不锈钢管道预制施工方案docx.docx

1、不锈钢管道预制施工方案docx.一、 Purpose 目的This statement is compiled to ensure the construction quality of Bayerproject pipe fabrication and meet the progress requirement. Thisstatement is used to guide the fabrication of all Stainless Steel pipe afforded by CNF in Bayer MDI 。为了保证项目管道预制工程的施工质量和满足工程进度要求，特编制本方案。本方

2、案用以指导拜耳异氰醋酸聚醚项目 MDI联合装置内 CNF承担的所有不锈钢材质管道的预制施工。二、 Applicable Scope 适用范围This statement is applicable for all Stainless Steel pipe fabrication work afforded by CNF in Bayer MNB(V210) / WNILINE(V310).本方案适用于拜耳项目 MNB(V210)/WNILINE(V310)装置内 CNF承担的所有不锈钢管道预制工程的施工。三、 Reference 编制依据Technical specification and

3、standard of this method statement:本方案编制依据的施工技术规范和标准为：（1） GB50235-97construction and acceptance of industrial metal pipeproject GB50235-97 工业金属管道工程施工及验收规范（2） GB50236-98welding project construction and acceptancespecification of site equipment and industrial pipeGB50236-98 现场设备工业管道焊接工程施工及验收规范（3） Bayer

4、 relevant technical document standard拜耳的相关技术资料（WN标准）（4） 管道相关图纸四、 Overview 工程概况1Work scope 工作范围The scope ofthis projectincludes allStainlessSteel pipefabrication of MNB/ANILINE包括 MNB 、ANILINE 两个装置中的所有不锈钢管道的预制。2Major project quantity 主要工程量Stainless Steelpipe in MNBisabout 4679m (pipe dia DN15- DN600),

5、which amounts to70 of the whole run.MNB 装置中不锈钢管大约 4679 米（管径 DN15- DN600）占总管道的 70.Stainless Steel pipe in ANILINE is about 1900m(pipe dia DN15- DN400), which amounts to 20 of the whole run.ANILINE 装置中不锈钢管大约 1900 米（管径 DN15- DN400）占总管道的20。五、 Technical conditions 技术条件1Technical documents 技术文件1.1 Three-d

6、imensional piping drawing used for industrialized prefabrication用于工厂化预制的管道三维图1.2 Relative construction technical documents (working instructor, process procedure) and management procedure相关的施工技术文件（作业指导书、工艺规程）和管理程序1.3 Construction technical clarification card施工技术交底卡1.4 Standard for piping materials a

7、nd fittings管材及配件尺寸标准2Quality control documents质量控制文件2.1 Materials qualification or acceptance report材料合格证或验收报告2.2 Working procedure handover slip操作工序交接单2.3 Conformance inspection table of piping prefabrication管道预制件的符合性检查表2.4 Tracking drawing and tracking sheet for welding craters焊口跟踪图及跟踪单2.5 Inspect

8、ion report (RT, PT, VT)检验报告（ RT、PT、VT ）六、不锈钢材料的验收及检验标准：1.管道用材料，焊接用材料必须具有制造厂的合格证明书和质量证明书，请业主协助完成此项工作。质量证明书应包括以下内容：.产品标准号材料的牌号材料的炉罐号、批号、交货状态、重量和件数品种名称、规格及质量等级产品标准中规定的各项检验结果技术监督部门的印记。2.按设计要求核对其规格、材质、型号。3.外观检查：无裂纹、缩孔、夹渣、折迭、重皮等缺陷，所有管道壁厚均不得有负偏差。4.法兰、焊环及盲板密封面平整、光洁、不得有毛刺及径向沟槽，螺栓，螺母的螺纹完整，无伤痕，无毛刺等缺陷，配合良好。垫片，无

9、折损、皱纹等缺陷。5.经检验合格的管材，应按规格尺寸分别放置在专门设置的地方，严禁与钢材混堆和直接接触或碰伤。6.材料负责人检查并收集管道、管件、阀门、焊丝等所有管材的合格证及质量保证书。7.弯头、异径管、三通、法兰、盲板及紧固件等进行检查，其尺寸偏差应符合现行标准，材质应符合设计要求。8.石棉、橡胶、塑料等非金属材料垫片应质地柔和，无老化变质或分层现象。表面不得有折损，皱纹等缺陷。金属垫片的加工尺寸、精度、光洁度及硬度应符合要求，表面应无裂纹、毛刺、凹凸槽径向划痕及锈斑等缺陷，包金属及缠绕式垫片不应有径向划痕、松散等缺陷。9.对验收后的不锈钢材料（管子、管作、法兰）每批进行5%的光谱分析检查

