洁净压缩空气管道工程施工方案 27页

ChinaNewMSDFacility-HangzhouProject杭州默沙东制药有限公司新生产基地项目WMSofCleanCompressedAirSystem洁净压缩空气工程施工方案27/27\nGeneral工程概况ThesystemofcleanandcompressedairbelongstotheworkscopeofQi’an.ThecleanandcompressedairwasdistributedfromPackagingBuildingL2toeachsinglelevelwithatotalpipelengthof250m,whichusesASMEBPE316Lmaterial.本工程洁净压缩空气工程属于我司施工范围，洁净压缩空气从包装二楼配送至各单体，管道长度约250m，采用ASMEBPE316L材质。BasisofCompilation编制依据ThecompilationofthisWMSisasper8232-M-SPEC-15211CompressedAirSystem-03andASMEBPEstandards.根据S2F15211压缩空气系统规范及ASMEBPE标准TechnicalMethodofMetallicpipeConstruction金属管道施工技术方案Theconstructionofmetallicpipelinemustbestrictaccordancewithrelevantstandardsandcompliedwithoperationprocessprocedureandcleaningmeasures.TheconstructionofASMEBPE316LpipelineshallbestrictlyinaccordancewithASMEBPEstandards,meanwhileitshallalsocomplywithcertainoperationprocessflowandadoptrelevantcleaningmeasures.对于ASMEBPE316L管路的施工必须严格按照ASMEBPE标准进行，同时需遵循一定操作工艺流程和保洁措施。1.Preparation施工准备Preparatoryworkshallbedonefortheconstructionasthefollowings:施工准备按以下几个过程：²Visualcheck直观检查Sampling:confirmthatnodamagesonthepipesandmeettherequirements.Checkwhetherthereisplasticcap.抽样检查，确认无损伤并符合要求，检查是否有塑料帽密封Checkthemodel,quantityandcertificates.检查型号，数量及证书Verifythedeliverylist.核对送货单Preparationoffabricationsite.加工现场的准备27/27\n²Acceptanceandreceivingshallbefinishedandconfirmedbythepersonresponsible.验收及接收由负责人完成确认²Thematerialwouldbestoredinspecificareaandclassifiedaccordingtothemodel,sizeandcleangrade.材料储存在指定区域内并根据型号、尺寸、洁净级别分类保存²Preventthematerialfrombeingbent,impacted,andextruded.材料运输不可弯曲，撞击，挤压等²Thereshallbedetailedrecordofmaterialdistributionandusage.材料取用需有详细记录²Sitemeasurementandinspectionofrelevantequipments.现场测量，相关设备的检查²Productionofsample.样本制作²Materialfabrication:pipecutting,chamfering,bendingandprecastwelding.材料预制：管道切割，面处理，弯曲及预制焊接27/27\n1.1ConstructionProcedure施工步骤Siteweldingincludes:其中现场焊接包括：²Pipepositioning,siteweldingandqualityinspection.Inordertoensurethatnooxidationandchangeofcoloronthesurfaceofeveryweldjoint,high-purityargonshallbeusedandensurethat27/27\nshieldingtimeisnotlessthan30min.管道定位，现场焊接，质量检查。为保证每一焊缝内表面无氧化变色,必须使用高纯度氩气，保证冲气时间不小于30分钟。²Non-weldingconnection:fittingsandequipmentconnection.非焊接连接：配件、设备连接。²Post-constructiontreatment:pipelineinspectionandpneumaticpressuretest.施工后处理：管道检查,气压试验。²Documenthandover:samplerecord,constructionrecordandtestreport.文件移交：样本记录，施工记录及测试报告。1.2FlowofPipingQI配管质量检查流程管道焊接否外观检查否是安全检查耐压检查泄漏检查否是机能检查移交给客户是1.3GeneralRulesofWelding焊接总则27/27\n²Thisspecificationisapplicabletothewelding,assemblingandinstallationofhygienepipes.本规范适用于卫生管道的焊接、装配和安装；²ThisspecificationisappliedspecificallyintheconnectionofcircumferentialbuttweldingheadbetweenASMEBPEstainlesssteel316Lpipefittings本规范特别用于ASMEBPE不锈钢316L管件间之圆周对接焊头之连接；²WeldinginthisspecificationshallmeetASMEBPEacceptancestandards.本规范中的焊接连接将需要符合ASMEBPE的验收标准；ThetermmakerofthisspecificationmeansQi’an,whichisresponsibleforassemblingandinstallationofpipes.本规范中术语装配者是指启安公司，他负责管道的装配和安装；“Client”meanstheenduserorotherrepresentative.