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 pipe shall be put on pipe connector, and pass through into each layer of pipe rack by lifting. The amount of pipe material shall be calculated in advance. B.管廊传管 Pipe delivery
管道穿入管廊各层后,应即刻组织人力将管道传输到安装位置,调整好各管线间间距，并临时固定好。管廊传管必须使用窜管器(如图4)进行。窜管器应牢固地安装在管廊横梁上，窜管器滚筒必须采用橡胶皮等缠好，以保护管线油漆及不锈钢管避免污染。窜管器宜每3米间隔距离安装1件，这样管子窜起来就容易得多。Pipe shall be delivered to the position of installation, adjusted the interval of each pipe, and fixed for the present. The pipe connector shall be fixed firmly on the beam. Wrapped the roller with rubber skin to protect painting and stainless steel pipe is prevented from pollution. Pipe connector shall be installed at intervals of 3 M, it is easy to pipe connectio
C.管道牵引 Pipe trailing
管廊在窜管器上牵引一般采取人工形式或采用倒链牵引。对于同层管道数量大且直径相对较大时，可采用卷扬机牵引，如图（5）。Pipe rack shall be trailed by manual or chain block. For a large quantity and diameter of pipe in the same, it shall be trailed by windlass. See sketch (5)
5.2.6.2.设备间管线铺设与安装 Pipeline laying and installation between equipments 安装时，首先测量好现场已安装完成的管线连接设备间距离、标高等参数，预制管段。将连接设备两端法兰固定在设备口，螺栓拧紧，数量不得低于4颗。Pipe spool shall be fabricated according to the distance, elevation etc. between pipe installed and equipment. Fix the flange on the end of equipment, tightening the bolt, and should be not less than 4.
然后采用吊车将预制管段吊装就位，组对，点焊好。Lift Pipe spool fabricated to the correct position by hoist, fit up and spot weld。
点焊好后，应采用临时措施加固避免变形（防变形的临时加固件，应在焊接工作彻底完成后才能拆卸）。待焊口根部焊缝完成后，拆卸组对管线，在地面完成剩余的焊接、探伤、试压、清洗等工作，然后复位安装。After spot welding, pipe spool shall be strengthened by temporary measures to prevent deforming (The temporary measures can‘t be removed until welding complete finish). After finish root welding of weld joint, remove the pipe spool fitted up, which shall be treated by welding, crack detection, cleaning on the ground, and be reposited and
Page 17 of 55
卷扬机 windlass 窜管器 Pipe connector 工艺管道 Process pipe 图（5） BPC Lemongrass Project in Malaysia —Piping construction method statement installed at last.
5.2.7.管道对口 Pipe fitting up
5.2.7.1.管道对口连接时，不得用强力进行组对，亦不得通过松或强紧连接螺栓或添加法兰连接垫片来调整组对间隙及管口平直度。During fitting up work, pipe cannot be jointed by the action of a strong force, also not be adjusted the interval and straightness by flange gasket. 5.2.7.2.管口组对时，应符合图（6）要求.
当管子公称直径小于100mm时，允许偏差值α为1mm；当管子公称直径大于或等于100mm时，允许偏差值α为2mm；但全长的偏差值不得超过10mm。管道坡口加工时，壁厚＜3mm采用I型坡口，壁厚≥3mm采用V型坡口；组对间隙应控制在2~4mm；允许最大错边量为壁厚的10%且不大于2mm。Pipe fitting up shall meet the requirement of sketch (6).When the nominal diameter of pipe <100mm, allowable deviation value α shall be 1mm. When the nominal diameter of pipe ≥100mm, allowable deviation value α shall be 2mm, but the whole deviation should not exceeds 10mm. For the pipe fit-up, adopt I type groove for the thickness less than 3mm, and adopt V type groove for the thickness ≥3mm; the space of the fit-up should be controlled within 2~4mm; permitted maximum unfitness value is 10 times of the wall thickness but not exceed 2mm.
