发布时间 : 星期日 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 涂抹专用的胶水。Generally the hot melt or bonding will be adopted for the non-metal pipes, keep the welding joints and adjacent area clean prior to hot melt, and use special equipment for welding, and the current and voltage of the equipment should follow the instruction of the manufacturer; clean the bonding place with cleaning agent prior to bonding, and then uniformly daub the special glue-water.
5.4.5.7.衬里管道安装工作宜安排工艺管道施工尾期进行。Lining piping installation should be executed at late stage of process piping work. 5.4.6.HDPE管道安装
5.4.6.1. HDPE管应放置在稳固的地上，堆放高度不超过1.5米并设置木垫块。管道和地面间的距离应为200mm。放置HDPE管的地面应平整无锋利物体。如果HDPE管存储在室外，则应在管子上覆盖薄膜以避免阳光直射。HDPE管的管件和其它部件应尽量存储在室内。HDPE pipe shall be placed on stable ground with timber supports, stackpile height not more than 1.5m. The clearance between pipe and ground shall be 200mm. The ground should be level and free of sharp object. When the HDPE pipes are stored outdoor, suitable sheets shall be covered over the HDPE pipe to prevent from heavy sunshine. HDPE Pipe fittings and other components shall be stored indoor as much as possible.
5.4.6.2. 在铣削管道时，若管材或管件连接面上有污物时，应先用洁净棉布擦净，并用铣削刀铣削待连接面，铣削后重新对口检查使接口吻合For milling of piping, surface of piping and fittings should be cleaned if any contaminants with clean cotton cloth prior to commencement. then contact face will be shaved. Finally check the connection ends match or not. 5.4.6.3.HDPE热熔对焊连接HDPE Butt fusion weld connection
A．将待焊接的管材放入动夹套及定夹套内，并使相对两管端伸出夹持点30—40mm（尽可能将较短的管段放在动夹套上）Pipe material need weld shall put into both rotary jacket and static jacket, and extend two relativity pipes 30-40mm from joint point.(Shorter spool put in rotary jacket as soon as possible)
B．旋紧手柄螺母，操作动夹套换向开关，使动夹套左右移动，初次校对待焊管端是否同轴，并通过旋转手柄螺母调整管材位置，使管端同轴；Tighten hand nut, and operate reverse switch of rotary jacket to make it move from left to right. First check up if they are coaxial of the need weld pipe ends, if not, adjust hand nut until them coaxial.
C.将铣刀放入两管端之间，放下铣刀手柄；启动铣刀，调节调压阀，推动活夹套，铣 削两管端口，并记录使动夹套刚好运动的压力Po，（拖动压力）当出现连续切削时，将换向阀手柄置于中位，关闭铣刀电机；Mulling cutter shall be put between two pipe ends and put hand down. Start up mulling cutter, adjust pressure regulating valve, push jacket, and cut pipe port. Record the pressure when jacket start moves (traction pressure), if continuous cutting, mulling cutter must shut down.
D.操作换向阀，撤出铣刀，并将两管端面再次相对，检查两管端之间是否有间隙、错位量不得超过壁厚的10%，两管端面间隙不得超过管径的2%; Operate reversing valve to back out of mulling cutter. Align the pipe face and check if any gap, dislocation shall not exceed than 10% of
Page 37 of 55
BPC Lemongrass Project in Malaysia —Piping construction method statement wall thickness, gap of pipe face not exceed than 2% of pipe diameter.
E.用清洁的布蘸酒精清洗管材焊接区域的内外表面，除去微法，水分、油脂等杂质；The cloth with alcohol shall be use for clean inner and outer face of pipe welding position to free moisture and grease etc.
F.接通电热板电源，当电热板温度达到焊接温度时，继续加热10分钟，使电热板温度均匀；Supply power to electric hot plate; continue heating for 10M more after plate reach welding temperature.
G.将电热板放在两根焊管端面之间，把焊管压在加热板上，并使其熔融以消除端的残余不平面。Put the electric hot plate against end face of two welding pipe, and press weld pipe in the hot plate to make pipe melting rough ends.
H.加热完后，移开加热器，侧向推压管材，管材的焊接面就粘在一起Once heating finish, remove the heater and lateral extrude pipeline so as to make weld face sticky together.
I.管材熔合一起后，焊接压力根据焊接管材管径、壁厚的不同做相应的变化。见下表：After pipe material bonding together, welding pressure shall be adjusted according to diameter and wall thickness of weld pipe material. As shown in form 6 Form 6 :SDR11系列 series 管径D mm 400 450 壁厚S mm 截面积 cm2 Sectional area 500 45.5 650 2.6 560 51 816 3.3 630 57.3 1031 4.2 36.4 415 1.80 41 527 2.28 P1=P2 Mpa SDR17.6系列series 管径D mm 壁厚S mm 截面积 cm2 Sectional area400 22.8 270 1.17 450 25.6 341 1.48 500 28.5 422 1.7 560 31.4 522 2.1 630 35.8 6681 2.7 P1=P2 Mpa 注：P1为起始加热压力，P2为焊接时压力Remark: P1 means initial heating pressure, P2 means pressure when welding.
J.继续保持挤压力，对焊机上的接口冷却时间（分）在20℃晴天时，其数值至少等于管壁厚度（mm），冷却期间挤压力始终保持不变。Extrusion pressure shall be keep up, when the interface of weld machine cooling time (M)on sunny 20℃, the value not smaller than pipe wall thickness(mm); Extrusion pressure remains constant during cooling period.