“业主”是指用户或其代表；“Weldinginspector”meanstheclientorrepresentativeofenduser,whowillberesponsibleforinspectingtheweldingworkofpipingcontractor.“焊接检查员”是指业主或用户代表，他将负责检查管道承建商的焊接操作。1.4Weldingspecification焊接规范ThisspecificationcoversthetungstenarcSSweldingequipmentsthatuseautomaticorbitalweldingmachines.本规范覆盖用自动轨迹焊接机的气体钨电弧不锈钢焊接设备。“Pipe”shallincludesallcomponentsthatrequirewelding.“管道”应包括所有需要焊接元件。1.5Generalrequirements总体要求²Operatorsofautomaticweldingmachineshalltakeweldingtesttoconfirmtheirqualification.pipematerialofcommonsizeoftheprojectshallbeusedintheweldingtest.27/27\n自动焊接机的操作人员将用样品材料做焊接测试以确认其资格。焊接测试应该选用项目常用的管材尺寸材料；²Tackweldingofthemoduleshallavoidilleffectoncompletewelding.组件的定位点焊必须避免对完全焊接的不良影响；²Tackweldingshallbeaslightaspossibletoreduceinternalstructuralchangecausedbyoverheatingofthematerial.定位点焊应该尽可能的轻，以降低过热而导致材料的内部结构变化；²Tackweldingshallpreventpenetrationoftheinternalsurface.定位点焊不应焊透内表面；²Afterthetackwelding,inspectthealignmentoftheweldingandtheweldjoint.定位点焊完成后，需要检查定位焊接的对准性和缝隙。1.Material材料²TheweldingmaterialsshallbecompliedwiththetechnicalspecificationofMSD.用于焊接的材料须符合甲方的技术规格；²Allpipesandfittingsshallbefullywelded.所有管道和配件须完全焊透；²Theweldingelectrodeshallbe2%thoriatedtungstenelectrodewithsquarebutt.采用的焊接电极为2%涂钍平头钨焊电极；²Theweldingelectrodeshallbereplacedifanystainisfound.焊接电极如有污染须更换；²Thepurityofargonasshieldinggasinsideandoutsidetheweldedpipesshallbeat99.99%.焊接管道内、外部保护氩气的最低纯度为99.99%；²Argonshallbeinjectedduringtheweldingasprotectivegastopreventoxidationoftheinternalweldingsurface.Blowoutalltheoxygenintheweldingareabeforethewelding.27/27\n焊接过程中必须要通入氩气进行保护，以防止焊接的内表面被氧化。在开始焊接前，吹走焊接区域的所有氧气。1.WeldingPreparation焊接准备²Weldingshallbepreventedwhentheweldingsurfaceisdamp.Nooutdoorweldingshallbedoneinextremehotwhether,strongwindoradverseatmosphericcondition,unlessappropriateprotectivemeasuresareadopted.当焊接表面潮湿时，不得进行任何焊接。除非有适当的保护措施，在严酷气候或风速高或不良大气条件下不得进行室外焊接；²Itisessentialthattheendfacesoftheweldingjointbeclean,levelandstraight.焊接接头两端面的清洁，圆整和平直是重要的；²Theprocessingmethodofmetalsshallensurethattheweldingsurfaceissmooth,freeofscratchandotherharmfulabnormity.金属加工方法应确保焊接端表面光滑，无划痕或其它有害的不规则形状；²Itissuggestivethat+GF+orequivalentequipmentsbeusedinthecuttingandfinaltreatment.建议采用+GF+或同类设备来处理切割和最终处理；²Thecuttingshallbelevelandstraight,andpipedeformationordamageshallbeprevented.Abrasivedustorburrontheendfaceofpipeshallbecleanedandremoved.切割必须平直和不会造成管件变形或损坏。切割的管件端面必须清洁以除去磨屑；²Nocarbonsteelcuttingtoolscanbeusedunderanycircumstance.碳钢切割工具在任何情况下都不得使用；²Toolsforthetreatment,assemblingandinstallationofweldingendface,shallbeinspectedbeforeusing,toconfirmwhetheritisapprovedorrustlessalloysteel,andwhetheritisclean,freeofgreaseandresidualofotherdirt.27/27\n用于焊接端面的处理、装配和安装工具，在使用前须检查是否是没有生锈的认可合金钢，清洁无油脂，和无其它污染残留物；²Nosulfenylcuttingoilshallbeused,unlessallresidualgreasehasbeenthoroughlycleanedinsideandoutsidethepipefittingsbeforethewelding.不得使用硫基切割油，除非在焊接前管件的内外表面都被彻底清除所有残留油渍；²Weldingequipmentsettingisrequiredtobedonewiththeweldinginspector.