MODEC

管系预制与安装工艺
PIPING FABRICATION & INSTALLATION PROCEDURE

标记 数量 修改单号 签名 日期 标记 数量 修改单号 签名 日期
Symb. Qty. Rev.No. Signat. Date Symb. Qty. Rev.No. Signat. Date
工 程 “海洋骄傲”轮改装工程 图 号
Project
TSJOC SRKP phase 1 Development Project Draw .No. DZY532-501-01GY
图 名 管系预制与安装工艺 设计 Design
Subject
PIPING FABRICATION & INSTALLATION PROCEDURE 校对 Check
工 程 号 设计阶段 标检 Stad.Ch
Project No. D07038019B62 设计
Design Phase 审核 Verify
比例 Scale - 质量 kg -

大连中远船务工程有限公司 船级 Class ABS 版本 Rev. AB

COSCO(DALIAN) SHIPYARD CO., LTD.
总页 Total 10 页数 Sheet 1
管系预制与安装工艺 DZY532-501-01GY 第 2 页
PIPING FABRICATION & INSTALLATION PROCEDURE

A.总则 GENERAL
1．范围 Scope
本工艺为碳钢管、不锈钢管和铜镍管,铝黄铜管，镀锌管在车间的预制和船上安装。玻璃钢管的工艺参
见厂家工艺和 ABS 规范。
This procedure is used for carbon steel 、stainless steel，Cu-Ni，AL-brass,and galvanized
pipe fabrication in piping shop and installation on board. Other procedure for GRP according
to the manufacture’s requirements and ABS rules.
2. 应用 Application
本工艺适用于”MODEC”的船厂负责制做管系的预制与安装。
This procedure applies to fabrication and installation of ”MODEC” piping supplied by shipyard.
3. 质量控制 Quality control
船厂将按照设计图纸、ABS 规范和管系预制和安装工艺、检验工艺、压力试验工艺进行预制和安装，
以保证设计要求和 ABS 规范。
Shipyard will fabricate and install piping according to design drawing、ABS rules 、piping
fabrication and installation procedure、supervision and inspection procedure、hydrostatic
pressure test procedure. So as to ensure compliance with requirements of design and ABS rules.

4. 材料控制 Material control

4.1.管线在车间预制划线、切割之前，需按车间用图检查管材及法兰、弯头等附件是否符合尺寸，材料质
量规格等要求，公差是否符合 ABS 要求。
To inspect all pipe、flange、fitting、etc according to shop drawing before marking cutting
line and cutting. Ensure that the correct grade of material has been supplied and that
identification, dimensions, material quality, and ABS rules preparations and tolerance are
in accordance with the applicable standards specifications and ABS rules.
4．2．检查管材在运输或接收过程中是否有损伤、径向凹痕、污染或是否正确标识等，如不合格应立即置
于另一区域以防不合格材料的使用，材料要求堆放整齐。
Material found to have been damaged or contamination during transmit or period to receipt,
or which is incorrectly marked, shall be immediately placed in another area separate from
acceptable material with sufficient safeguards to preclude it being used. Radial grooves
or scratches are not allowed.
4．3．管材、附件等应分类储存一处并由专人管理。
Pipe、fitting etc should be stored on separate area for each material type. And administrated
by special person.

B.预制 fabrication
1.管段预制流程图：Pipe spool fabrication flow
注：对碳钢管，ABS 船检和船东有权在预制后、镀锌前和镀锌或酸洗后，对管系进行检查 。
对铜镍管，ABS 验船师和船东有权在装配时和预制后对管系进行检查。
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PIPING FABRICATION & INSTALLATION PROCEDURE

Note: ABS and owners reserve the right to inspect the pipes
For carbon steel pipe 1) After completion of fabrication, before galvanising/grit blasting
2)After galvanisation/acid cleaning.

For Cu-Ni pipe and fittings ,at fit-up and after completion of fabrication..

碳钢管件生产流程 carbon steel fabrication flow

根据图纸领配管材及法兰、弯头等附件
prepare pipe、flange、fitting、etc. according to shop drawing.

