发布时间 : 星期五 文章巴斯夫工艺管道施工方案更新完毕开始阅读99bde4c85f0e7cd18525368e
BPC Lemongrass Project in Malaysia —Piping construction method statement
目 录Contents
一、工程概况 General ............................................................................................................... 2 二、编制依据 Reference ........................................................................................................... 3 三、施工准备 Construction Preparation ................................................................................. 3 四、施工管理Construction Management ................................................................................ 4 五、管道安装 Pipe installation ................................................................................................ 10 六、材料管理Material management ...................................................................................... 39 七、施工进度控制与管理Control and Management of Construction Progress .............. 41 八、人力计划Manpower Plan ................................................................................................. 42 九、机具动员计划Mobilization plan of equipments and tools ........................................... 43 十、安全文明施工Safety and housekeeping ....................................................................... 44 十一、安全分析Safety analysis .............................................................................................. 47
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BPC Lemongrass Project in Malaysia —Piping construction method statement 一、工程概况 General
本工程位于马来西亚关丹吉本工业园的柠檬香精项目。 业主方为巴斯夫马来西亚国油化学公司(简称BPC)，管理公司由FLOUR负责，综合专业工程C420区域由中国化学工程马来西亚公司（以下简称―CCEM‖）承建。
The project is BPC Lemongrass Project which is located in Gebeng Industrial Park of Kuantan Malaysia. The Owner is the BASF PETRONAS Chemicals SDN BHD (BPC). Owner representative is FLUOR. Multi-discipline work (Area C420 Citral plant) is contracted and constructed by China Chemical Engineering (M) SDN BHD. (Hereinafter referred to as CCEM)
㈠、工程简介 Project description
1、本项目地上工艺管道主要由管廊管道和装置区域管道工程组成。管道总长约42.5KM，约22.0万DB，主要材质有碳钢A106-B、A53-B、A312-TP316/316L、A312-TP304/304L、合金钢及非金属管道HDPE等。
The A/G process pipes of the project are mainly for the pipe rack and the plant area. The total length of the pipes is about 42.5km, which consists of about 120,000 DB in total. And the major specifications are carbon steel A106-B, A53-B, A312-TP316/316L, A312-TP304/304L, Alloy and non-metal pipe, such as HDPE, etc.
2、管道的主要连接形式有焊接、法兰连接以及螺纹连接和卡套连接等。
The main connection ways for the pipe include welding, flange connecting and thread connecting and jacket connecting.
3、从管道输送的介质及操作温度、压力等级划分为常压及压力管道。
The pipes are divided into atmospheric pressure pipe and pressure pipe by service media, operation temperature and pressure rating.
㈡、工程特点 Project features and challenges
1、本管道工程材质多样，管径跨度范围大，温度、压力范围广，这给施工方面带来较大难度。 There are various types of pipe materials, which have wide range of pipe diameters, temperatures and pressures, bringing much difficulty to construction.
2、本工程有易燃、有毒介质管线，施工质量要求高，特别对焊接质量更为严格。
The project has pipes servicing inflammable and toxic media, which demands high standard on construction quality, especially on welding quality.
3、该工程的设备较多，增加配管难度；阀组、仪表调节元件多且要求配管质量高，增加管道施工的复杂性及难度。
The project has large amount of mechanical equipment, which makes tubing more difficult. Valve sets and instruments have many regulating elements, which demands high standards on pipe work quality, and meanwhile makes it more complicated and difficult.
4、管道的总DB量较大，走向复杂，管线密集，加大施工工作量；工作任务重，施工人员多，加大管道施工管理工作难度。
The pipe routes are complicated and concentrated with large Diameter Bore quantity, which
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BPC Lemongrass Project in Malaysia —Piping construction method statement makes work quantity more while heavy work load and large amount of constructors, and makes pipe construction & management work more difficult.
