Carbon steel process pipeline installation technology briefing 1. Project overview 1. Project Overview: The carbon steel process pipeline installation project is 5km in length. The pipe material is No. 20 steel pipe, which transports steam, water, and fuel oil media.; The working pressure is 0.4~1.6MPa, the test pressure (water pressure) is 0.6~1.875 MPa, and the working temperature is about 200°C at normal temperature. It is divided into boiler, rotating equipment, static equipment, tanks and other piping and indoor and outdoor overhead pipeline installation. The construction period is from early April to mid-April (3.5 months). 2. The main physical engineering quantities are shown in Table 2.9-1. The main physical engineering scale is shown in Table 2.9-1. Serial number name unit quantity remarks 1 Seamless steel pipe 20g m 850 DN15~DN350 2 Seamless steel pipe 20 m 4700 DN15~DN250 3 Steel plate coil Q235 m 24 DN600 4 Steel pipe lined with plastic (rubber) pipe m 626 5 Valve 623 6 Type steel T 11.8 Pipe supports (hanging) racks 7 standard supports (hanging) racks 1116 8 Insulated pipe shell cubic meters 194 9 Galvanized thin steel plate square meters 3500 &=0.5 3. Project Features: This project is basically in the winter construction period. ; The conveying medium has high temperature and high pressure, and is a flammable and combustible medium. ; Lined pipes and pipe fittings are easily damaged and appropriate protective measures should be taken. ; Some pipelines require sandblasting and chemical cleaning ; The project is located in a refinery, and construction fire should be strictly managed. 4. Construction basis (1) Construction drawing of the thermal part of the boiler room. (2) Construction drawing of the thermal part of the water treatment station. (3) Boiler room and water treatment station engineering construction organization design (installation part). 2. Construction preparation 1. The main operators are plumbers, electric welders, and gas welders, and are supported by crane workers, painters, tinplate (insulation) workers, and other types of work. 2. Construction materials and measures Materials used (1) Construction materials should be prepared according to the main material plan and delivered to the site in time to achieve supporting and continuous supply. The main materials are Q235 coiled steel pipe, No. 20, 20g seamless steel pipe, plastic-lined (rubber) steel pipe and supporting pipe fittings, valves, flanges and other materials. (2) Materials used for construction measures The main materials used for measures include materials for prefabricated platforms and materials for system pressure testing, namely steel plates, pipes, steel sections, and track timbers, etc. (3) Main construction equipment Construction equipment mainly includes truck cranes, electric welding machines, argon arc welding machines, grinding wheel cutting machines, beveling machines, air compressors, pipe benders, electric pressure test pumps, guide chains, jacks, gas welding tools, hand grinders, levels, wrenches, pipe wrenches, hand hammers, etc. 3. Construction technology 1. Pipeline prefabrication (1) Pipeline prefabrication should be carried out on the platform, and the prefabricated dimensions should be carried out according to the revised pipe section diagram, with room for adjustment to ensure transportation and hoisting conditions, markings, and openings should be blocked in time. (2) The prefabricated combined sections should have sufficient stiffness and strength. Otherwise, temporary reinforcement measures should be taken. If necessary, the location of the binding points of the lifting rigging should be marked. (3) For pipe cutting with DN ≤ 150, use a grinding wheel cutting machine, and for DN ≥ 200, use oxyacetylene flame cutting. After oxyacetylene flame cutting, the iron oxide must be cleaned and the pipe end must be polished. (4) Beveling and counterbeveling are processed using beveling machines, hand grinders and files. Its bevel form and counterpart: Wall thickness ≤3mm is an "I" shaped opening (no beveling), and the gap between the openings is 0~1.5mm. ; Wall thickness >3mm, 60°~70° "V" shaped opening, blunt edge 1~1.5mm, gap 2~3mm ; ; When pipes and fittings with different wall thicknesses are assembled and the difference in wall thickness is greater than specified in the specification, they shall be processed in accordance with the specification. Pipe welding (1) Welding methods Class II, Class B, purified air, fuel oil, lined pipelines and Class III and Class C pipelines are all fixed welding joints using argon arc welding or argon arc welding, and other pipelines are welded by manual arc welding. (2) Welding rods and wires should be selected with models (brands) E4315 (J427) and E4303 (J422), specifications of ¢3.2~¢4.0 welding rods, steel grades H08MnA and H08A, and specifications of ¢2~¢2.5 welding wires. (3) When welding pipes, when the wind speed is greater than or equal to 8m/s (gas shielded welding is 2m/s), the relative humidity is greater than 90%, it rains or snows, or when the ambient temperature is lower than -20°C, when welding carbon steel, measures such as windproof, rainproof (snow) and heating or preheating of the welded parts shall be adopted, otherwise welding shall not be carried out. (4) The welding joint should be cleaned when it is covered with water, frost, rain (snow) or water or wet, and should be heated to 40~60℃ for dehumidification. The preheating range should be no less than 100mm on both sides of the center of the welding joint. (5) After welding, the welds should be cleaned, marked with the welder code, and visual inspection and X-ray inspection should be carried out according to the grade and category of the pipeline. The repair of unqualified welds should be qualified according to the regulations. 3. Pipe hoisting (1) Before hoisting prefabricated pipes, the inside of the pipe should be cleaned, and the hoisting equipment selected should be selected through calculation. (2) It must be stable when hoisting and firmly positioned on the pipe frame. (3) The elevation, coordinates, slope direction and gradient of the pipeline during installation should meet the design requirements, and the circumferential welds should be staggered with the pipe frame (in compliance with the specifications). 