林德3PE防腐方案Word格式.docx
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Projectoverview
1、工程概况.........................................................1-3
Fabricationreference
2、编制依据.........................................................3-3
Constructionprinciple
三、施工原则.........................................................3-3
3PEanticorrosiveproductionprocess
四、3PE防腐生产工艺流程..............................................4-9
3PEanticorrosivespecificproductionsteps
5、3PE防腐具体制作步骤.............................................9-13
Heatshrinkabletapeanticorrosiveconcretesteps
六、热收缩带防腐具体步骤............................................14-15
Safetyattentions
七、安全注意事项....................................................16-16
ProjectOverview
一、工程概况
ThisprojectisLindeHuayi(Chongqing)GasesCo.,Ltd1BillionNm3/yearSyngasCO/H2project,locatedinChongqing(Changshou)ChemicalIndustryPark,andthemainworkcontainssubstation、compressionunit、powerabsorptionunit、washingunit、rawgascompressorunit、Hightemperatureshiftunitetc..
本项目为林德化医(重庆)气体有限公司10亿Nm3/年合成气制备CO/H2项目,位于重庆(长寿)化工园区内,其中主体工作包括变电所、压缩单元、变电吸附单元、洗涤单元、原料气压缩单元、高温变换单元等。
Undergroundpipelinecontainscirculatingwatersystem,watersystem,watersupplyanddrainagesystem,atotalofabout1744mweldingpipeextension,Dia-intotalof10070inch,buriedsteelpipeanticorrosionmethods3PEcoating,toensurethattheundergroundpipelineanticorrosionconstructionsafety,highquality,efficientcompletionoftheproject,especiallythepreparationofthisplan.
地下管道包括循环水系统、工业水系统、给排水系统,管道共计延长米约1744m,焊接Dia-in共计10070寸,埋地钢管防腐方法采用3PE涂层防腐,为保证地下管道防腐施工安全、优质、高效完成,特编制本方案。
Fabricationreference
二、编制依据
1)Linderelateddrawingandtechnicalstandard林德相关图纸、技术标准
2)Polyethylenecoatingforburiedsteelpipeline
埋地钢制管道聚乙烯防腐层........................................(GB/T23257-2009)
3)Watersupplyanddrainagepipelineengineeringconstructionandacceptance
《给排水管道工程施工及验收规范》...................................(GB50268-97)
4)Petroleumandchemicalequipmentandpipelinetechnicalspecificationforthecoatinganticorrosion
《石油化工设备和管道涂料防腐蚀技术规范》..........................(SH3022-1999)
5)Technicalcodeforconstructionsafetyinpetrochemical
石油化工施工安全技术规程.........................................(SH3505-99)
6)Petrochemicalindustryspecificationforconstructionandacceptanceofwatersupplyanddrainagepipeline
石油化工给排水管道施工及验收规范.................................(SH3533-2003)
7)Steelsurfacebeforeapplicationofpaintandrustgradesandpreparationgrade
涂装前钢材表面锈蚀等级和除锈等级..................................(GB8923-88)
ConstructionPrinciple
三、施工原则
Undergroundpipeline,pipeanti-corrosionworkbyprofessional3PEcoatingmanufacturers,inChongqingarea3PEcoatingtechnologyandscaleofproductiontoreachthecoastalareasofthecorrosionandscale,isnowtheChongqingarea3PEpipelinecoatingproductionintherangeof20-950mm,thediametermorethan950mmpipeusingthermalbeltwindinganticorrosion,andallfittings,mending,weldingusingthesamePEshrinkwithanti-corrosion,anti-corrosionprocessingplantintheaboveworkfocusedonthecomplete,reachthemaintenanceperiod,transportedintotheconstructionsiteinstallation,pressuretestafterpassingtherequiredrepairingandmending.