需与焊接检查员一起设定焊接设备；²Thisinspectorshall,signtheweldinglogwithhissignatureandthedateaftercheckingwhetherallthesettingsconformwiththemainprogram.此检查员将检查所有设置是否符合主程序。他将签署焊接日志和注明日期；²Everyweldershalltakeaweldingtestbeforetheworkeveryday.Theweldingsampleshallbetaggedandforwardtotheweldinginspector.Eachautomaticweldingmachineshallbesubjecttotest.每天开始时，每个操作人员要作焊接测试。这些焊样将编号，并呈交给焊接检查员。每台自动焊接机都需做测试。1.Warm-uptemperature预热温度²Warmingupisnotneededifthetemperatureofweldingmaterialsisnotlowerthan10ºC在焊接材料的温度不得低于10ºC。一般来说，不需要预热。2.powersupply供电²Theelectriccurrentshallbeinconformitywithcorrespondingweldingform.电流应与注明在相应的焊接表相符。3.Weldingprocedure焊接程序27/27\n²Weldingproceduressuchasweldingsequence,settingofweldingprocedureandpositionofweldingelectrodeshallbealsoinconformitywithcorrespondingweldingform.焊接工艺，如焊接次序，焊接程序设置，焊极位置等，都将与相应的焊接表相符。1.Procedureofautomaticwelding自动焊接程序²Allmainprogramshavespecifiedparametersfortheweldingofpipeandfittingswithdifferentdiametersorsizes.所有主程序都规定了不同尺寸管件焊接的一组参数；²Theweldingprocedureofautomaticpipeweldingsystemshallcomplywiththeproceduremadebywelderandtheinspector.自动管道焊接系统的焊接程序都须符合焊接操作员与检查员一起制定的程序；²Approvedweldingprocedureshallbeusedforbothformalandtestwelding.正式和测试焊接需采用已认可的焊接程序；²Weldingsampleshallbenumberedinorder(suchasT1,T2).Theweldingsampleshallhavecompletetraceabilityandshallsubjecttoinspectionbyindependentinstitution.焊接样品必须按顺序编号(如T1，T2等)。焊接样品，具备完全的可追朔性，将备独立机构检验；²Allsamplesonsiteeverydayshallbelefttotheclientduringthewholeconstructionphase.在整个施工阶段，所有每天的现场样品将留予业主；²Thecalibrationofautomaticpipeweldingsystemshallbecomplywiththeproceduremadebywelderandtheinspector.自动管道焊接系统的校正都须符合焊接操作员与检查员一起制定的程序。2.Document文档27/27\n²Qi’anisresponsibleforprovidingallreportsofweldingrecordofthissystem.Thereportsshallbefilledincompletelywhichshouldincludesatleast:启安将提供此系统所有焊接记录报告。此焊接记录报告表格，必须完全填写，最少包含：Systemname系统名称Weldjointnumber焊接号Nameofthewelder焊接工姓名Equipmentno.设备编号Weldingdate焊接日期No.ofweldingprocedure焊接程序编号Signatureofoperators(ifany,theinspector)焊接操作工(如有，还加上检查员)签名²Recordofautomaticweldingshallbeprintedbytheequipmentandthereshallbeweldjointnumberintheweldingreport.设备将打印相应自动焊接记录。在此焊接记录中要有焊接编号。²Weldingmap(withcorrespondinggroove,sizeandlength,andallweldjointnumbersmarkedonit)shallbeusedandupdatedthroughouttheconstructionperiodandacompletiondrawingshallbegeneratedwhentheprojectiscompleted.焊接图(标示相应的坡度，尺寸和长度，所有焊点编号)将在整个施工期间使用并且更新，在工程完成生成竣工图。²Eachweldjointshallbenumberedinaprogressivemanner,allweldjointsshallbemarkedintheweldingmapandweldingreport.每个焊点以累进方式编号。所有焊点标示在焊接图和焊接报告中。27/27\n1.内窥检查Endoscopicinspection²Whenrequiredbyspecifictermsorprovisionofthecontract,endoscopicinspectionshallbedoneunderthetermsorprovisionthereof,andtimedelayshallbetakenintoconsiderationtherefore.当相应的条例或合同规格要求时，内窥检查将在符合条例或合同规格下进行。须考虑到因此而造成的时间延误。