4. Pipe connection (1) Pipe welding For pipe welding, please refer to the above content about pipe welding. (2) The thread processing of threaded connecting pipes should be tapered and the surface should be smooth. Broken or missing wires should not exceed 10% of the total length of the wire. The threaded joints should be wrapped with polytetrafluoroethylene or coated with sealing paste. The joints should be screwed in 2 to 3 buckles by hand, and then tightened with a wrench. The tail thread should be 1 to 2 buckles, and the joint surface should be cleaned. (3) Flange connection 1) The flange should be inspected before installation and tightening. The sealing surface must not have defects that affect the sealing performance. Rust, oil stains, welding slag, etc. on the flange must be cleaned up. 2) After installation, the parallel deviation, radial displacement and spacing value of the flange must be strictly controlled within the range allowed by the specification, and all flange fastening bolts can pass through the bolt holes freely and vertically. 3) Pipe flange bolts with design temperatures higher than 100°C (except for electrostatic jumpers) should be coated with trifluid molybdenum grease\graphite oil or graphite powder. 4) Pipes with a design temperature ≥250°C should be heat-tightened during operation according to design requirements or specifications. 5. For valve installation, please refer to Section 2.10 "Technical Briefing on Stainless Steel Pipe Installation" for the valve installation content. 6. Pipeline system testing and purging (1) Pipeline system testing and purging should be carried out according to the system, and can also be carried out in sections according to the pipeline layout and connection conditions. (2) Pipeline testing generally uses water medium, but when testing is conducted in winter, solving the freezing of the water medium is the primary issue in the test. (3) Pipeline test in winter The pipeline test pressure is 1.25 times the working pressure (water) and 1.1 times the working pressure (air). The media used in different pipelines are as follows. 1) For pipes with nominal diameter ≤300mm and test value ≤1.6MPa, use air medium. 2) For pipes with nominal diameter >300mm and test value ≤0.6MPa, use air medium. 3) For outdoor medium-pressure pipelines (3.8MPa main steam pipeline), single-pipe steam tracing is used for heating and the water medium is used for testing. 4) For indoor medium-pressure pipelines, indoor steam heating and water media are used for testing. (4) Pipe purging and purging medium must have sufficient pressure, flow rate and flow rate. The flow rate is: Not less than 1.2m/s ; Air is not less than 20m/s ; Steam is not less than 30m/s. When purging, the main pipe → main pipe → branch pipe should be carried out in sequence. 1) Steam pipelines (high pressure, medium pressure, low pressure), first use 0.6MPa compressed air to purge, and then use 0.8MPa steam to blow the line before ventilation. 2) Purify the purified air, non-purified air, fuel oil, fuel gas and outdoor pipelines with 0.6MPa compressed air. 3) Lined pipes and indoor layout pipes should be flushed with water medium (domestic or process water) not less than 0.8MPa. 4) The flushing of water treatment system pipelines, lined pipelines, softened water pipelines, and deoxygenated water pipelines must comply with production process requirements. (5) After testing and water flushing, the water must be drained to prevent freezing accidents, and the water treatment system pipelines should be handed over to Party A (production unit) in a timely manner. (6) After passing the test and purging, records should be kept and submitted to the project for archiving. (7) The construction of oil brushing and insulation projects for process pipelines should be carried out according to their construction techniques. 4. Quality standards 1. Basic items (1) The pipeline slope is generally 0.003, but shall not be less than 0.002. (2) The valve installation position and direction should be correct. The connection is strong and tight. The operating mechanism is flexible and accurate. 2. Allowable deviation items (1) The allowable deviation of coordinates and elevation shall not be greater than 15mm. (2) The allowable deviation of the verticality of the riser shall not be greater than 2 mm per meter and the total length shall not be greater than 15 mm. 3. Quality inspection points (1) Inspection (spot inspection) of pipes and fittings used in Class B and Class II pipelines must comply with specifications. (2) Welding quality inspection results (X-ray inspection). (3) Valve and pipeline strength and tightness test results. (4) The tightness and flushing cleanliness of the lining layer of the lined pipeline. (5) The cleanliness of hydraulic oil pipeline oil cleaning must meet the design requirements. (6) The installation position of the spring support (hanger) of the steam pipeline, the spring adjustment strength, the firmness of the fixed bracket (pipe holder), and the stretching amount of the compensator. (7) Cleanliness of purified air pipelines. 5. Protection of finished products (1) Pipes are not allowed to be used to erect scaffolding or sling lifting equipment to prevent damage to the pipeline. (2) The installed valve should not be opened at will before entering the medium to avoid damage to the sealing surface. For valves installed at low altitude, the handwheel can be removed before delivery to prevent objects from falling and being damaged. (3) Valuable small-diameter valves, instruments and other items can be removed after installation to avoid loss or damage. (4) When connecting pipelines to equipment, do not create additional stress on the equipment to prevent damage to the equipment (especially rotating equipment). (5) When purging the pipeline system, it should be isolated from the equipment in the system to prevent debris from entering the equipment. The blowing port should be directed outside the building (structure) to avoid damage and dirt of the building (structure). 6. Precautions (1) When connecting pipes, pipe fittings, and valves, it is prohibited to use strong combinations to avoid stress in the pipelines. (2) When pipeline prefabrication and installation are interrupted, the opening must be blocked to prevent debris from entering the pipe. (3) After welding the inner port of the flat welding flange, the welding slag should be cleaned up. (4) After passing the test and purging, all temporary blind plates in the system must be removed, and the installation records must be checked to see if they match the installation quantity. (5) When purging pipelines, do not use iron rods or hammers to hit the pipelines. Use wooden hammers or wooden rods.