地下管道、管件防腐工作由专业3PE防腐厂家完成,鉴于重庆地区3PE涂敷技术及生产规模达不到沿海地区的防腐水平及规模,现目前重庆地区3PE管道防腐生产范围在20-950mm,对于管径超过950mm的管道采用热缩带缠绕防腐,且所有管件、补伤、焊口同样采用聚乙烯热缩带防腐,以上防腐工作集中在加工厂内完成,达到养护期后,运入施工现场安装,试压试验合格后按规定补口补伤。
四、3PEanticorrosiveproductionprocess3PE管道防腐生产工艺流程
4.1Thefollowing950mmpipelineanticorrosionprocess950mm以下管道防腐流程
Bottom→spray→epoxypowder底层→喷涂→环氧粉末
middlelevel→extrusioncladding→adhesive中层→挤出包覆→胶粘剂
outersphere→extrusioncladding→PE外层→挤出包覆→PE
1)Pipesandblasting管道喷砂
2)Pipelinethroughthelinesintothehigh-frequencyheatingtoheat,afterthegluemachineglue.管道经过流水线进入高频加热机进行加热,经过涂胶机上胶。
3)Highfrequencyheatingequipmenttopolyethyleneparticlesofmoltenpolyethylene
高频聚乙烯加热设备将聚乙烯颗粒熔化
4)Pipelinecoatingmachinetostartcoating3PE管道包覆机开始包覆3PE
5)Enterthecoolingproductionline进入冷却生产线
6)Inletpipegrindingprocessing进入管口打磨处理
7)Inspectionandidentificationofissuanceproceduresindicatedfactory
检查合格并注明标识发放出厂手续
4.2Morethan950mmpipeline,welding,pipe,heatshrinkabletapeanticorrosiveprocess
950mm以上管道、焊口、管件、热收缩带防腐流程
五、3PEanticorrosivespecificproductionsteps3PE防腐具体制作步骤
5.13PEpipelineanticorrosion3PE管道防腐
5.1.1Preparatoryprocess准备工序
1)Accordingtotheproductiontasklistinthesteelpipespecifications,adjustalltransmissionlinesonbothsidesofthedrivingwheelofthedistanceandangle.De-rustingproductionlinepipebottomheightfrom540mm;
3PEcoatingproductionlinepipeendawayfrom630mm.根据生产任务单中的钢管规格,调整好所有传动线两侧传动轮的距离和角度。
除锈生产线管底离地高度540mm;
3PE防腐生产线管底离地630mm。
2)AdjustthegoodadhesiveandPEextruderoffrontandrearposition.调整好胶粘剂和PE挤出机的前后位置。
3)Adjustthepositionandangleofsiliconrubber.调整硅胶轮的位置和角度。
4)Adjustthespraygunpositioninradialandpointtothepipeaxis,thedischargeneedleintothesteelpipesurfacedistance120-150mm.调整喷粉枪的位置在钢管径向并指向钢管轴心,放电针针尖到钢管表面的距离120-150mm。
5)Sizeextruderintheplanstarted3hoursbeforethestartofheating.大小挤出机在计划开工前3小时开始加热。
6)1hourbeforethestartofPErawmaterialpreheatinganddrying,thedryingtemperatureisnothigherthan80DEGc.计划开工前1小时进行PE原料预热烘干,干燥温度不高于80℃。
7)Checktheoperationconditionofequipment,givethetransmissionpartslubricatingoilfilling;
thefasteningshaftcouplingscrews,crossshaftandtheexpansionjointstoaddenoughoil;
inspectionofliftingmechanismpositionandlimitdevicereliability.
检查设备运行情况,给各传动部位加注润滑油;
紧固传动轴的联结螺丝,给十字轴和伸缩节加足油;
检查升降机构的位置及限位器的可靠性。
8)Anticorrosionepoxypowdercoating,adhesive,polyethylenetheirqualityshallmeetthespecifications,andthroughinspectionandacceptance.防腐用的环氧粉末涂料、胶粘剂、聚乙烯其质量应满足规范要求,并经过检查验收。
5.1.2Barepipetube裸管上管
a.Accordingtotheproduction,taskorderstopipetransporttubeontheplatform.
根据生产任务单将钢管转运到上管平台。
b.Inspectionoftheappearancequalityofsteelpipe,toseeifthereareanyextrusiondeformation,scratchesandotherdefects,suchastimelytomakeamark,putitsmaterialunqualifiedareaorrepairarea.检查钢管的外观质量,察看有无挤压变形、碰伤等缺陷,如有及时作出标记,将其放到材料不合格区或修复区。
5.1.3Blastcleaning抛丸除锈
1)Rustmustbecheckedandclearedbothinsideandoutsidethepipesurfacegreasydirt,burrs,attachmentandotherimpurities.除锈前必须检查并清除钢管内外表面的油污、毛刺、附着物等杂质。
2)Pipesurfacetemperatureisbelow3℃steelpipemustbeheatedto40~60℃,thenthepipeuniformthroughthede-rustingmachine,de-rustinggradereachesGB/T8923-88standardSa2.5grade,theanchorlinestoadepthof50-75μM.
