巴斯夫工艺管道施工方案.doc

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1、目 录Contents一、工程概况 General2二、编制依据 Reference3三、施工准备 Construction Preparation3四、施工管理Construction Management4五、管道安装 Pipe installation10六、材料管理Material management40七、施工进度控制与管理Control and Management of Construction Progress42八、人力计划Manpower Plan42九、机具动员计划Mobilization plan of equipments and tools44十、安全文明施工Sa

2、fety and housekeeping45十一、安全分析Safety analysis48一、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。Theprojectis BPCLemongrass Project which is located in Gebeng Industrial Park of Kuantan Malaysia. The Owner is the BASF PETRONAS Chemi

3、cals 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)、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

4、、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-TP316/31

5、6L, 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 an

6、d pressure pipe by service media, operation temperature and pressure rating.、工程特点 Project features and challenges1、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 const

7、ruction. 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

8、 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 wi

9、th large Diameter Bore quantity, which 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 Reference1、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

10、Contract3、国际通用标准：International StandardsaASME bASTM cANSI4、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-EM

11、SP-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

12、-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 Plan5、

13、我公司企业标准Company Standardsa. 压力管道安装质量手册（QG/CC-7.PP.0501-00）Quality Handbook for Pressure Pipe Installationb. 压力管道安装质量体系文件（QG/CC-7.PP.0502-00）Quality System Document for Pressure Pipe Installationc. 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 Preparat

14、ion.标准、规范准备Preparation of Standard and Specification3.1.1. 收集管道施工要求的规范、标准。To prepare standard and specification of pipe construction3.1.2.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 construction3.2.技术准备 Technical Pr

15、eparation3.2.1.图纸会审 Drawing joint review；管道预制、安装方案的编制与审批 Method statement compilation and Approved for pipe fabrication and installation；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 Others3.3.1.施工计划编制 Construct

16、ion 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 atta

17、chment 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

18、 quality assurance system4.1.1.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

19、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

20、 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防腐保温施工队质检责任师工艺责任师焊接责任师设材责任师计量责任师项目质保工程师专业技术人员管道施工队压力管道质量保证体系理化责任师 各专业质检员无损检测责任师图（1）

21、QA System of Pressure PipeProject QA EngineerWelding principleProcess principleQuality check up principleMeasurement principleMaterial principlePhysical and chemical principleNDE principleQuality inspectorDiscipline techniciansPiping teamsAnti-corrosion teamSketch 14.2.1.压力管道安装时，为确保其安装质量其处于受控状态,应建立如

22、图(1)的压力管道安装质量保证体系。When installing the pressure pipe, QA/QC system (see sketch 1) of pressure pipe installation shall be setted for controlling installation quality. 4.2.建立健全安全管理体系 To set integral safety management system 4.2.1.建立以项目经理为第一安全责任人，专业安全工程师、安全人员为主导的安全控制体系。Built a HSE control system, which

23、shall include project manager as a first responsibility person and HSE engineer and supervisor as key persons.4.2.2.落实安全责任到施工班组、到施工责任人。Safety responsibility shall be put into work team/group and personal. 4.2.3.现场施工人员必须遵守现场的安全规定，定期进行安全学习与培训。Construction stuff shall comply with the safety requirement

24、, and carry out safety training regularly.4.2.4严格执行各安全制度与操作规程，做到安全、文明、环保施工。Safety system and operation specification shall be carried out strictly for safety, health and environmental protection construction.4.3工艺管道检验与试验计划 Inspection and test plan of process pipe 在工艺管道的施工过程，全方位的质量监督。并极力配合业主、管理公司、监理、

25、质检站对各检查点的监督检查工作；严格执行停检点、必检点的监督检查。在管道施工过程中，应切实重点做好质量监督检查控制工作，以便更好地控制管道施工的质量，执行相关ITP计划。During process pipe construction, Well cooperated with BPC/FLOUR, supervision and relative government bureau for supervision of each inspection point. Strictly comply with supervision and inspection requirements on

