installation and operation. Each kind of pipe to be arranged along hull st
14、ructure or tank neighborhood as practicable as possible and not in the way of passageway, alleyway, exit, door, manhole and hatch cover.1.4 In alleyway area, pipeline cannot be arranged on the positions for inspection to ensure that working staff has enough space to disconnect maintain and inspect e
15、quipment. The dismantling workload must be minimum when pipes are being inspected.1.5 The piping to be arranged as far as possible from switchboard, control box and cable.1.6 The following pipes in F.O. tanks cannot put through accommodation: air pipes, overflow pipes, sounding pipes and filling pip
16、es and cannot be in the way of the alleyway. If any, they must be connected with tubes.1.7 To avoid arranging oil pipes, water pipes and exhaust pipes over monitoring room, electrical equipment (as well as their backs). If any, they must be connected with tubes.1.8 Chunnel, exhaust pipe and silencer
17、 to be kept away from oil pipes and oil tanks.1.9 Sounding pipe to be arranged vertically to deck.1.10 To set “S” bends under the sewage pipes and sink draining connections; to choose water-closing scupper for accommodation cabin. The inclination of their drainage pipelines cannot be less than 30mm/
18、1000mm. To consider flange connections outside the accommodation for preference and install drain connections. Choosing tube connections in accommodation in order to avoid disconnectable joints. 1.11 Cargo oil pipes to be connected by butt-welding and to reduce the amount of disconnectable joints.1.
19、12 The supports of bigger pipelines to be welded on the hull structure.1.13 Bends or expansion compensation to be taken into consideration for the following pipelines to avoid the deformation of hull structure caused by pipelines expansion.a. The ballast pipes, bilge pipes in tanksb. The pipes acros
20、s through two watertight bulkheadsc. The pipes connected with equipment shaking tremendously. 2. The principle of fittings arrangement2.1 Valves, cocks and filters to be installed on the spaces easy for operation, the operating direction of hand wheel to be horizontal.2.2 The space between hand whee
21、ls is over 30mm when valves are being installed side by side.2.3 The inlet/outlet pipes connected with tank to be centralized arranged according to corresponding systems.2.4 The hand wheel to be parallel to checked steel plate when valve is arranged under the steel plate. And to open holes on the co
22、rresponding position of the plate for installing movable cover board.2.5 In principle, the valves of mud box filter and bilge pipeline to be laid under the checked steel plate and to consider the possibility of cleaning.2.6 The heating coil to be arranged around the suction.3. The installation requi
23、rements for pipelines passing through the hull structure3.1 To use penetration pipe or flange welding board when pipe passes through the hull structure of deck, watertight bulkhead, double bottom and engine room wall.3.2 The type of penetration pipe is QJ/XG02.028-94 (tube welding type); flange type
24、 penetration pipe refers to CBM1093-81, CBM1094-81, welding fixed type refers to CB/T3480-92.4. The pipe processing4.1 Generally to be bent in cold process, if necessary, molding bends can also be used, especially for those pipes with outer radius over 100mm. The bending of cargo oil pipes can use 3
25、16L stainless steel molding bends. Welding three-way pipe can be used for branches.4.2 In general, the bending radius of pipe is twice or three times of its outer radius.4.3 To do strength test after finishing pipe manufacture and do tightness test on board. In case that the strength test is not app
26、licable in workshop, it can be done on board with the tightness test together. (Except for fittings).4.4 The pipe flushingAfter finishing manufacture, the following pipes to be cleaned by chemical particle: Fuel oil pipes, lubricating pipes, hydraulic pipes, compressed air pipes, and be applied with
27、 oil inside and paint outside. Before installing, the opening of pipes must be closed and the seal can be removed after pipes have been installed on board. Flushing pipes before they start working.4.5 The pipelines of seawater, fresh water, ballast, bilge, air, drainage and potable water to be galva
28、nized according to drawing. The layer of galvanizing to be smooth. Galvanization missing, flowing, stripping off and bubbling as well as other bad conditions cannot be found.4.6 H.T and L.T fresh water pipes to be cleaned by chemical particle and phosphate coated. To be applied with paint outside.4.
29、7 When welding has destroyed galvanization, the surface shall be touched up with zinc solution paint.4.8 Cargo oil pipes are to be 316L stainless steel pipes; flanges are 316L welding neck flanges. Welding wire to be recommended by pipe manufacturer and be supplied with pipe material.5. The installa
30、tion requirements for piping and fittings5.1 To confirm the base of pipe installation before installing.5.2 Only acceptable pipes can be installed on board. And to keep clean inside.5.3 To confirm the installing position first before piping installation, such as seawater main pipe, suction, then to
31、fit them according to the corresponding system.5.4 System washer choosing:Potable water supply system nontoxic silicon rubber washerFuel oil, lubricating oil, compressed air non-asbestos washerSteam systemBallast, bilge, cooling water, drainage non-asbestos washerExhaust graphite washerCargo oil pip
32、ing PTFE washer5.5 The support CB/T 3780-97 to be galvanized as “U” shape. (If it locates inside the tank, galvanization is not necessary)5.6 316L stainless steel pipe to be installed in cargo oil area after all welding and grounding works have been finished. Otherwise, it must be protected with asb
33、estos clothes or other clothes with three protective function (such as fireproof, waterproof)6. Inspection 6.1 To check if the integrity of piping meets with the drawing requirements after finishing installation. Fittings must be fixed correctly and bolt must be fit tightly.6.2 To do tightness test or strength test in accordance with the drawing requirements.