²评定标准AWSD18.1:1999Specificationforweldingofausteniticstainlesssteeltubeandpipesystemsinsanitary(hygienic)applications卫生洁具用奥氏体不锈钢管和管道的焊接规范1-4是可以接受的From1to4,itisacceptable.Discolouration/Oxidation变色和氧化AmountofoxygeninppminthebackinggaspersampleNo.1–10No.3–50No.5–200No.7–1000No.9–12500No.2–25No.4–100No.6–500No.8–5000No.10–250002.Dailyweldingtestpiece每日焊接样品²Equipmentweldingprocedureshallbeusedfordailyweldingsamples,whichshallbenumberedinorder(suchasT1,T2).Allthesesamplesshallbesubmittedtotheclientthroughouttheconstructionperiodonaregularbasis.每日焊接样品应采用设备焊接程序。这些样品必须按顺序编号(如T1，T2等)27/27\n。所有这些焊接样品将在整个施工期间提供给业主；²Theresultsofdailysamplesshallberecordedinthefully-filledtestreportofautomaticweldingequipment.每日样品结果必须收集在完全填写的自动焊接设备测试报告中。1.6AssemblyandInstallation装配和安装1.Receiving,StorageandDisposalofPipeMaterials管件材料接收储存和现场处理²Pipematerialsshallbeconfirmedandinspectedbyrelevantpersonnel.管件材料需由专人确认和检验；²Thestorageofpipematerialsandthepreassembledfittingsshallfreeofcontaminationbygrease,dampandothersubstance.pipematerialsandthepreassembledfittingsshallbeappropriatelyhandledtoavoidanypossibledeformation,scratchingandothertangibledamage.管材和预装配件的存放应注意不会被油脂，潮湿或其它物质污染；管材和预装配件应处理得当，以避免变形，刮伤或任何有形损伤；²AllSSmaterialsshallbeseparatelyinspectedandstoredwithotherconstructionmaterials.Storageareashallbeindoorwithprotectivemeasuresagainstcorrosiveenvironmentandtemperaturevariation.所有不锈钢材料应与其它施工材料分开检查和储存。储存区必须在建筑物内，并且有防护任何腐蚀性环境和温度变化的措施；²Accessshallbestrictlyrestrictedincaseofmateriallossordamage.Onlywhenneededintheconstructioncanmaterialbewithdrawn.通道应严格限制以确保材料不会受损伤和丢失。只有在施工需要时才能从储存区提取材料。2.Classification分类²Allmaterialshallbeclassifiedaccordingtospecificationandappropriatelystoredanddisposed.所有材料将按规格进行分类，并且适当储存和处理以便于辨认。27/27\n1.Assembly装配²Theassemblingshallbeinaccordancewiththerequirementsofthisspecificationandcurrentdetailedinstallationrequirements(drawingsetc.)装配应按照此规格的要求和已有的详细安装要求(图纸或其它)进行。2.pipelayout,cuttingandassembling布管、切割和装配²Thepipefittingsshallbecutpreciselyaccordingtothesizeonthedrawingtomeetsiterequirement.管件应按图纸上的尺寸精确切割以适应现场情况；²Theburronendfaceofpipestobeweldedshallberemoved,thecuttingfaceshallbelevelandthechamfershallbefreeofcuttingarc.Terminaltreatmenttoolsshallbeusedinthetreatmentofendfaceofpipeedgeandburr.Thetoleranceofpipeshalltheconsistentwiththatofthefittingstoensureweldinglinearity.所有待焊接的管件端面需清理毛刺，并且切割面应平直，边角无切割圆弧。管件边缘的端面处理和清理毛刺应使用终端处理工具，并且其公差与配件一致以确保适当的焊接线性；²Inspectthepipeendafterthecuttingtoensurethatitislevelandstraight.检查切割管件终端，以确保其平直；²Whenremovingburr,internalpolishingthatdamagetheinnerandouterdiameterorthepipeshallbeprevented.清除毛刺应避免破坏内外径，或损伤管件的内抛光；²Abrasivedustaccumulatedattheendofthepipeandfittingsshallbecleanedandremoved.在管件端口积聚的磨屑必须擦拭干净；²Allpipeandfittingsofthepipelineshallrefrainfromexcessiveelasticityorassembledunderstress.所有安装在管线上的管件不应受过分弹力和受力下装配；²Heatingandbendingthepipetoachievelinearityisnotallowable.不允许通过管件加热和弯曲以达到线性整齐。27/27\n1.AcceptanceofWeldingProcedureandQualification焊接程序和资格认可²Allweldersshallbequalifiedwith6monthsofworkingexperienceandtheiroperationonthesiteshallbesubjecttoqualifiedtestbyLL.所有焊工应得到LL考试合格确认后，方可进入现场施工；²Weldingprocedureshallbesubmittedtotheweldinginspectorforreviewandapprovalbeforethecommencementofwelding.