10、。七、 Fabrication preparation and step 施工预制准备和步骤10. Preparation for fabrication 预制准备10.1. According to the demand of Bayer project work, Stainless Steelfabrication yard is set in (CNF Weiwu Road).根据拜耳要求和施工的需要分别设置两个预制场地： 不锈钢预制场设置在（ CNF 卫五路）.10.2. Before fabrication, pipe professional technician shall t

11、imely do theshift work of drawings, mark weld NO. SW-shop weld; FW-field weld.The principle of drawing shift: expand fabrication depth based onthe convenient transportation and installation together with plansketch, in order possibly to finish fabrication work in fabricationshop and管道预制前，管道专业技术人员要做好

12、图纸转换，标定焊口号： SW 表示预制焊口， FW 现场焊口，预制分段。图纸转换的原则是：为了尽可能多在预制车间内完成管道的制作， 结合平面图在考虑方便运输与安装的前提下，尽量扩大预制深度。10.3. Any people who join the fabrication work (helper excluded) must be proficient technician. Worker who does pipe welding must hold effective certificate being conformed to the work they conduct.These p

13、eople must have received the welder training of this projectand has qualified the test. 凡参加管道预制作业的人员（辅助工除外）必须是熟练的技术工人。参与管道焊接的工人必须持有与所从事的作业相符且在有效期内的合格证书，并经业主焊工培训考试合格的施工人员。10.4. Properly requisite fabrication material as per fabrication progress, received material must have certificate and re-check re

14、port. The vent and hygiene shall be good in fabrication yard, equipment process ability in fabrication shop shall meet the operation requirement and have good operation performance. Tool and machines in fabrication shop shall be complete, having special lay down areaand full time keeper. Equip one s

15、et of 3m3 oil-free compressor and corresponding line arrangement for in-pipe blow of pipe fabrication piece. 根据预制进度计划合理领用预制材料，领用的材料必须具有产品合格证或复验报告。必须是经过标色的不锈钢管道： HB/1.4306（褐色）；H2/1.4404（无）；H1/1.4307/1.4306（蓝色）；HU/1.4539（桔黄色）。预制场地应有良好的通风状态和卫生环境，预制车间的设备加工能力须满足预制的操作要求，并具有良好的操作性能。预制车间的工机具应齐全，并有专门的堆放场所和.进

16、行专人管理。 预制场地需要隔离的地方，用橡胶皮或石棉板做好隔离准备 。配制一台 3m3 无油空压机及相应的管线布置，用于管道预制件的管内吹扫。2 Fabrication step (see Appendix1) 施工预制步骤material requisition and check 领料、核对材料 ID transfer ofpipe 管子标识移植 size lineation 划线标注尺寸 baiting andcutting 下料切割 Pipe ID transfer 管子标识移植 Groovetreatment 坡口加工 aStainless Steelembly and weldin

17、g 组对、焊接weld ID 焊缝标识 Visual Inspection 目视检查 NDT inspectionNDT检查 spools clean 管段清洁 spool ID 管段标识 sealand storage 封口保护、堆放储存2.1 Batching 配料Full-time material person shall be in charge of batching, in principle,batching of piping fittings shall be completed as isometric axis drawing,all requisited materi

18、al must be marked for batching and construction.配 料应 由专 职 材料 员负 责， 原则 上按 等 轴 图进 行 管配 件配 料， 所有领用的材料必须进行标识后，方可领出配料施工 。2.1.1 Batching work shall be made according to prefabrication weeklyplan and material delivery as per isometric axis drawing. 配料工作应根据预制周计划和材料到货情况按等轴图进行配制。2.1.2 Special box can be used

19、separately for storage as each isometric axis drawing. It is also allowable to batch in several drawings ortens of drawings; furthermore, batched material schedule shall bepasted on the box. 可按每张等轴图用专用箱子分开配放，也可几张或几十张图纸开在一起配好，并在箱子上贴上配好的材料清单。2.1.3 Whenprefabrication personnel requires (of specially de

20、livery),requisition persons shall recheck according to material schedule andsign it for confirmation. Onelist shall be in two copies; requisitionperson and material person keep each one copy.预制人员领用（或专送）时，领用者应按材料清单进行复查并在清单上签字确认，清单一式两份，领用者和材料员各保管一份。2.2 Bating and cutting 下料切割2.2.1 Spool field bating a