200
图（6）Sketch 6
钢板尺 steel ruler α 5.2.7.3.作为封闭管段组对时，其首先应根据现场实测的安装长度进行下料加工，其偏差
不得超过1.5mm，确保焊口间隙，保障焊接质量。Seal pipe spool shall be fabricated as per surveyed installation length with allowance no more than 1.5mm, to keep a interval between weld joints with a high quality of welding. 5.2.8. 法兰安装 Flange installation
5.2.8.1.法兰连接应与管道同心，并确保螺栓自由穿过螺栓孔； Connected flange shall be a same center with pipe.
5.2.8.2.垂直或倾斜法兰面螺栓孔应垂直跨中安装，其连线水平度不得大于1.5mm；水平法兰面螺栓孔安装应跨装置南北或东西方向；All bolt holes of flange shall straddle vertical and horizontal centre lines of the pipe. Levelness shall be no more than 1.5mm. Flange bolt holes on horizontal pipe shall straddle the site system lines, i.e. site Plant North/South or Plant East/West. 5.2.8.3.水平法兰水平度及垂直法兰的铅锤度不得大于法兰外径的1‰，且不得大于2mm。The verticality of horizontal and vertical flange shall be no more than outer diameter 1‰ (2mm). 5.2.8.4.当法兰采取螺纹连接时，管端应低于法兰密封面1.5mm. If treaded connection is used to flanges, the end of pipe shall be lower than the sealing face 1.5mm.
5.2.8.5.不得用强紧螺栓的方法或松螺栓方法来消除歪斜。同时，不得加偏垫或多层垫等方法
Page 18 of 55
BPC Lemongrass Project in Malaysia —Piping construction method statement 来消除法兰接口端面的间隙、偏斜、错口或不同心等缺陷。It is not allowed to tighten or loose bolt for adjust tilted surface of bolt, meanwhile not allowed to add partial pad or cushions to eliminate defects of clearance, deviations, mismatch and disalignment.
5.2.8.6.动设备法兰口最终连接时，必须在联轴器上架设百分表监视动设备的位移。 当动设备额定转速大于6000r/min 时，其位移值应小于0.02mm；当额定转速小于或等于6000r/min 时，其位移值应小于0.05mm。Flange connection of rotary equipment must be tested with dial gauge.installing the dial indicator on coupler to monitor equipment 's dislocation. When rated speed is more than 6000r/min, the dislocation value should be less than 0.02mm, when rated speed is not more than 6000r/min, it's dislocation value should be less than 0.05mm. 5.2.9.垫片安装 Gasket installation
5.2.9.1.垫片安装前，应按图确认其型号规格是否满足设计要求。法兰安装前，应检查法兰密封面及密封垫片，不得有影响密封性能的径向划痕、斑点、破损、皱折等缺陷。同时，配对法兰环槽密封面与金属环垫还应作接触线检查，当金属环垫在密封面上转动45°检查接触线不得有间断现象。Before gasket installation, the type and specification shall be confirmed to meet the requirement of design. Before flange installation, check the sealing face and sealing gasket which free of scratch, stain, damaged and wrinkled etc.. Contacting line check between flange ring seal face and metal ring gasket shall be done in the manner that no discontinuous line existing when rotate metal ring gasket for 45°.
5.2.9.2.安装时，必须确保垫片安装位置应在法兰密封面中心，1个密封面只安装1块垫片，禁止安装多层垫。During gasket installation, gasket must be placed in the center of flange surface, only 1 piece gasket can be used for flange surface instead of multi-piece. 5.2.10阀门安装 Valve installation
5.2.10.1.阀门安装前应检查阀门的规格型号是否与设计一致，并检查填料其压盖螺栓应留有调节余量。The type and specification of valve shall be checked for meeting the requirement of design, a suitable space shall be remained between gland bolt and filling material.