管子材料检查
inspect pipes and fittings

划线打标记
marking

切割与打坡口
cutting and edge preparation

法兰与管附件检查
inspect flange and pipe fitting

对中与点焊
alignment and tack welding

焊接
welding acc. to approval WPS

NDT 检 验
NDT Test acc.to PT4 ABS rules

SHG QC 焊接检验
SHG QC visual inspection

ABS & Ower 焊接检验

ABS & Ower visual inspection

管段的车间压力试验
Hydro. test of spool acc. to part 4 ABS rules

酸洗磷化 镀锌 酸洗喷漆
acid pickling phasphate galvanization acid +paint

分区储存
storage according to systems
管系预制与安装工艺 DZY532-501-01GY 第 4 页
PIPING FABRICATION & INSTALLATION PROCEDURE
铜镍合金管件生产流程图 Cu-Ni alloy pipe fabrication flowED
根据图纸领配管材及法兰、弯头等附件
prepare pipe、flange、fitting、etc. according to shop drawing.

管子材料检查
inspect pipe
(ABS witness point)

划线打标记
marking

切割与打坡口
cutting and edge preparation

法兰与管附件检查
inspect flange and pipe fitting
(ABS witness point)

对中与点焊
alignment and tack welding

焊接
welding

NDT 检 验
NDT test acc. to Pt4
ABS rules

ABS & 船东焊接检验

ABS & OWER inspect welding

分区储存
storage according to systems
所有一、二级管段在预制完后，涂漆和上船安装之前，应以 1.5 倍设计压力做车间内液压试验。
All class ⅠandⅡ pipes and integral fittings after completion of shop fabrication, but
before insulation and coating, are to be hydrostatically tested, preferably before installation,
at 1.5times the design pressure.
2. 预制步骤 fabrication sequence
2．1．管子材料检查 inspect pipe material
按车间用图检查要预制的管子的材料、型号及尺寸是否正确。
Inspect supplied pipe for fabrication according to shop drawing, ensure that material
quality, dimensions, identification are in accordance with the drawing.
2．2．划线打标记 marking
管系预制与安装工艺 DZY532-501-01GY 第 5 页
PIPING FABRICATION & INSTALLATION PROCEDURE

2．2．1．根据设计图纸给出的直管段长度在管子原材上划线。
Mark cutting line on pipe according to cutting length given at shop drawings.
2．2．2．对每段画好了线，即将被割下使用的直管段用马克笔将设计图上的管号标记在管段上。
Mark the spool number given at shop drawing on pipe for cutting with mark pen.

2．2．3．对每个预制完的管件，需用薄铁皮标签打上管号。
Mark spool number on tag which made from galvanized steel plate and attach it at
corresponding spool completed with steel wire.
2．2．4．标签尺寸如下：dimension of tag is as following

2．2．5．标签用钢丝系于管上，所系方法如下：tags shall be attached as following by steel wire.

（无法兰管段） （有法兰管段）
2．3．切割与打坡口 cutting and edge preparation
2．3．1．无缝碳钢管的切割机为：高速切割机、砂轮机、坡口机、火焰切割器和锯床。铜镍合金管的切
割机有：高速切割机、砂轮机和锯床。
Carbon steel pipe shall be cut by use of flame cutters or high speed cutters or grinders
or bend saw machines. Cu-Ni alloy pipe shall be cut by use of high speed cutters or grinders
or bend saw machines.
2．3．2．打坡口用坡口机和砂轮来完成，坡口的角度详见焊接工艺。
Beveling will be performed with a beveling machine or grinder. Preparation will be in
accordance with the approved WPS.
2．3．3．钢管焊接支管形式如下图 1，当支管壁厚小于 6 mm 时，不用开坡口；当壁厚等于或大于 6mm，
并当主管直径大于或等于 2.5 倍支管直径时，在整个支管端部开坡口；当主管直径小于 2.5 倍支
管直径时，可在支管端面沿主管轴线方向左右部位，局部开坡口，如图 2 所示，在θ部位开坡口。
Welding branch line as following, when branch thickness is bellow 6mm, need not beveling;
when it is equal to or bigger than 6mm, while the main line diameter is bigger or equal
to 2.5 times the branch line, bevel the branch line around the circle; when the main line
diameter is smaller than 2.5 times the branch line’s, bevel the branch line inθarea,
as figure 2.
管系预制与安装工艺 DZY532-501-01GY 第6页
PIPING FABRICATION & INSTALLATION PROCEDURE