二、编制依据 Reference 1、施工设计图纸及技术要求；
Construction design drawing and specifications & code; 2、本项目的施工合同 ； Project Construction Contract 3、国际通用标准： International Standards a．ASME b．ASTM c．ANSI
4、马来西亚香精项目管道工程相关标准和技术文件: Related piping specifications of Lemongrass Project
9355-C400-EPSP-ACC-001 REV.0-Piping material specification Line Class –process of lifting piping
9355-C400-EMSP-ACC-0022 REV.1-General material requirement 9355-C400-EMSP-ACC-0004 REV.0-pipe support
9355-C400-EMSP-ACC-0009 REV.1 Specification for positive material identification 9355-C400-EMSD-ACC-0001 REV.0-jacked piping detail
9355-C400-EMSP-ACC-0014 REV.0-shop and field fabrication /installation and Handing process/utilizing piping
9355-C400-EMSP-ACC-0017 REV.0-Pipe Pressure Testing
9355-C400-EMSP-ACC-0006 REV.1-Specification for welding and NDE for equipment/field fabricated piping
JB -9-017-Rev.0- Field material management control procedure JB-15-003-Rev.0-Lemongrass site Non Destructive Test Execution Plan JB-15-004 Lemongrass welder Test center Plan 5、我公司企业标准 Company Standards
a. 压力管道安装《质量手册》（QG/CC-7.PP.0501-00） Quality Handbook for Pressure Pipe Installation
b. 压力管道安装《质量体系文件》（QG/CC-7.PP.0502-00） Quality System Document for Pressure Pipe Installation c. 压力管道安装《作业指导书》（QG/CC-7.PP.0503-00） Work Guidebook for Pressure Pipe Installation 三、施工准备 Construction Preparation
3.1.标准、规范准备Preparation of Standard and Specification
3.1.1. 收集管道施工要求的规范、标准。To prepare standard and specification of pipe construction
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BPC Lemongrass Project in Malaysia —Piping construction method statement 3.1.2.收集施工记录和交工资料表格。To prepare construction record and handover document. 3.1.3.熟悉业主关于管道施工的特殊要求。To know the special requirement of pipe construction 3.2.技术准备 Technical Preparation 3.2.1.图纸会审 Drawing joint review； 3.2.2管道预制、安装方案的编制与审批
Method statement compilation and Approved for pipe fabrication and installation；
3.2.3根据管道单线图、平面图、流程图组织技术交底. Technical disclosure work shall be done as per pipe isometric drawing, elevation plan and workflow chart. 3.3.其他 Others
3.3.1.施工计划编制 Construction Method Statement Preparation
根据工程实际及工期要求，编制施工计划。The plan shall be compiled as per site condition and required construction duration. 3.3.2.施工人员准备 Manpower Preparation
根据现场施工条件，合理组织管道安装人员（人力计划详见附表）；The personnel for pipe installation shall be mobilized suitably according to site condition. (see attachment of manpower plan)
3.3.3.施工机具准备 Equipment and Tools Preparation
根据现场施工条件，合理组织管道安装的施工机具（施工机具详见附表）。The equipment and tools for pipe installation shall be mobilized suitably according to site condition. (See attachment of equipment and tools)
四、施工管理Construction Management
4.1.建立健全质量保证体系 To establish quality assurance system
4.1.1.建立以项目经理为第一质量责任人，各专业质量工程师、质检人员为主导的质量控制体系。质量文件的建立和管理要细化到每个环节，分工明确、责任分明。
The project manager is first responsibility person and each discipline engineer and QA/QC inspectors are leading roles for QA/QC control system.
4.1.2.建立明确的质量责任制度，质量责任分解到各个岗位、各个环节、各个工种。从制度上落实谁管生产谁管质量，谁施工谁负责质量，谁操作谁保证质量。
To establish quality system defined, which shall be applied to each position, each step and each discipline to ensure quality control during construction.
4.1.3.积极主动配合业主、管理机构的工作，认真和严格地执行其发出的指令、意见和建议。
To assist and execute the instruction, suggestion and comment by Owner and management agency.
4.1.4.对有特殊资格要求的管理人员和操作人员须经资格审查和确认，持证上岗。
For management person and operator with special requirement, the qualification certificates shall be examined and confirmed.
4.2.压力管道施工质量保证体系 QA/QC System of Pressure Pipe
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