Construction Preparation Material Entry Inspection (Oxygen Pipeline Degreasing) Pipeline Fabrication Pipeline Installation Tests Blowing Commissioning Delivery
5.1.1 Construction Preparation
(1) Familiarize yourself with and review the drawings and design documents, and participate in the design briefing in due course;
(2) Find out the content of the project, the project volume, workload;
(3) Prepare the pipeline construction technical plan and organize technical briefing;
(4) Prepare construction machinery and equipment and engineering facilities; and organize technical briefing. p>(3) Preparation of pipeline construction technology program, and organize technical briefing;
(4) Preparation of construction equipment and engineering facilities
(5) Organization of the construction team, training personnel (including welders);
(6) Reasonable arrangement of the construction plane, and according to the requirements of the site leveling, pipeline laying, connecting the water and electricity and the installation of setting up the required large temporary facilities;
(8) The construction team will be responsible for the construction of the pipeline, and will be responsible for the construction of the pipeline, and will be responsible for the construction of the pipeline, and will be responsible for the construction of the pipeline and its construction.
(7) pipes, fittings, valves and other reserves have hit the road more than 60%, other materials also have appropriate reserves, and can enter the site one after another to ensure continuous construction.
(8) and pipeline-related civil works have been tested and qualified to meet the installation requirements, and has handover procedures.
5.1.2 Oxygen pipeline degreasing
Stainless steel oxygen pipeline internal mopping method to remove dirt, degreasing agent using industrial carbon tetrachloride, the use of wooden stakes will be closed to the head of the pipe, industrial carbon tetrachloride filled with pipeline, and then flat every 15 minutes to rotate 90 degrees, 2 hours after the carbon tetrachloride discharge, with white paper or white cloth to check the inside of the pipeline is not seen grease for qualified, and then the pipe will be Closed until the completion of the installation is strictly prohibited contact with grease.
5.1.3 Pipe processing
(1) Pipe cutting
a Carbon steel pipes are mechanically or flame cut; stainless steel pipes are cut by air plasma or toothless saws, and stainless steel saws are used for cutting.
bThe quality of the pipe cut should meet the following requirements:
Ⅰ) The surface of the cut is smooth and free of cracks, heavy skin, burrs, bumps, indentation slag, oxides, iron filings and so on.
II) The inclination of the end face of the notch △ shall not be greater than 1% of the outer diameter of the pipe, and shall not exceed 3mm.
△
(2) Pipe, fitting beveling
a Carbon steel pipeline beveling can be machined or flame cutting, stainless steel pipeline using air plasma or sander processing, the bevel surface should be free of burrs, cracks, thermal processing should be carried out after the oxidized skin, Slag and other cleaning, and the unevenness of the sanding level.
b The pipe bevel form and size should be in accordance with the relevant provisions.
(3) pipe section prefabrication
a pipe section prefabrication according to the pipeline single-line diagram, depending on the actual situation on the spot to determine the length of the pipe section, prefabricated pipe section will be cleaned up, closed in time the mouth.
b When the pipe is grouped, the bevel and its internal and external surfaces should be cleaned, the inner surface of the butt joints should be flush, the amount of misalignment should not be more than 10% of the back of the wall, and not more than 2mm.
c When the pipe is aligned, the straightness should be measured at the center of the interface 200mm, and the permissible deviation of the nominal diameter of the pipe is more than 100mm is 2mm, but the whole length is not more than 10mm.
The pipe is aligned by the single line drawing of the pipe, and the length of the pipe is determined according to the actual situation on site. p>
200mm 2mm
5.1.4 Welding of pipes
(1) The grade and specification of welding materials should meet the design requirements, and the quality of welding materials should be in accordance with the current national standards.
(2) welding rods, wires and other welding materials should be dried before use in accordance with the provisions of the factory manual and welding process requirements, and keep dry during use, the flux skin of the electrode without shedding and cracking, otherwise it shall not be used.
(3) welding work to be done before the start of welding process evaluation, process evaluation in line with the design requirements and specifications, welding work can be formally carried out.
(4) welding welder must have a welding position and welding material range of valid certificates before welding.
(5) welded joints before welding drug on its internal and external surfaces within 20mm to clean up, there shall be no oil, water, paint, rust and other debris.
(6) in the rain, snow and wind conditions when welding, welding parts of the drug to take appropriate protective measures to prevent rain, snow, wind on the welding quality.