在开始焊接前，焊接程序应提交给焊接检查员核准。2.Installation安装²Allpipeandfittingsofthepipelineshallrefrainfromexcessiveelasticityorassembledunderstress.Nocuttingorweakeningbracketwithshallbeusedintheinstallationofpipework.所有组装管件应在不受过分弹力和受力下装配。不允许有切割或弱化的支撑物作管道安装；²Installationofpipeandfittingsshallbeablefreelyexpandandcontract,sothatitwon’tdamagetheconnectorsandbracket.所有管件安装应可以自由膨胀和收缩，而不至于损坏连接和支撑；²Allpipesshallhaveappropriategradient(0.5%,max1%.)toensurecompletedrainage.所有管道必须有适当的坡度(0.5%最大1%)以确保完全排水。3.Welding焊接接口²Allweldingshallbepreparedanddoneinaccordancewiththisspecificationandrequirementsstatedhereinabove.所有焊接应按照本规格前文所述的要求进行准备和装配。4.Packagejoint快装接口²Noscrewjointshallbeused.不得使用螺纹接口。27/27\n1.Bracketandconduitinstallation支撑和穿管²Thebracketofpipeshallbedesigned,assembledandinstalledaccordingtoparameteranddetailsofthedrawing.管件的支撑应按管件支撑图纸上的参数和细节设计、装配和安装；²Stainlesssteelpipeandfittingsshallbeinstalledundertherecommendationsofthevendor.不锈钢管件的安装按制造商的建议进行；²Installationofhangerandbracketshallbeeconomicalandmeanwhilemeetrequirementsofdrawingsandspecifications.吊架和支撑的安装应尽量的经济，并符合支撑图纸或规格上的描述；²Thegradientofpipebracketshallbeinaccordancewiththatrequiredinthedrawings.管道的支撑应符合管道图纸上要求的坡度；²Theinstalledpipesshallatleastmeetspecificationofinspectionandtest.所有装配的管道应最少符合检查，检验和测试要求规格。1.7Inspection检查1.Scope范围²Inspectionlistoftheweldinglogwillbeusedinverifyingmajorinformation,preparationandqualityinspection.焊接日志检查清单将用于查核主要信息，准备和质量要求；²Weldinginspectorshallinspectweldingrecords,setting,endoscopicinspectionandvisualcheckofthecontractorsinaccordancewithweldingrequirements.Thisworkcanbedoneatanytimeasitisagreedandunderstoodbybothparties.焊接检查员按照焊接要求，检视分包商的焊接记录、检查和设置、内窥检查，以及目检。在双方同意并理解相应的时间延误下，此工作须在任何时间进行；27/27\n²Theweldinginspectororhisrepresentativeshallvisuallycheckallweldjoints.焊接检查员或其指定代表应目检所有焊接。1.FittingsandweldingNo.配件和焊接编号²Eachweldshallbenumberedinthediagram.每个焊接应在其立体图中编号；²Theinspectorshallkeeptheinspectionlist,whichshallbeusedfordistinguishingforactualweldingspots.检查员应保留焊接检查清单，而且实际的焊点以此编号辨别；²Recordofeachweldingspotshallincludesallitemsdeserved.每个焊点的记录应包括所有相关的条目。27/27\nWeldingpreparation焊接准备Theweldinginspectorshalldecidewhethertomakethefollowinginspectionandconfirmation.焊接检查员决定是否进行下列检查/确认。²Confirmationofpipesection管道截面确认Lengthofpipeshallbemarkedinthepipedrawingaccordingtorelevantrequirements.管道的长度按要求在管道图纸中标示；Cleanallpossiblesundriesinthepipeendgeneratedduringthecutting.要去掉管道端口切割产生的任何可能之污物；Toolsshallbepreventedfrombeingcontaminatedbycarbonsteel.工具不得被碳钢所污染；Confirmtheroundnesstoleranceofpipe确认管道圆度公差。²Cleanness清洁确认Approvedethanolshallbeusedforthecleaningoffittings.用酒精清洁配件。Thecleanedandreadily-preparedpipeendshallrefrainfromtouchingskinbeforethewelding.在焊接前，已清洁和准备好的端口不得接触皮肤。Thereshallbenovisibleforeignmattersintheendofthepipeandcomponents,includingfiberfromthecloth.在部件的端口不得有可目见的异物，此包括清洁布的纤维。Thetungstenelectrodeshallbecleanandfreeofcontamination.钨焊极必须清洁和无污染。²Jointpreparation接口准备27/27\nThicknessofgapbetweentheendsofweldingcomponentsshallbemeasuredwithfeelergauge焊接组件端口间隙用厚度塞尺测量，不得超过0.25mm。