21、nd cutting shall be done after reviewing spool isometric, the major reviewing point:管段现场下料切割前应首先对管段单线图进行审核，主要审核：Drawing number, line number, spool number and material is as per design or not. 图号、管线号、管段号及材质是否与设计相符；Spool segment and reserved weld for field installation of each isometric axial drawing

22、is reasonable or not, and field resurvey for spool fabrication size shall be necessarily conducted. Accurately calculate when confirming baiting size of each spool, mainly considering about difference between fabrication spool size and baiting spool size, baiting spool size shall deduct theoretical

23、size of elbow, tee and reducer, as well as regulated weld assembly gap; and thickness of flange and gasket, as well as theoretical size of other fittings (such as valve, filter; etc). confirm practical size of fabrication baiting after measuring in order to increase the measuring accuracy. 每一张等轴图的管段

24、分段、现场安装预留口是否合理，并应对管段预制尺寸进行必要的现场复测。在确认每一段下料尺寸时，应精确计算，主要考虑预制段尺寸和下料段尺寸之间的差异，下料段尺寸应去除弯头、三通、大小头等管配件的理论尺寸以及规范规定的焊口组对间隙；法兰、垫片的厚度以及其它配件（如阀门、过滤器等）的理论尺寸。以提高测量准确度，测量后确定预制下料的实际尺寸。2.2.2 Original mark shall be transferred before cutting pipes, pipe materialwithout mark or with blurry mark shall not be used.管子切割前应

25、移植原有标记， 没有标记或标记模糊不清的管材不得使用。2.2.3 Pipe cutting generally adopts mechanical method, any following machinecan be adopted according to situation:管子切割 必须应采用机械方法， 根据情.况可采用下列任何一种机械：Pipe lathe 管子车床Band saw machine带锯床Abrasion wheel cutting machine 不锈钢专用 砂轮切割机 和砂轮片2.2.4 Stainless steel pipe also can be cut by

26、 plasma cutting machine不.锈钢管也可以用等离子切割机进行切割。2.2.5 When stainless steel pipe is cut by abrasion wheel cutting machine or grinded by abrasive disk, must use alumina substrate, and abrasion sheet which has cut or grinded stainless steel cannot be used to cut or grind stainless steel pipe. 不锈钢管用砂轮切割机切割或用

27、砂轮打磨时， 必须用氧化铝基的砂轮片，且切割或打磨过碳素钢的砂轮片不能用来切割或打磨不锈钢管。2.2.6 Pipe cut shall be as per the following requirement: 管子切口质量应符合下列要求：Cut surface shall be smooth, free of crack,double skin, burr, concave and convex, contracted opening, sinter, oxide, slagor other defects or debris. 切口表面平整，无裂纹、重皮、毛刺、凹凸、缩口、熔渣、氧化物、铁屑

28、等。Tilting error of cut end face shall not be 1% bigger thanexternal diameter of pipes, and no more than 3mm. 切口端面倾斜偏差不应大于管子外径的 1，且不超过 3mm。（如执行的标准不同时，按相应标准执行）2.3 Groove Processing 坡口加工2.3.1 Groove shall be processed after marking and cutting on pipe (material) by construction personnel according to f

29、abrication isometric drawing shifted by technical person. Beveled spool shall be put on process bench (fabrication shop) for groove grinding. 施工人员依据技术人员已转化的预制单线图纸对管道（素材）进行划线、切割下料后进行坡口加工。 坡口加工的管段应放置在加工台上（预制车间）进行坡口打磨；2.3.2 Groove type and size of pipe and fitting shall be conformed torequirement of co

30、rresponding to drawing and design document, when there is no.demand on design, confirm as per item B.0.1 of GB50235-97 Appendix B.管子、管件的坡口型式和尺寸应符合相应的图纸和设计文件的要求，当设计无规定时，按 GB50235-97 规范附录 B 第 B.0.1 条规定确定。2.3.3 Processing of piping slope is commonly adopting mechanical method, for example, after slope

31、is processed in a way of heat processing, oxide skin, sinter and surface layer that will have effect on the quality of joints at slope shall be removed, and the place that is convex or concave shall be ground and leveled. Stainless steel shall be cut or grinded by special abrasion sheet, and cannot be mixed with carbon steel abrasion sheet.管道坡口加工一般采用机械方法， 不锈钢管道的坡口加工可采用坡口机加工或等离子切割加工方法。 采用等离子切割 方法加工坡口后， 必须除去坡口表面的氧化皮、熔渣及影响焊接质量