(7) oxygen pipeline welding, the bottom layer of the weld using argon arc welding, manual welding cover.
(8) straight section of the two weld spacing: DN ≧ 150mm, not less than 150mm; DN <150mm, not less than the outer diameter of the pipe.
(9) circumferential weld from the support, the net distance from the hanger is not less than 50mm.
(10) weld bead after welding, timely clean up around the weld bead spatter and flux skin, etc., the width of the weld on each side of the edge of the bevel is not more than 2mm, the depth of biting edge is not greater than 0.5mm, the surface reinforcement is not greater than 2mm, the concavity is not greater than 0.55mm.
(11) Weld inspection butt welds should be 1% ray inspection, to Ⅱ piece of qualified.
5.1.6 Pipeline support, hanger production and installation
(1) Pipeline support, hanger should be installed in the pipeline according to the design of the amount needed to centralize the processing, prefabrication in advance.
(2) Piping support, hanger form, processing size should be consistent with the design requirements.
(3) the sample and the number of materials, according to the processing process of the pipe rack should be reserved for the corresponding cutting and processing margins.
(4) steel plate, steel should use oxyacetylene flame cutting, generally preferred mechanical cutting, cutting should be clear burr. Mechanical shear kerf quality should meet the following requirements:
A, shear line and the number of material line deviation is not greater than 2 mm;
B, the fracture at the surface of the crack, iron prongs is not greater than 1 mm;
C, the profile end of the shear slope is not greater than 2 mm.
(5) the use of handmade, semiautomatic cutting, should be removed from the slag and spatter, and the quality of the cut should be Meet the following requirements:
A, manual cutting of gas cutting line deviation is not greater than 2mm, semi-automatic cutting is not greater than 1.5mm. manual cutting of gas cutting line deviation is not greater than 2mm, semi-automatic cutting is not greater than 1.5mm. manual cutting cutting cutting line deviation is not greater than 2mm, semi-automatic cutting is not greater than 1.5mm.
B, the perpendicularity of the end face of the kerf is not greater than
(6) The bolt holes of the support and hanger shall be processed by drilling machine or hand drill, and shall not be cut by oxyacetylene, and the processing deviation of the holes shall not be more than its free tolerance.
(7) pipe support, hanger ring (U-type card) should be bent flat steel, the arc part should be smooth, uniform, the size should be equal to the outer diameter of the pipe.
(8) The working surface of the bracket base plate should be smooth and clean.
(9) After the slide of sliding or rolling bracket is processed, protective measures should be taken to prevent drag scratching or bruising.
(10) support, hanger welding should be made according to the design requirements, its assembly size deviation shall not be greater than 3mm.
(11) pipeline support, hanger welding should be carried out cosmetic inspection, shall not be oil leakage welding, under-welding, cracks, burn-through, biting and other defects, spattering near the weld should be cleaned up.
(12) pipe support, hanger angle weld should be full of weld meat, smooth transition, weld foot height should be not less than 1.5 times the thickness of thin parts. Welding deformation must be corrected.
5.1.7 Pipeline test and pipeline blowing
(1) pipeline test
A, hydraulic test (steam pipeline test)
A) hydraulic test medium: clean water as a medium;
B) system water injection: the pipeline should be opened to the exhaust valve at each high place, the air exhaust. When the water is full, close the exhaust valve and the water inlet valve, and pressurize with a hand crank test pump or electric test pump.
C) test steps:
(A) boosting speed of not more than 250KPa/min;
(B) boosting to 50% of the test pressure to stop the pressure check;
(C) if there is no abnormality, 25% of the pressure to each time the pressure is measured slowly rise to the test pressure, stop the pressure for 10min;
(D) lowering the pressure to the design pressure stopping pressure 30min check the tightness of the system to no pressure drop, no leakage, no deformation visually.
D) test pressure
Design requirements, according to the design requirements.
B, air pressure test (oxygen pipeline test)
A) air pressure test medium: air, nitrogen and other inert gases; gas source using the compressor of the project device.