26、hold point and witness point. During pipe construction, the following issues shall be focused on for better fabrication quality.4.4.工序交接 Work procedure handover4.4.1.做好各道工序之间的交接工作，确保上道工序不合格的产品严禁进入下道工序。Handover between each process shall be well performed to ensure no unqualified product being used i

27、n the next process.4.4.1.1.管件、阀门、管材等工程材料经检验不合格者，禁止用于本工程施工；同时临时管道，管件和阀门材料需要合格。It is forbidden to use non-conforming construction material, such as pipe fitting, valve and pipe material, in this project；The temporary materials should be qualified too.4.4.1.2.管道除锈、防腐检查及管件组对不合格，不得进行焊接工作。Poor fit-up pipe

28、 fittings cannot be welded. 4.4预制产品安装前，必须经相关的质量检查人员或专业工程师检查，确认合格后，方可用于安装施工。Before installing, fabricated products must be inspected and approved by related quality inspector or discipline engineer.4.4.1.4 预制管段安装前需对管段内部垃圾进行清理，并组织检查，检查合格后才能继续安装。The internal waste of pre-fabricated spools should be rem

29、oved before installation of pre-fabricated spools, the inspection will be performed, the pre-fabricated spools can be installed after passing the inspection. 4.4.1.5 预制管段安装前需对有法兰面的管道进行保护，法兰面安装时需安装临时橡胶垫，避免对法兰水线照成机械损坏。 The pipe with flange face should be protected before installation of pre-fabricated

30、 spools, the temporary rubber gasket need to be installed while flange face is being installed, to avoid the mechanical damage for flange seal surface. 4.4.2.施工过程必须加强施工班组的自检工作，严格“三检”制度（自检、互检、交接检），确保每道工序产品合格。During construction, internal inspection of construction team shall be improved. “Three Inspe

31、ctions” Regulation (internal-inspection, mutual-inspection and joint inspection) shall be strictly complied to ensure products used in each process are qualified. 4.5.工艺管道焊接质量保证体系 QA/QC system for Process pipe welding4.5.1.现场施焊人员资格审查；Qualification examination for site welder4.5.2.焊接工人上岗前，现场实际操作考试；We

32、lder shall pass welding test in site before any work.4.5.3.焊接过程合格率考核与控制；Test and control of welding qualification rate 4.5.4.焊接工程师及焊接质量检查人员现场指导、检查； Site guidance and inspection acted by welding engineer and welding quality inspector.4.6施工技术及资料管理 Construction technique and document control 4.6.1.施工过程

33、中必须严格执行相关的规范、标准、要求等。Related specification, standard and requirement shall be performed strictly during construction.4.6.2.严格按照我公司质量体系文件运行程序进行施工和管理。Related specifications, standards and requirements, etc. shall be strictly complied in the process of construction. 4.6.3.施工图纸管理 Management of constructi

34、on drawing (IFC drawing)4.6.3.1.施工前，施工图纸必须经专业工程师审查，并进行图纸会审。IFC drawing must be reviewed and joint reviewed by discipline engineer before construction.4.6.3.2.图纸收发必须进行登记，以便核查。图纸版次更替应做到及时，确保施工图纸一直处于最新版次。对于旧版次应即刻回收，并做好登记保管，做到无遗漏。 Drawing issuance status shall be recorded for easy check. Drawing version

35、 shall be updated timely to make sure always using the latest version. Old version shall be returned back timely, record shall be made as well to avoid missing items4.6.3.3.施工图纸发放前，必须对施工队进行技术交底及图纸答疑。Technical disclosure and drawing clarification shall be done to construction teams before issuing IFC

36、 drawing.4.6.3.4.图纸设计变更应及时传达到施工队，并及时对图纸进行修改，并及时执行设计变更。Design change shall be informed to construction team， drawing shall be revised timely and design change shall be complied timely as well. 4.6.4.施工过程记录应做到及时、准确，并签字保存妥当。 Construction process records shall be made timely, accurately and well-kept.4.