a 直支管 b 斜支管
Straight branch Angle branch

图 1 figure 1

θ 支 θ
管

θ=90°
θ=90°

主管

图 2 figure 2

2.4 对中与点焊 ALIGNMENT AND TACK WELDING

2.4.1.预制公差 fabrication tolerances
如图 3 所示，“A”尺寸公差±3mm。 “A” dimension tolerances are ±3mm. Show in figure 3.

X X

X-X

图3 figure 3
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PIPING FABRICATION & INSTALLATION PROCEDURE

2.4.2. 相邻两道焊缝之间最小距离不小于 50mm，直管最小切割长度不小于 50mm。

The clear distance between centerlines of adjacent girth butt welds of process piping shall
not be less than 50mm. The minimum pipe length allowable between circumferential welds
in straight lengths greater 50mm.
2.4.3. 管子对中内径极限偏差 2.0mm。The internal radial misalignment should not exceed 2.0mm.
2.4.4. 管子未完全对中时，可采用液压顶或丝扣顶的方法调整，但不得引起有害应力，禁止使用加热管子
大锤砸的方法。
Misalignment may be elevated by the use of hydraulic or screw type clamps. Hammering or
heating the pipe is not permitted.
2.4.5. 法兰对中方法：法兰螺栓孔以通过中心的垂直线和水平线为对称，即双眼正对中法，图纸中有特
殊标注的除外。
The bolt holes of flanges shall straddle the normal horizontal and vertical centerline
of pipe.
2.4.6. 定位点焊 tack welds
2.4.6.1. 对中完成后，应用手工电弧焊或氩弧焊进行定位点焊。Prior to performing main welds, tack
welds shall be done by either shielded manual arc welding or gas tungsten arc welding
as determined by the approved WPS.
2.4.6.2. 点焊要由有资格的焊工完成。Tack welding shall be made by qualified welders.

2.4.6.3. 不同直径管的点焊数及尺寸规定如下：The length and number of tack welds for the diameter
of pipe being welded shall be specified as follows (see table):
公称直径 DIA. MM 点焊长度 LENGTH OF TACK MM 点焊数 NUMBER OF TACKS
≤50 20～30 MIN. 3
50～150 20～30 3～4
>150 20～30 4～6
2.4.7 临时附件的使用 Temporary attachments
2.4.7.1 管子制作过程中需要临时附件，如夹具、过桥、定位板条等焊到管子上时，其材料须与管子材料
一致或相当。
The use of cleats, bridge pieces, tacking strips or other attachments welded temporarily
to pipework to facilitate fabrication shall be of the same or equivalent material as the
pipework to which it will be attached.
2.4.7.2 临时附件拆除时，切割位置在距管子表面 3MM 处，然后用砂轮打磨，打磨部分须光滑平整。
Temporary attachments shall be removed by cutting to within 3mm of the pipework surface
and then by grinding flush with the surface.
2.4.7.3 拆除临时附件时，禁止将其击碎或砸下。
Removal of temporary attachments by breaking off or hammering is strictly forbidden.
2.5. 焊接 welding
所有焊接将按焊接工艺（WPS）执行，各种焊接方法详见焊接工艺，焊接工艺的要点应醒目地写在
管系预制与安装工艺 DZY532-501-01GY 第 8 页
PIPING FABRICATION & INSTALLATION PROCEDURE
施工现场的黑板上。
All welds shall be performed in accordance with the approved WPS. Which shall be displayed
on a notice board close to the work.
2.5.1 铜镍管焊接时，应采用内部惰气保护，做法如下：
When welding Cu-Ni pipe, inert gas should be used to protect the weld point, welding method
as bellow:
weld 焊点，将要焊接的缝隙露出一点
wire rope 钢丝绳