B) test pressure
Design requirements, according to the design requirements; design does not require strength test according to the working pressure of 1.15 times the implementation of the working pressure, the working pressure of the tightness test implementation;
C) Strength test:
Strength test, the pressure should be gradually and slowly rise, the first rise to 50% of the test pressure, check, such as no leakage and anomalies, continue to test the pressure of the pipeline test. And anomalies, continue to 10% of the test pressure, step by step pressure until the test pressure. Each level of experimental pressure should be stabilized for 3 minutes to reach the test pressure after 10 minutes of pressure stabilization to no leakage, no deformation of the visual inspection is qualified;
D) tightness test
Strength test qualified, down to the working pressure for tightness test. Test with neutral soapy water brush weld, flange and other easy to leak, check no leakage is qualified.
(2) pipeline blowing
Steam pipeline installation using air blowing, the selected mobile air compressor flow rate of not less than 20M / S, oxygen pipeline using production plant air compressor for blowing, blowing process, when the visual inspection of the exhaust without smoke, should be set up in the exhaust port with a white cloth or oiled white lacquer on the wood of the target board to check the target board in 5 minutes, no rust, dust, moisture and other debris is qualified. Other debris is qualified.
5.1.4 Steam pipeline installation
1) When the pipeline is laid, the slope of the pipeline should be not less than 3‰, and the placement of hydrophobic device should be carried out in strict accordance with the requirements of the drawings;
2) The thermal compensation of the pipeline adopts the combination of natural compensation and corrugated compensator; the distance between the corrugated compensator can be determined according to the drawings or according to the amount of expansion of the pipeline.
3) horizontal pipe sections, valves, orifice plates on the front side of the water prone to accumulate, are installed trap-type drain valve;
4) horizontal horizontal pipe sections need to be used on the eccentric reducer, and should be leveled on the lower side, in order to facilitate the release of water;
5) branch must be from the main pipe on the upper part or on both sides of the lead, can not be drawn from the lower part of the lead;
6) main trunk line of the trap must be installed in the upper part of by-pass pipe, and the traps can be used in the piping, the main line must be installed in the upper part of bypass pipe, and the traps can be used in the pipeline expansion. Installation of bypass pipe, and the installation of traps, bypass valves to facilitate the removal of the river maintenance;
7) compensator on both sides of the first bracket shall not be fixed, in the compensation of elbow bending starting point between 0.5-1.0M, shall not be set up bracket;
8) In order to pipe running insulation layer is not destroyed, the bracket is set up in the pipeline under the height of greater than the thickness of the insulation layer of the bracket; guided bracket guide slot River sliding bracket should have a gap of 3~5mm, the guide, the center of the sliding bracket and the center of the sliding bracket should be the same, to avoid damage to the corrugated expansion joints;
6. Ensure that the quality of the project's technical and organizational measures
6.1 Quality Assurance System
The Company establishes a quality assurance system in accordance with the following principles.
6.2 Quality Control Procedures
6.2.1 Control of Raw Materials: The main construction materials required for this project are all under the responsibility of the construction unit, and the purchased materials and equipments must have production licenses, quality assurance certificates, factory certificates, and test and inspection reports. Processing and ordering of finished products, semi-finished products and components supply by the construction unit according to the progress of the design requirements of the standard is responsible for processing and ordering, while accepting the supervision, construction unit supervision.
6.2.2 Construction of the whole process of quality control: in the construction process, seriously do a good job in the control of raw materials, process control, control of construction operations, strengthen the quality management of each process, the handover inspection between the various processes and professional trades between the handover link of the quality of the project to take effective measures to strengthen the inspection and acceptance, and grasp the whole process of quality management.
6.2.3 Strengthen the inspection and acceptance system
6.2.3.1 The main materials, semi-finished products, finished products, building components, appliances and equipment for on-site acceptance. Where the design of the safety function of the relevant products, should be in accordance with the provisions of the quality acceptance specification for each professional engineering re-inspection, and by the supervising engineer, the construction unit of the technical person in charge of the inspection and approval.
6.2.3.2 Quality control of each process is carried out according to the construction technical standards, and inspection is carried out after the completion of each process. Relevant professional trades between the self-check, mutual inspection, special inspection, the formation of records, without supervision engineers, construction units, the technical person in charge of checking and approval, shall not carry out the next process of construction.
6.2.3.3 Strictly implement the hidden works acceptance system, the hidden works, foundation groove inspection records and other processes must be accepted by the owner, supervisory and quality inspection departments, and sign to confirm before moving to the next process.
6.2.3.4 Adhere to the sample lead system, each sub-projects should be done before the operation of a large area in addition to the teacher's samples, after passing the acceptance, strictly according to the sample standards for construction.
