pipeprefabrication guidelines.docx
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pipeprefabricationguidelines
管道预制导则
pipe-prefabricationguidelines
目录
Contents
第一章焊接规范及要求
Chapter1Codeandrequirementsforwelding
第二章焊接材料
Chapter2Weldingmaterials
第三章管道加工
Chapter3Pipingmachining
第四章焊接检验
Chapter4Weldinginspection
第五章焊接试件
Chapter5Weldedjointspecimens
第六章管道安装
Chapter6Erectionofpiping
第七章安全事项
Chapter7Safetyproceeding
第八章引用标准
Chapter8ExecutiveStandards
一焊接规范及要求Codeandrequirementsforwelding
1适用于含碳量≤0.3%的碳素钢、低合金结构钢、低温钢、耐热钢、不锈钢、耐热耐蚀高合金钢现场焊接设备和管道的手工电弧焊、氩弧焊、二氧化碳气体保护焊、埋弧焊及氧乙炔焊；
Thisfileisapplicabletoweld（suchasmanualarcwelding、argonarcwelding、CO2shieldwelding、submergedarcweldingandoxyacetylenewelding）atplantbetweencarbonsteel（CarbonContent≤0.3%）、Lowalloystructuresteel、lowtemperaturesteel、heat-resistantsteel、stainlesssteel、highalloysteelequipmentsorpiping.
2焊接设备、检验设备等均应具有参数稳定、调节灵活、安全可靠的性能，并能满足焊接工艺的要求；
Welders、checkingdevicesetc.musthavestableparameter、flexibleconditioning、safetycapacity，andcouldappeaseweldingtechnology.
3施焊环境应符合下列规定：
Weldingenvironmentshouldaccordwithfollowingrules:
1）焊接的环境温度应能保证焊件焊接所需的足够温度和焊工技能不受影响；
Weldingenvironmenttemperatureshouldguaranteethatweldmentneededenoughtemperatureandwelder’sabilitycouldn’tbeaffected;
2）焊接时的风速不应超过下列规定，当超过规定时，应有防风设施：
Thewindspeedduringweldingshouldnotupwardsoffollowingrules,thefacilitymustbedoneifthewindspeedisovered:
1手工电弧焊、埋弧焊、氧乙炔焊：
8m/s
manualarcwelding、submergedarcweldingandoxyacetylenewelding:
8m/s
②氩弧焊、二氧化碳气体保护焊：
2m/s
argonarcwelding、CO2shieldwelding:
2m/s
3）焊接电弧1m范围内的相对湿度不得大于90%；
Therelativehumiditywithin1mofweldingarcmust≤90%;
4）当焊件表面潮湿、覆盖有冰雪，或在下雨、下雪刮风期间，焊工及焊件无保护措施时，不应进行焊接；
Weldingshouldnotbedonewhenweldmentsurfacehumidity、coveredwithsnowandice,orwelderandweldmenthavenoprotectduringraining、snowing、winding;
4焊接人员、无损检测人员均应持有相应资格证书；
Welderandnon-destructivetestingpersonnelmusthaverelevantcertificateofcompetency;
5每名焊工应有施工单位统一规定的代号和相应的钢印字头，低温钢管道、不锈钢管道的焊接接头应用记号笔作出焊工代号标识；其他管道的焊接接头宜用钢印作出焊工代号的标识，标识深度不大于0.5mm；
Everyweldermusthasasymbolandrelevantsteelsealbyconstructionunit’sspecified.Welder’ssymbolmustbesignedwithmarkerforweldedjointoflowtemperaturepiping、stainlesssteelpiping;other’scouldbesignedwithsteelseal,signdepth≤0.5mm;
6焊缝的设置应避开应力集中区，便于焊接和热处理，并应符合下列规定：
Weldseam’scollocationmustbeavoidedstressraiser,easytoweldandheattreatment,andaccordedwithfollowingrules:
1）钢板卷管或设备、容器的筒节与筒节、筒节与封头组对时，相邻两纵向焊缝间的距离应大于壁厚的3倍，且不应小于100mm；同一筒节上两相邻纵缝间的距离不应小于200mm；
Forsteelplaterolled-upcylinder、vessels’shelltoshell、shelltoheadpairing,thedistancebetweencloserlengthwaysweldingshould＞thricewallthicknessand≥100mm;thedistancebetweencloserlengthwaysweldingshould≥200mmonsameshell;
2）除焊接及成型管件外的其他管子对接焊缝的中心到管子弯曲起点的距离不应小于管子外径，且不应小于100mm；管子对接焊缝与支、吊架边缘之间的距离不应小于50mm。
同一直管段上两对接焊缝中心面间的距离：
当公称直径大于或等于150mm时不应小于150mm；公称直径小于150mm时不应小于管子外径；
Thedistancebetweenbuttweldingcentertobendpointshouldnotlessthanpipeoutsidediameterand≥100mmexceptpipefittings;Thedistancebetweenpipe’sbuttweldingtoedgeofsupport、hangershouldnotlessthan50mm;Thedistancebetweentwobuttweldingcenteronsamestraightpipe:
shouldnotlessthan150mmwhennominalsize≥150mm;shouldnotlessthanpipeoutsidediameterwhennominalsize＜150mm;
3）不宜在焊缝及其边缘上开孔，当不可避免时，应对开孔直径1.5倍或开孔补强板直径范围内的焊缝进行无损检验，确认焊缝合格后方可开孔，补强板覆盖的焊缝应磨平；
Itisn’tgoodtoopeningonweldingoredge,whenineluctability,thenon-destructivetestingshouldbedoneforweldingwithindiameterareaof1.5timesopeningorreinforcementpad,openingcouldbedoneaftercheckedout,theweldingcoveredwithreinforcementpadmustberubdown;
7焊件组对前应将坡口及其内外侧表面不小于10mm范围内的油、漆、垢、锈、毛刺及镀锌层等清除干净，且不得有裂纹、夹层等缺陷；
Thesurfaceandtheareaofinside、outsidenotlessthan10mmofweldinggroovemustbecleanedupbeforepairing,suchasoil、paint、dirt、rust、burrandzinccoat,welddefectsuchascrack、interlayeretc.isneverallowed;
8管子、管件的坡口形式和尺寸应符合设计文件规定，当设计文件无规定时，可按下表的规定确定：
Groovetypeanddimensionofpipe、pipefittingshouldaccordwithdesigndocuments,andcanaccordingtofollowingtableifdesigndocumentshavenoprovision:
项次NO.
厚度T（mm）
thickness
坡口名称
Groovename
坡口形式
Groovetype
坡口尺寸Groovedimension
备注
remark
间隙mmc
clearance
钝边p
mm
rootface
坡口角度α（β）
grooveangle（º）
1
1~3
Ⅰtype
0~1.5
/
/
single-sidedweld
3~6
0~2.5
/
/
double-sidedwelding
2
3~9
Vtype
0~2
0~2
65~75
9~26
0~3
0~3
55~65
3
6~9
Vtypewithbacking
3~5
0~2
45~55
9~26
4~6
0~2
4
12~60
Xtype
0~3
0~3
55~65
5
20~60
DoubleVtype
0~3
1~3
6
20~60
Utype
0~3
1~3
（8~12）
7
2~30
TtypejointⅠtypegroove
0~2
/
/
8
6~10
Ttypejoint
SingleVtypegroove
0~2
0~2
45~55
10~17
0~3
0~3
17~30
0~4
0~4
9
20~40
TtypejointsymmetricalKtypegroove
0~3
2~3
45~55
10
Ø≤76
管座坡口
Bushinggroove
2~3
/
50~60
（30~35）
11
Ø76~133
管座坡口
Bushinggroove
2~3
/
45~60
12
法兰角焊接接头
Flangefillet
/
/
/
K=1.4T
E=6.4and≤T
13
承插焊接法兰socket-weldingflange
1.6
/
/
K=1.4T
14
承插焊接接头socket-welding
1.6
/
/
K=1.4Tand≥3.2
9管道坡口加工宜采用机械方法，也可采用等离子弧、氧乙炔焰等热加工方法。
采用热加工方法加工坡口后，应除去坡口表面的氧化皮、熔渣及影响接头质量的表面层，并应将凹凸不平处打磨平整；
Pipegrooveshouldbedonebymachine,andmaybedonebyhotfinishedmethodtoo,suchasplasmaarc、oxyacetylene;ifusehotfinishedmethod,oxidation、sinter、surfacelayerwhowillaffectweldingqualityshouldberemoved,andburnishedtoflat;
10管道组成件组对时，对坡口及其内外表面进行的清理应符合下表的规定；清理合格后应及时焊接；
Whenpairing,accordingtofollowingtabletocleangrooveandit’ssurfaceinsideandoutside;weldimmediatelyaftercheckout;
Pipemetal
Cleanarea（mm）
Cleanobject
Cleanmethod
carbonsteel
alloysteel
stainlesssteel
≥10
oil、paint、rust、burretc.
Manualormachinework
11除设计文件规定的管道冷拉伸或冷压缩焊口外，不得强行组对；
Weldjointmustnotbeforcedassemblyexceptwhichiscoldpullpipeorcoldextrusionpipebydesigndocument;
12管道对接焊口的组对应做到内壁齐平，内壁错边量应小于壁厚的10%，且不大于2mm;
Insidewallshouldbeguaranteedflatforpipebuttweldingpairing,offsetofplateedgesofinsidewallshouldlessthan10%ofwallthicknessand≤2mm;
13不等厚管道组成件组对时，当内壁错边量超过上条的规定或外壁错边量大于3mm时,应按下图进行修整：
Forpairingwithdisaffinitywallthicknesspipe,whenoffsetofplateedgesofinsidewallisoveredofaboveitemoroffsetofplateedgesofoutsidewallis＞3mm,shouldaccordtofollowingdrawingtoadjust:
注：
用于管件且受长度条件限制时,图（a）①、（b）①和（c）中的15º角可改用30º角。
Note:
indrawing（a）①、（b）①and（c）:
thedegree15ºcanbechangedto30ºwhenuseforpipefittingandlengthconditionislimited.