5.2.10.2.当阀门与管道以法兰或螺纹方式连接时，阀门应以关闭状态安装。当阀门与管道以焊接方式连接时，必须将阀芯打开焊接；承插焊阀门安装时，应确保管段光滑，并与阀门内凸台留出1-1.5mm间隙。When valve is connected to pipe by threading, it shall be in closed status. When valve is connected to pipe by welding, it shall be in opened status. When valve is installed by socket welding, pipe spool shall be smooth and keep a distance of 1-1.5mm with valve boss. 5.2.10.3.水平管线闸阀安装时，应水平斜45°以上范围，以图纸为基准，以避免阀芯因重力而脱落或发生故障。For horizontal pipeline gate valve installation, which shall be an angle of 45 degree to prevent valve core drop off or go wrong due to gravity.
5.2.10.4.如无特殊要求，对于截止阀应按阀体标识方向安装，低进高出的原则。Globe valve shall be installed according to direction of instruction on the valve body, base on the principle of low to high.
5.2.10.5.对止回阀安装方向，阀体标识方向必须与工艺管道流向一致。For installation direction of check valve, the direction of instruction on the valve body must accord with flow
Page 19 of 55
BPC Lemongrass Project in Malaysia —Piping construction method statement direction of process pipeline.
5.2.10.6.安全阀的安装应符合以下规定：Safety valve installation shall comply with regulation is shown as bellow.
A.安全阀应垂直安装；Safety valve shall be installed vertically.
B.管道投入运行前，安全阀必须经具有资质的专业机构进行调校，安全阀经最终调校合格后，应进行铅封并作好相应的资料；Before pipeline using, safety valve shall be regulated by qualified organization, and then be sealed with lead. Make relevant document.
5.2.10.7.调节阀、流量计安装，必须在其两端增设临时盲板，以防止异物进入阀体内，其安装方向应按阀体标识方向与介质流向保持一致。孔板、流量计前后直管段的长度应符合图纸和规范要求。孔板、连接流量计的法兰内壁焊缝必须打磨平整。For control valve and flowmeter installation, the blank plate shall be set on the ends of them to prevent foreign matter form entering. The direction of installation shall be the same with flow direction of process pipe in accord with valve body sign. The straight pipe length connecting the orifice and flowmeter should apply with the requirement of the drawing and specification. The inner wall of flange for the orifice and flow meter must be ground flatly.
5.2.10.8.取样阀安装，其位置应符合图纸，且便于操作。The location of sample valve shall meet the drawing and be easy to work.
5.2.10.9.对于球阀、蝶阀等，一般无方向要求，为便于检修，安装时应按阀体标识进行安装。For ball valve and butterfly valve installation, which shall be installed according to valve body sign, shall be easy to maintain and repair, and no requirement of direction.
5.2.10.10.所有的阀门安装时，必须确保操作方便、安全可靠。所有碳钢阀门丝杆在阀门安装必须涂抹好油脂进行保护。All valve installation must be safety and easy to operation. Oil grease shall be used for protect carbon steel valve rod. 5.2.11.螺栓安装 Bolt installation
5.2.11.1.法兰连接螺栓应使用同一规格，安装方向一致。螺栓紧固后应与法兰紧贴，不得有楔缝。需安装垫圈时，每颗螺栓不得超过1只。紧固后，螺栓应与螺母保持齐平或1～2个螺距。为拆卸方便，一般地应使用双头螺栓。The same type bolt shall be use for flange connection, and keep the same installation direction. Tighten bolt and keep close to flange, free of interval. When gasket is installed, there shall be not more than 1 piece. After bolt tightening, the distance of 0-5mm shall be kept from bolt to nut in order to take the bolt down easily. Threaded stud shall be used in general.
5.2.11.2.所有不锈钢螺栓、合金钢螺栓安装时，必须涂抹二硫化钼油脂，以防止紧固过程中
发生过烧，致使螺栓不能拆卸；所有露天装置和用于设计温度高于100℃或低于0℃的碳钢螺栓安装时，必须涂抹黄油。
When installing stainless steel bolt,alloy steel bolts, Molybdenum disulfide grease shall be covered to avoid bolt is too hot,which affect the bolt removal, For device in open air, and carbon steel bolt installation, which the design temprature is more than 100℃or less than 0℃,consistent
Page 20 of 55