6.3 Quality Assurance Measures
1) Strengthen technical management, and conscientiously implement the technical management system. Before the commencement of construction, implement the post responsibility system of personnel at all levels, and do a good job of technical briefing; during the construction, we should carefully check the implementation and carry out comprehensive quality management activities. Do a good job of hidden project records; after the end of construction, seriously carry out project quality inspection and evaluation, and do a good job of technical file management.
2) seriously carry out raw material inspection, steel, and other materials must provide quality assurance, and according to the provisions of the sampling.
3) technical review is to prevent errors in construction, to ensure the quality of the project, to prevent the occurrence of quality problems of an effective technical management system, so in the construction process must strengthen the technical review work.
4) Quality control measures
The quality of the disease is mainly due to the occurrence of the disease is not foreseeable, did not take effective preventive and curative measures, not in strict accordance with the requirements of the process of construction, the key links are not handled seriously, resulting in the occurrence of quality problems. For the construction of common quality problems occurring characteristics, analyze the causes, develop appropriate preventive measures to prevent and eliminate quality problems.
5) Strengthen the project quality pre-control, project construction quality to meet the standard, must take prevention as the main focus, for this reason, our company will focus on quality management of the project quality pre-control, through the sub-projects to ensure that the branch project is good, through the branch project is good, to ensure that the unit project is good.
7. Ensure the safety of technical and organizational measures
7.1 All participants in the construction personnel must strictly comply with the "Construction Safety Technical Regulations" of the relevant safety management system, and accept the supervision and inspection, the need to carry out safety education before entering the scene must wear a good helmet, work in accordance with the provisions of the wearing protective equipment;
7.2 lifting construction workers must be Close cooperation, coordination, careful operation, follow the command, all the scaffolding used at high altitude must be tied firmly and reliably, and check the qualified;
7.3 all the selection of machinery, tools, rigging, etc. must be strictly checked, unqualified products are strictly prohibited. The site of the machine tools and materials and other neatly stacked, all demolition components timely transported out of the scene, to achieve civilized construction;
7.4 The operating personnel should wear good labor insurance according to the requirements of the height of the work to be tied up with a good safety belt, set up a qualified scaffolding;
7.5 work on the heights of the work must be tied up with a good safety belt, it is strictly prohibited to throw the catch or throw down from a height of the tools, materials and other items;
7.6 All selected machines, tools, rigging, etc. must be strictly examined, unqualified products are strictly prohibited from using. p>
7.6 site lifting and hoisting operations set up temporary cordon and warning signs, prohibit pedestrians and vehicles, should be set up lifting safety cordon area, set up a person to monitor, strictly prohibit unrelated personnel to enter;
7.7 lifting and hoisting operations, must be licensed, strict implementation of the lifting measures, the use of rigging to be carefully examined. Lifting command must be a clear division of labor, unified command, there are flags and whistles, clear signals;
7.8 lifting process, the operators should hold their positions, follow the command, found that the problem is immediately reported to the commander, no unauthorized operation without the commander's orders;
7.9 lifting operations, should be carried out first test lifting, to meet the mechanical properties of the crane before the official lifting. After lifting, there should be a person to observe the operating condition of the crane, found abnormal situation, immediately report to the person in charge of the command, and take appropriate measures;
7.10 crane driver or lifting personnel in the operation of the crane must be ringing or whistling before the prompt, in the lifting of the object is close to the manufacture of the person, should be given to the ringing of the prompt. Emergency stop signals shall be carried out immediately regardless of who gives them.
7.11 construction site pulling, lifting and other work to have a person in command and clear construction methods. Commanders and operators should stand 2 meters away from the lower part of the crane, to be lifted after the fall of stability, before approaching the picking rigging;
7.12 acetylene, oxygen cylinders, should be equipped with a tempering valve and other fire safety devices. When in use, shall not be placed on overhead lines, production equipment, process piping below the vertical, as well as dirty oil wells and sparks splash down, in the field construction operations, fire must have a fire ticket.
7.13 site temporary construction of electricity must be implemented "three-phase five-wire system", "three-level control and two-level protection", which the first level of protection of the leakage switch leakage current according to the actual power consumption to determine their own, the leakage action time to be less than 0.1 seconds.
7.14 All electrical equipment, tools, lighting, must be implemented to protect zero. Protective zero line must be laid separately, not allowed to pass through any switch and fuse, and in the branch point, end point and equipment concentration point to do repeated grounding.