Thetungstenelectrodeshallbeplacedinthecenteroftheweldingspot.钨焊极应置于焊点中央。²Settingofweldingmachine焊机设置Thesettingofparametershalltakereferencefromrelevantweldingformsintheweldingprocedure.参数的设置应按焊接程序中相应的焊接表进行。Positioningofgassource确认气源就位。1.weldinginspection焊接检验Eachweldingsampleandallerectionweldingshallbeinspectedbyvisuallycheckingthepipeinterior.If,thereisreparabledefectinthewelding,secondweldingshallbemadetorepairthedefectbeforetheremovingthememberfromtheweldingmachine.Ifthesecondweldingfailstorepairthedefect,thismembershallbedeemedasdisqualifiedandshallberejectedintheassembling.Theautomaticweldingshallbecontrolledasfollows:每个焊接样品和所有装配焊都要目检管道内侧。如焊接有可修复的缺陷，在焊接部件拆离焊机前进行第二次焊接以修复缺陷。如果重新焊接未修复缺陷，则此焊接视为不合格并不得装配。所有自动焊接按如下控制：²Specificweldingprocedureshallbeusedtofinishadailysample.对每日样品，用选定的焊接程序完成一个焊接²Allautomaticweldsshallhaveprintedreportwithweldingparameters.对于所有完成的自动焊接，含有焊接参数的焊机打印报告²10%ofthetotalweldjointsneedendoscopicinspection.总焊缝10%的焊缝需要进行内窥检查。27/27\nThefollowingtableshallbeapplicableifthereisanydefect如有表面缺陷，则本规格条目适用。表1：AB须进行重新焊接的缺陷Defectswhichreworkmaybeneeded不合格的缺陷：须与受热区(棕色)一起切除：Defectstoberejected:Cutoutrequiredtogetherwithitsheataffectedzone(browncolor):1.未焊透incompletepenetration2.多孔porosity3.沙眼pinhole4.冷隔coldlap5.过度穿透(<0.4mm)burnthrough6.未对准(<0.55mm)misalignment1.裂纹cracks2.过烧excessivepenetration3.解块sugaring4.冷隔coldlap5.过度穿透(>0.4mm)burnthrough6.未对准(>0.55mm)misalignmentItmaybedeemedasdisqualifiedifthereiscrack,incompletepenetration,excessivepenetrationandmisalignment.点焊如有破裂、未完全焊透、过烧、组件未对准，则视为不合格。Makevisualcheckontheweldpieceafterremovingitfromtheweldingmachine焊件移离焊机后，对焊接外观进行目检。27/27\n1.ProtectionofpreassembledFittings预装配件的保护²Allopeningsshallhavecoversandappropriateprotection.所有开口应有适当的保护，保持密封；²Thereshallbeprotectivemeasuresforpackageflangeandflangefacetopreventanypossibledamage.快装接口和法兰端面应有保护措施以防止损坏；²Allpreassembledmembershallbeplacedonthewoodshelvesintheprotectiveareaduringthedisposalandstorageperiod.除了在工作台上，在处理和存放期间，预装配件应置于保护区内的木支架上。2.Acceptance验收²Theinspector,shallsignhisnameandthedateonthefinishedlistafterfillingintheinspectionlist.Ifthereisanydisqualifiedwelding,specificcauseofitshallberecorded.Theweldinginspectorshallsignthelistwhentheweldingisdone.焊接检查员应完成焊接检查清单并须在完成的清单上共同签署和注明日期。如在任何地方有不合格焊接，则不合格原因应被记录。焊接检查员应在焊接完成时签署清单。3.OtherRequirements其它要求²Theinspectorshallconfirmthatpurginggasandthereservedflowmetertoensurethatitisinstanding-bystatus.检查员应确认吹扫气体和后备气体流量计处于准确工作状态。²Ifanytoolormemberwascontaminated,cleanandtestitaccordingtostandardprocedureofASTM如任何工具或组件被怀疑有污染，应按ASTM标准程序进行清洁和测试。27/27\n1.8Pneumaticpressuretestandcleaning气压测试与清洁Thisspecificationwasincluded,afterthecompletionofpipingsystem,inalltheworkfortestingthesystemperformanceandcharacteristics.本规程包含在管道系统完成后，为测试系统性能和特性而进行的所有工作。1.Pneumaticpressuretest气压测试²Theinspectorshallwitnessallpressuretests.所有压力测试应当同检查员一起进行；²Operatorsofthetestshallbesecurelyprotected,thereshallbeappropriatemetersandpressurereliefdeviceforthesystemwhichpneumaticpressuretestbedone.