14在焊接和热处理过程中，应将焊件垫置牢固；
Weldmentshouldbeputhardduringweidingandheattreatment;
15当对螺纹接头采用密封焊时，外露螺纹应全部密封；
Revealativemalethreadshouldbeallpressurizedwhenweldthreadedjoint;
16对管内清洁要求较高且焊接后不易清理的管道，其焊缝底层应采用氩弧焊施焊。
机组的循环油、控制油、密封油管道，当采用承插焊时，承口与插口的轴向不宜留间隙；
Forsomepipe,whichinsidecleangradeishigherordifficulttocleanafterwelded,argonarcweldshouldbetakentoweldbottomwelding;foroilpipe,socketandspigotshouldnothavenclearanceataxialdirectionwhenusesocketwelding;
17法兰的焊接按相应法兰标准，螺栓孔应跨中布置；
Flangetopipeweldaccordingtorelevantflangestandard,boltholesofflangeshallbestraddledonaxisofthepipe;
18尺寸在DN25以下的焊接阀门焊接时应将阀门打开；
Weldingvalveswhichdiameter≤25mmshouldbeopenedduringwelding;
19与母材焊接的工卡具，其材质宜与母材相同或同一类别号，拆除工卡具时不应损伤母材，拆除后应将残留焊疤打磨修整至与母材表面齐平；
Forchuckingappliance,whichisweldedtobasemetal,it’smaterialshouldbethesamewithbasemetalorsameclass,shouldnotdamnifythebasemetalwhenbackout,rudimentalcratershouldbeburnishedtoflatwithbasemetalsurfaceafterbackout;
20严禁在坡口之外的母材表面引弧和试验电流，并应防止电弧擦伤母材；
Prohibittostrikearcandtestelectricityatbasemetalsurfaceoutofgroove,andavoidarctobruisebasemetal;
21对含铬量大于3%或合金元素总含量大于5%的焊件，氩弧焊打底焊接时，焊缝内侧应充氩气或其他保护气体，或采取其他防止内侧焊缝金属被氧化的措施；
Forsomeweldments,whichChromiumcontent＞0.3%orconcentrationofalloyingelement＞0.5%,insideweldingshouldbepuffedwithargonorotherprotectivegaswhenuseargonarcbackingweld,ortakeothermeasuretoavoidinsideweldingmetalbeoxidation;
22焊接时应采取合理的施焊方法和施焊顺序；
Logicalweldmethodandsequenceshouldbetakenduringwelding;
23施焊过程中应保证起弧和收弧处的质量，收弧时应将弧坑填满，多层焊的层间接头应错开；
Weldingqualityatscratchstartandrun-outpositionshouldbeguaranteed,cratershouldbefilledinatfade-out,weldjointshouldbestaggeredformulti-layerwelding;
24管子焊接时管内应防止穿堂风；
Draughtshouldbeavoidedduringpipewelding;
25除工艺或检验要求需分次焊接外，每条焊缝宜一次连续焊完，当因故中断焊接时，应根据工艺要求采取保温缓冷或后热等防止产生裂纹的措施，再次焊接前应检查焊层表面，确认无裂纹后，方可按原工艺要求继续施焊；
Eachweldingshouldbecompletedcontinuouslyexceptdispartweldbytechnologyorinspection;ifinterruptwelding,somemeasureaccordingtotechnology,suchasheatpreservationcoolingslowlyorpost-heatetcshoutbedonetoavoidcrack,weldingcouldbecarriedoverbyoriginaltechnologyaftercrackonlayerhasbeenconfirmdnonentity.
26应根据设计规定对奥氏体不锈钢焊缝及其附近表面进行酸洗、钝化处理；
Weldingandit’sroundsurfaceofausteniticstainlesssteelshouldbeacidpickledandpassivatedaccordingtodesignrules;
二焊接材料Weldingmaterials
1母材——被焊工件材料
basemetal__weldmentmaterial
常用管道材料牌号、化学成分对照见下表
Materialtrademark、chemicalcompositionofstaplepiperefertofollowingtable:
牌号
trademark
化学成分（质量分数）%chemicalcomposition
C
Si
Mn
P
S
Ni
Cr
Cu
20
0.17~0.23
0.17~0.37
0.35~0.65
≤0.030
≤0.030
≤0.30
≤0.25
≤0.25
16MnR
≤0.20
0.20~0.55
1.20~1.60
≤0.035
≤0.030
0Cr18Ni9
≤0.07
≤1.00
≤2.00
≤0.035
≤0.030
8.0~11.0
17.0~19.0
Q235
≤0.22
≤0.35
≤1.40
≤0.045
≤0.045
2焊接材料
Weldingmaterial
1）焊接材料包括焊条、焊丝、焊剂、气体、电极和衬垫等，焊接材料质量证明
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