7.15 Strict implementation of the "one gate, one machine, one insurance" system, prohibit the use of a gate more than one. The site prohibits the use of knife switches, all replaced with air switches and leakage protector, electrical equipment should keep the cable insulation and good grounding. Hand-held power tools should be electric shock protector, to achieve "a machine a guarantee" to prevent electric shock accidents.
7.16 All switches, sockets and plug protection cover should be intact, do not use two wires directly in the socket hole.
7.17 Electric wires, cables, welding handle wires and wheel wires are not allowed to be twisted together with steel wire ropes, and it is strictly prohibited to pull and pull wires indiscriminately, and it is not allowed to tie wires and cables with metal wires, and the racking wires should be insulated with insulators or other insulating measures.
7.18 welding and cutting place and its surrounding area without the possibility of fire. Cables, welding equipment and hoses, meters, torches, cylinders are checked before use. Acetylene meters are used with flashback arrestors.
7.19 Protective measures are taken during welding and flaming operations to avoid injury to nearby personnel. Acetylene cylinders are placed upright, with anti-vibration ring and sun protection measures. The distance between cylinders and open fire is not less than 10m.
7.20 High-altitude workers use tool bags to prevent the tools and materials used from being thrown up and down. Properly store tools and accessories during operation to prevent them from falling, and collect all tools, accessories and scattered materials in a safe place when construction is suspended or finished.
7.21 All personnel entering the construction site must be in accordance with the unified provisions of the project, correctly wearing helmets, safety belts, safety shoes, protective glasses, labor gloves and other personal protective equipment, safety protection facilities must be constructed in synchronization with the main body, "four mouths," "edge "must take protective measures, it is strictly prohibited to throw objects from a height, it is strictly prohibited to climb the railing privately.
7.22 Participants in the construction must be familiar with the construction site, familiar with the content of the work, construction procedures, inspection requirements, etc., and strictly in accordance with the requirements of the construction technology program.
7.23 Welding must be cleaned of surrounding flammable materials, pay attention to the direction of the wind and the direction of sparks falling, and stay away from painting, anticorrosion and other dangerous operations.
7.24 Rope buckles and carabiners are used correctly, rope buckles should be lined up, there shall be no mutual extrusion, dead bend phenomenon; carabiners must not be lateral force.
7.25 rope buckle winding should be clamped at the pipe skin or wood, no obstacles in the direction of the rotation of the rope buckle in the process of lifting; lifting process should be set up to slip the tail rope, is strictly prohibited with the loose objects for lifting operations.
7.26 construction process must be done in advance to prevent rain, moisture, anti-skid measures. Night construction must have enough lighting.
8. Technical and organizational measures to ensure the construction period
8.1 Technical and organizational measures to ensure the construction period
1) The site has set up a pragmatic, competent and efficient project manager department, centralized leadership, unified coordination, and organizational structure to ensure the realization of the overall progress goal.
2) According to the requirements of the total progress plan, construction materials, machinery and equipment, capital needs plan, coordinated by the project department.
3) Before the construction should pay attention to the preparatory work, check the implementation of construction readiness.
4) Do a good job of technical preparation for construction, construction should be in advance to solve the technical problems on the drawings, to avoid errors and omissions due to drawings, resulting in delays in the schedule, the key projects should be prepared before the construction of construction programs, and approved by the review of the construction staff in advance of the briefing.
5) According to the construction progress plan in advance of the organization of the labor force into the field, and after training, assessment, to ensure that the appropriate ability and qualifications of skilled tradesmen on duty.
6) According to the construction progress plan in advance to prepare the project materials and construction materials into the field, and after re-inspection and transportation to the site of the designated location spare.
7) According to the construction progress plan, put in a variety of major construction equipment to meet the needs of construction.
8) Strictly in accordance with the specifications, procedures and work instructions required to standardize the construction, to avoid reworking due to quality problems caused by delays in the schedule.
9. Civilized construction measures to prevent nuisance
1) Strictly implement the "noise control management measures" ZD/12Y-C01-01-2003, reasonable arrangements for night construction projects, effective control of construction noise, construction workers shall not be noisy and bumping into other objects, to reduce man-made noise nuisance phenomenon.
2) It is strictly prohibited to burn toxic and harmful objects at will, polluting the environmental air.