钢管表面温度低于3℃时钢管要加热到40-60℃,然后将钢管匀速通过除锈机,除锈等级达到GB/T8923-88标准的Sa2.5级,锚纹深度达到50-75μm。
3)Rustafterplacementof4hoursormoreorreturnstainlesssteelpipesneedtorust.除锈后放置4小时及以上或返锈钢管须要重新除锈。
5.1.43PEtoppipe3PE上管
a.Onthefronttubeinadeposition-managementplatforminspectionandremovalofsteelpipewithinnerandoutersurfaceoftheburr,dustandotherimpurities.Ifdefectstoreturnmaterialunqualifiedareaorrepairarea.上管前在存管平台上检查并去除钢管内外表面的毛刺、灰尘等杂质。
如有缺陷返回材料不合格区或修复区。
b.Thepasteevenlyintheprotectivepaper(100mmwidth),andonitsleftsideof10mmwidedon'
tspreadthepaste;
andthentheprotectivepaperformationattachedtothepipeend,notenosmearpastesideatadistanceofnozzleinner.将浆糊均匀涂抹在防护纸(100mm宽)上,并在其一侧留10㎜宽不要涂浆糊;
然后将防护纸平整贴附在钢管管端,注意没有抹浆糊的一侧在距管口的内侧。
c.Thepipeintothepipepullingdevice,throughthetubeisputintothetransmissionlinesteelpipe;
pipeandnozzledistanceascloseaspossibleto,payattentiontothegoodjoint.将管放到拔管器上,通过拔管器把钢管放到传动线上;
上管时前后管口的距离尽量靠近,注意对好接头。
d.Beforethestartofproductionprocessinatimelyandcleardrivingwheelonthedust,debris.开工前和生产过程中及时清理传动轮上的灰尘、杂物。
5.1.5Intermediatefrequencyheating中频加热
1)Startthecoolingwaterpressurepump,checkiftheheaterwateroutletpipeofthewatercoolingsystemineachcasewhetherthereisabnormal.起动冷却水加压泵,检查中频加热器冷却系统每个出水管的出水情况是否有异常。
2)Startingthedriveline,steelpipetomoveuniformly.启动传动线,让钢管匀速前进。
3)Startfrequencyheater,slowlyrotatingheatingpoweradjustmentknob,thesteeltemperatureto200-220℃,foratleast30minutesretestonce.启动中频加热器,缓慢旋转加热功率调整旋钮,将钢管温度加到200-220℃内,至少30分钟复测一次。
4)Afterworktostopandstartinreverseorder.工作完毕时停止过程与启动顺序相反。
5.1.6Drydusting喷粉
a.Afterheatingthesteelpipeintothespraybox,openthesprayingequipment;
accordingtothepipesizeidentifyopenequipmentnumber.ThecoatingthicknesstoachievetherequirementsinTable1;
coatingonthesurfaceofasteelpipetobeuniform.加热后的钢管进入喷涂箱后,打开喷涂设备,根据钢管的大小确定打开的设备数量。
使涂层厚度达到表1要求;
涂层在钢管表面要均匀。
b.Apressureofnotmorethan0.1MPa,twopressuresshallnotexceed0.05MPa.
一次气压不宜超过0.1MPa,二次气压不宜超过0.05MPa。
Table1表1
SteelpipeDN(mm)钢管公称直径
Epoxypowdercoating
环氧粉末涂层
(μm)
Adhesivecoating
胶粘剂涂层
Minimumthicknessofanticorrosivecoating防腐层最小厚度(mm)
Ordinarygrade普通级(G)
Strengthengrade
加强级(S)
DN≤100
>80
170-250
1.8
2.5
100<DN≤250
2.0
2.7
250<DN<500
2.2
2.9
500≤DN<800
3.2
DN≥800
3.0
3.7
5.1.7Adhesive,PEwinding胶粘剂、PE缠绕
1)Accordingtothepipesizeandthetransmissionlinespeedregulationofthespeedofextruder,cross-linkingagent,polyethylenethickness(coatingthicknessgaugetest)accordingtotable1control:
根据钢管的大小和传动线的速度调节好挤出机的转速,胶联剂、聚乙烯层厚度(用涂层测厚仪检测)按表1控制:
2)Ensurethatthethicknessofthecoating,controlofseamwidthof15±
5㎜.
保证防腐层厚度,控制压缝宽度15±
5㎜。
3)Afterworkintimetoclearupthepowder,spraygunandthepipeline,topreventfouling,prepareforthenextus