37、6.5为加强质量管理，保证为业主提供合格的工程项目产品，在施工过程管理工作中，使用公司开发的管道施工管理系统软件，跟踪、记录管道的主要施工信息、质量日检信息、无损检验信息等，以便施工人员及时了解相应的质量进度信息，便于质量管理和控制，同时辅助生成主要的交工资料，提高交工的质量。 To improve quality management and provide qualified product to the Owner, company developed pipe construction management software will be used in the constructi

38、on to trace and record major construction information, daily quality inspection information, NDE information, etc, which make constructor know related quality progress information well and easy to management and control quality. Main handover document will be generated as auxiliary function, which i

39、mproves handover quality as well.4.7.现场安装管道的标识 Pipe identification for site installation4.7.1.管材、管件的追溯检查 Traceability of pipe material and pipe fitting4.7.1.1材料到预制区域后按管道预制过程标识和出厂标识的要求严格执行，以实现管材鉴定到管道安装的全过程可追溯性。 Arrived at fabrication area, materials shall be marked as per requirements on pipe install

40、ation process and manufacture to make traceability of whole process from pipe material identification to pipe installation possible.4.7.材料使用前，应先确认材质色标是否符合规定。Ensure the material color system applies to the requirement prior to use.4.7.1.3.材料分离、分割而使原标识不全时，要进行原标识的移植；Original identification shall be rel

41、ocated if material is incomplete by separating or cutting.4.7.2.安装管段的标识 Pipe spool identification for site installation 4.7.2.1.管段及焊口的编号和标识工作贯彻管段安装全过程。采用在单线图上标明焊口检验状态，在实物上用记号笔做标识方法进行标注。Serial number and identification of pipe spool and weld joint shall be made during whole pipe spool installation pr

42、ocess. Mark inspection status of weld joint in the ISO drawing. Mark identification on spool by marker pen. 4.7.2.2.管端上的焊工号、焊口号及安装管段号不得用打钢印，而采用记号笔（不得含锌、氯离子等对母材有危害的成分）在距焊缝边缘50mm处标注，字迹清晰工整。Welders ID number, No. of weld joint and No. of installation spool, which are in the pipe end, shall not be steel

43、 stamped but be marked at 50mm away from weld joint edge by marker pen (free of zinc, and cholrion, which is harmful to base metal) in a visible and neatly way. .2.3.管段及焊口的标识方法如下：管道标识的责任：焊工代号由焊工填写，质检员代号由质检员检验后填写，其余标识（预制管段号、管段长度或炉批号）均由管工填写。管工和焊工自检合格，且所填内容齐全后，由管工班长或焊工统一向质检员报检，经质检员外观检查合格后报FLOUR检查，由FLOU

44、R点口确定需检测的焊口并在焊缝上用记号笔按照要求作为无损检测的标识（RT、PT等）标识内容见图（2）：Identification method of pipe spool and weld joint as follows: Responsibility of pipe identification: welders ID number will be filled by welder, quality inspectors ID number will be filled by quality inspector after inspection, other identification

45、s (No. of fabricated pipe spool, length of pipe spool or heat No.) will be filled by pipe fitter. Pipe fitter and welder shall inspect fabricated pipe and complete identifications firstly, then pipe fitter leader or welder leader shall report to quality inspector for inspection. Quality inspector wi

46、ll report it to FLOUR if visual inspection is accepted. Weld junction should be determined according to FLOUR spot weld junction, and marked NDE (RT, PT, etc.) on the weld joint by marking pen as per requirements. Refer to Sketch (2) for detailed mark. Diagram 2Pipe spool length L= No. of pipe spool

47、 Fabricated areaWeld seamSpool fabrication Identification Pipe materialISO Dwg No.No. of weldWelders ID No.Weld date五、管道安装 Pipe installation5.1.施工准备 Preparation 5.1.3.3.施工人员准备 Manpower mobilization 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）；Pipe installation person shall be mobilized according to site construction condition. (detailed manpower plan is attached as bellow) 5.1.3.4.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）。Equipment and tools shall be mobilized according to site construction condition. ( detailed equipment and tools