所有测试进行时应对操作人员的安全作好预防，要进行气压测试的系统应该带有合适的表和压力安全泻载装置；²Insulationshallberemovedinallconnectionsincludingtheweldjointsinordertoobservethetest.所有连接点，包含焊缝应该去除绝热保温以便在测试过程中观察；²Equipmentsthatdonotrequirepressuretestsshallbedisconnectedwiththesystemorbeisolatedwiththetestsystemduringthetest.不需要进行压力测试的设备，在测试过程中应该与系统断开或使用其他合适的方式与测试系统隔离开；²Necessaryvalvescanbeinstalledforthetest.可以安装测试过程需要的阀门；²Pressuregaugeofthepipelineshallnotbetestedinpressurebeyonditsrange.Componentandequipmentwithoutclearlydefinedtestpressureshallbeexcludedinthetestitem.在管线上的压力计不应在超过量程的压力下测试。没有表明测试压力的部件和设备应排除在测试内容之外；27/27\n²Makevisualcheckonthepipelinetobetestedtoensuretovisibledefectandallconnectionsaretight.在进行所有测试之前，需目测管线系统以保障没有可见的缺陷且所有连接紧密；²Allcontrolvalvesshallbefullyopenaslongastheyarenotbeingtested.控制阀门只要不是正在被测试，应该打在全开的位置；1.Testreport测试报告Thecontractorshallappropriatelyrecordtheresultsofeachtest,whichshallinclude“Hydraulictestcertificate”andthetestnumber..承包商应为每个测试做相应记录，记录包含‘气压测试证书’和测试编号。²TestNo.测试编号；²Testdate测试日期；²system系统名称；²Testmedium,pressureandholdtimeunderacertainpressure测试媒介，压力和相应压力下维持的时间。2.Hydraulicpressuretest气压测试²Thehydraulicpressuretestshallbemadeaspertechnicalspecificationoftheproject,non-involvingvesselandcomponentsshallbeisolated.气压测试压力需根据项目技术要求进行，用干燥清洁的氮气（粒度不超过0.5µm）进行试验；²Allpressuretestofthecleancompressedairsystemshallbeconductedunder1.15timesofthedesignpressureor1000kpa(takethelargerone).Thetestpressureshallbemaintainedatleast8hoursandthensprayallconnectionswithsoapywater.Observeandrepairtheleakagepointsifdetected.Testagainuntilnoleakageisfound.洁净压缩空气管道系统应在1.15倍的设计压力27/27\n或1000kpa压力（取较大值）,对系统施加试验压力，8小时后才能切断系统的压力源，通过在各个连接处涂抹肥皂水，对有泄漏点处进行修补，然后重复进行试验，直到不出现泄漏点。4.SystemCleaningandFlushing系统清洁和清洗²FlushandcleanalltheinstalledpipelineinaccordancewihprocedureforSSpicklingandpassivation.清洗和清洁全部安装好的管线，应按照不锈钢清洗，酸洗和钝化规程执行。Degreasing,picklingandpassivationofpipingsystem管道系统脱脂、酸洗和钝化Thistechnicaldocumentdealswithchemicaltreatmentofthedistributionsystem.Allpipeandfittingsusedinthisdistributionsystemis316LSSmaterialwithmechanicalorelectricalpolishing.本技术文件说明的是分配系统的化学处理操作。用于该分配系统的管道和管件是机械或电抛光的316L不锈钢材料。Thechemicaltreatmentshallfollowtheproceduresbelow:系统的化学处理包括以下步骤：²De-ionizedwaterflushing去离子水冲洗²Degreasing脱脂²PicklingandPassivation酸洗钝化Degreasingistoremovetheoxidategeneratedintheweldingandprecipitateproducedbymechanicalpolishing.脱脂是除去焊接过程中产生的氧化物和机械抛光产生的沉淀层。Picklingandpassivationistoresumetheoxidatedanticorrosivecoatingwhichwaslostinmechanicalandchemicaltreatment.酸洗钝化是重新在表面镀上在机械和化学处理中除去的氧化防腐层。1.Safety安全Qualifyingofhydraulicpressuretest水压测试合格27/27\nSafetyprotectivemeasuresinthechemicaltreatment在化学处理中的安全防护措施：²Warningsignsandplateshavebeenattachedinthepicklingandpassivationarea.酸洗钝化区已粘贴警示标示或悬挂警示牌。²AllPPE(rubbergloves,apron,facemask,gasdefenseshield,exhaustfan)thatOperatorsneedshallbeavailable.操作者所需的劳保防护用品（包括橡胶手套、围裙、面罩、防毒面罩、排风扇等）已到位。²Stircontinuouslywhenaddinganddissolvingthechemicals.在加入和溶解化学品时必须连续搅拌。