K.对接完毕，应对焊环进行检查，合格的焊接，焊环的几何尺寸均匀程度都应达到下列要求：Welded loop at the end of butt joints should be check. And the eligible welding uniformity of geometry size also should meet those requirements.
a、翻边对称Symmetric flanging
Page 38 of 55
BPC Lemongrass Project in Malaysia —Piping construction method statement 接头应具有沿整个圆周平滑对称的翻边，翻边最低处不应低于管材表面；Butt joints should have flanging along the whole circumference smoothness symmetrically.
b、对正Contraposition
管材、管件连接时应尽可能对正，错位量不应超过壁厚的10%，沿相邻两组件翻边的外圆周的任一处都不应超过该值。Accurate contraposition as possible as we can when we link with the pipe and pipe fittings and the displacement should be not more than 10% of the wall thickness. Shall be not
环的宽度(The height of the ring) 0.35～0.45S 环的高度(The height of the ring) 0.2～0.25S 环缝高度(Circumferential seam height) 0.1～0.2S
注：S为管材壁厚Remark: S is refers to the thickness of tube
L：施工前，厂家应对施工人员进行培训，并提供施工指导文件。Before installation，
Constructor and workers should take training from vendor，and vendor should supply the related policy paper
5.5压力试验与管道吹洗hydrotest and blowing of piping
管道安装完成后，应按图纸要求，进行静电接地，经试验、检查合格，应进行管道试压、吹扫。管道压力试验与管道吹洗另写详细的试验与吹洗方案。
After completion of construction and qualified inspection, hydrotest and blowing shall be performed. Separate Method Statement of Hydrotest and Blowing will be prepared in detail. 5.6管线绝热施工hot insulation of pipeline
管道试压、吹扫合格后，应对需要绝热的管线进行绝热施工工作，另见《工艺管道绝热施工方案》。Hot insulation of pipeline shall be carried out after qualified hydrotest and blowing, separate 《Construction Method Statement of Hot Insulation of Piping》 will be prepared.
六、材料管理Material management
6.1.材料的检、试验管理inspection and test management of material
6.1.1材料运到预制现场后，现场的材料负责人及时组织组织相关部门人员进行验收，以确定其名称、规格型号、数量、外观与材料标准及设计文件的符合性。经检验不合格的材料，不能投入使用并应立即更换。材料的检、试验管理工作按材料标准、FLOUR的相关文件、订货合同、设计图样及施工规范、国家和地方有关法规的要求进行。Once materials arrive at Material supervisor should organize relevant person to check conformance of the material like designation, specification, quantity and appearance with material standard and design document. Rejected material could not be used but should be replaced. Management of material inspection and test should be performed as per relevant documents such as purchase order, design drawing, construction specification, national and local regulation. 6.1.2.材料检验、试验工作流程及其内容如下： Work flow of material test and inspection
6.1.2.1.到货材料由保管员进行数量验收，有差错时由施工员复核； Material keeper shall count
Page 39 of 55
BPC Lemongrass Project in Malaysia —Piping construction method statement the quantity when materials arrive and discipline technician recheck if difference observed. 6.1.2.2.检验员作外观质量验收和几何尺寸检测； Quality inspector shall perform visual inspection and dimension.
6.1.2.3.由材料责任工程师对质量证件进行初审，质量检验员进行复审； Engineer who takes responsibility for material shall check the quality certificate first and quality inspector will verify. 6.1.2.4.需作试验的材料，根据要求委托有资格的检试验机构对材料进行试验； Materials to be tested should be tested by certified test institution as per requirements.
6.1.2.5.对检试验机构出具的检试验报告进行审核； To check test report issued by test institution
6.1.2.6.通过以上检、试验均合格的材料，方可使用； Only after qualified test, could materials be used.
6.1.2.7.检验不合格的材料，应隔离存放并做好标识，避免混淆； Rejected materials should be isolated and marked to avoid mixing. 6.1.2.8.检验合格的材料，应在实物上和证件上进行标识。 Qualified materials should be physically marked, certificate as well.
6.1.3.若材料的质量证明文件上有漏项指标或对其技术指标有质疑，可按材料标准进行所缺指标或其质疑指标的试验；业主、施工规范有要求时，可按其所要求的项目进行材料的检、试验。 If any item missing on quality certificate or any doubt on technical data shown on certificate, intended test could be performed as per material standard or project requirements by Owner and construction specification.
6.2材料的仓储管理storage management of materials
6.2.1.材料的储存场地可分为：焊条库、库房、料棚或料场等。Storage yard could be divided into: electrode warehouse, warehouse, material shed or material yard, etc.
6.2.2.材料到库后，保管员及时对材料的包装、数量和外观进行检查，并认真做好到货记录，同时通知检验员进行验收。After materials arrive in warehouse, keeper should check packing, quantity and appearance; and make material arrival record; inform inspector to inspect for acceptance. 6.2.3.对未检验材料，存放在―待验收区‖；或直接存放于货位，挂―待验收料‖标牌；对检验发现的不合格材料存放在―不合格品区‖；或挂―不合格品‖标牌。
Un-inspected materials shall be placed in For Inspection Area or material rack with tag Un-inspected; rejected materials shall be place in Reject Area; or tagged with Reject. 6.2.4.材料保管保养safekeeping and maintenance of material
6.2.4.1.保管员凭材料员开具的《入库单》及时建帐。Keeper shall make record in timely manner as per inventory list issued by materialman.
6.2.4.2.进库的材料均需分类、分别存放，并挂料签或标牌。Stored materials shall be classified and stored separately with tag.
6.2.4.3.库存材料要做到保管台帐、实物、料签、及质量证件 ―四对口‖。 For materials storage, Record, substance, material receipt and quality certificate should be complied with each other 6.2.4.4.材料维护保养的一般原则根据供货商的要求及总包单位、业主的指导，采取相应的措
Page 40 of 55