²limeorsodiumbicarbonateshallbepreparedtoneutralizethesolutioninwheredropswasneglected.准备几袋石灰或碳酸氢钠，防备在有滴漏的地方中和溶液。²Refertosafetyinstructionofthechemicals参照化学品的安全说明。1.chemicaltreatmentofcompressedairsystem压缩空气系统的化学处理²De-ionizedwaterflushing去离子水清洗Connectthepicklingandpassivationbarrel,pumpandvalve,pressuremeterandconnectorswiththesystemtobeflushed.Flushthesingle-pipesystemwithde-ionizedwater,dischargefor3-5minateachusingpoint,andturnoffthevalve.将酸洗钝化桶、酸洗钝化泵、阀门、压力表及连接件与被清洗系统连接起来，对于单管路系统，用去离子水清洗并在各个使用点排放3-5min，然后关闭阀门。²Degreasing脱脂Solutionformulation溶液配制：Solution（W/V）:2%sodiumhydroxide+98%de-ionizedwater:(W=2%*V，W-NaOH,SolutionVolume)溶液（W/V）：2%氢氧化钠+98%去离子水：（W=2%*V，W-NaOHweight氢氧化钠重量kg，V-SolutionVolume液体体积L）1）Maketherequiredsolutioninthepicklingandpassivationbarrelaccordingtotheformulation.在酸洗钝化桶中按照酸洗溶液配制方法配制所需溶液27/27\n1）Stircontinuouslywhenaddinganddissolvingthechemicals.Pouringthechemicalintothebarrelinaone-offmannerisstrictlyprohibitedincaseofsplashingofthesolution,whichcanscaldthepeopleonsite.加入溶解化学品时需边搅拌边溶解，严禁将所需化学品一次性倒入酸洗钝化桶内，造成配制液溅出，烫伤现场人员，2）Forsinglepipelinesystem,filleachusingpointwiththesolutionunderambienttemperatureandsoakitfor60minandmakegoodrecordoftheprocess.对单管路系统，在环境温度下使各个使用点充满溶液，浸泡60min，并做好记录，3）Afterthedegreasing,dischargethedegreasingsolutiontowasteliquorbarrel.Flushthepipewithde-ionizedwaterandthendischargeitintothewasteliquorbarreluntiltheliquidinthebarrelwasneutralized(PH6-8obtainedbytestpaper)脱脂结束后，将脱脂溶液排放至废液收集桶中，管道用去离子水冲洗，并将冲洗液排放至废液收集桶中，直至用PH试纸测试为中性（PH6-8）。²Formulationofpicklingandpassivationsolution酸洗钝化溶液配制溶液（V2/V1）：20%硝酸溶液nitricacidsolutionV2=(20%V1)/(C2)V1-volumeofpassivatedliquid钝化液体积，LV2-volumeofstrongnitricacid浓硝酸体积，LC2-concentrationofstrongnitricacid浓硝酸浓度1）Maketherequiredsolutioninthepassivatedbarrelaccordingtotheformulation在钝化桶中按照钝化溶液配制方法配制所需溶液2）Stircontinuouslywhenaddinganddissolvingthechemicals.Pouringthechemicalintothepicklingandpassivationbarrelinaone-offmannerisstrictlyprohibitedincaseofsplashingofthesolution,whichcanscaldthepeopleonsite.加入溶解化学品时需边搅拌边溶解，严禁将所需化学品一次性倒入酸洗钝化桶内，造成配制液溅出，烫伤现场人员，3）Turnontheexhaustfantoblowofftheacidmisttopreventtheoperatorsbeingpoisonedbytheacidmist.为防止操作人员酸雾中毒，在必要情况下开启排风扇，将空气中的酸雾吹散，4）Forsinglepipelinesystem,filleachusingpointwiththepassivatedsolutionunderambienttemperatureandsoakitfor120minandmakegoodrecordoftheprocess.对于单管系统，在环境温度下，使各个使用点充满钝化液，浸泡120min，并做好记录，27/27\n1）Afterthepicklingandpassivation,dischargethesolutiontowasteliquorbarreltoneutralizethedegreasingsolution.Thenflushthepipewithde-ionizedwateranddischargetheflushliquidintothebarreluntiltheliquidinthebarrelwasneutralized(PH6-8obtainedbytestpaper).酸洗钝化后，将酸洗钝化液排放至废液收集桶，以中和脱脂溶液，并对管道用去离子水冲洗，并将冲洗液排放至废液收集桶，直至用PH试纸测试为中性（PH6-8），2）NeutralizethewasteliquidinthewasteliquorbarreltoPH6-8andthenperformoff-sitetreatmentinaccordancewithLLrequirements.将废液收集桶中得废液进行中和处理，使废液中和成中性（PH6-8），然后按照LL要求进行场外处理。Resumethesystemafterthepicklingandpassivationanddrythepipelinebypurging.酸洗钝化完成后，恢复系统，并对管线进行吹扫干燥。27/27