wire rope 钢丝绳

hose for I.G 通氩气软管 DAM2(sponge)海绵塞住

min 最小 150
mm
sealing tape 用胶带密封对焊缝隙
DAM1(sponge)海绵塞住

2．6．焊接检查 inspect welding

镀锌之前进行焊接外观检查，检查详细步骤依据检查工艺执行。
Visual inspection shall be performed before hot galvanize treatments. Visual inspection
will be done in accordance with the approved inspection procedure for piping.
2.7 NDT 检验 DNT test
For NDT of spools, according to ABS rules .
2.8 车间压力试验 Hydro. Test of spools
For Hydro. Test of spools, according to ABS rules .
2.9 镀锌 galvanization
镀锌应按设计图纸的要求和镀锌工艺进行。
Galvanization will be done in accordance with the requirement of shop drawing and the
approved galvanization procedure for piping.
2．8．分区储存 storage
预制完的管段应分系统妥善存于一区域，避免混乱和使受损伤。
After completion of galvanization, the spools shall be stored in accordance with systems.
Avoid confusion and damage.

C．安装 installation
1． 安装 installation
1.1 所有管段的安装应根据提供的图纸进行，如：总布置图、ISO 图、管支架图以及其它制造图纸。
All piping work will be completed in accordance with approved piping drawings such as Plot
plans, sections, general arrangements, isometrics, piping material classes and pipe support
general arrangements, standard/special support details etc. and relevant vendor drawings
as applicable.
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PIPING FABRICATION & INSTALLATION PROCEDURE

1.2 管段安装之前的吊运应用软吊带，以减少运输损伤。管段应在无应力状态下安装，对中以后与设备相
连。连接法兰的螺栓应拧紧到相应的力矩。需外部刷漆的管的刷漆在管路的冲洗和压力试验完成后进
行。
Upon commencement of pipework installation the pipe spools will be lifted onto the module
utilizing tower cranes and soft sling to minimize handling damage. Piping shall be installed
in such a way that no forcing or springing of the pipework is required for the alignment
and make-up of butt welds or flange connections to equipment. Flanging and bolting for spools
shall be fastened according to required torque. Final painting of piping needed on outer
diameter to be applied after flushing and successfully completion of pressure test.
1.3 焊接或热处理等热操做应在做绝缘保护之前进行。
Final welding or other heat works will be done prior to insulation.
1.4 所有阀门的两端应有保护物，其安装应按有关图纸进行。
All valves shall be installed in accordance with the relevant drawings. And both ends shall
be protected before installation.
1.5 管段在与设备或管段之间连接时不允许存在应力变形。
When making up connections to equipment or piping components; Forced distortion of the
piping is prohibited.
1.6 管及法兰、阀等的绝缘按相应图纸和工艺进行。
Insulation of pipe, flange, valve, etc. shall be carried out as relevant drawings and
procedure.
1.7 管段穿过船体结构时应按图纸、有关工艺标准和 ABS 规范安装相应的通舱件。
Piping passing through hull bulkhead shall be installed penetration as per specification
requirement. practice standard and ABS rules.
2 设备管路 equipment piping
2.1 与设备相连接的管段应严格对中，不应对设备的接口产生任何应力。
Piping connections to equipment shall be installed and properly aligned without putting any
stress on equipment nozzles.
2.2 法兰的连接螺栓应按顺时针对角依次拧紧确保垫片平整、密封。
Flanged connections shall be tightened sequentially diagonally opposite in a clockwise
direction to obtain an even gasket contact on the flange faces.

3 支撑 supporting
3.1 管路应按相应的图纸要求进行支撑、导向、固定。
Piping will be supported, guided, and anchored in accordance with origin relevant
drawings.
管系预制与安装工艺 DZY532-501-01GY 第 10 页
PIPING FABRICATION & INSTALLATION PROCEDURE

3.2 任何因为施工、检查或安装的目的而做的临时支撑不能对永久支撑或设备产生负荷。
Any temporary supports required for construction, testing or installation purposes shall not
to put increased loads on other permanent supports or equipment.
4. 保护 protection
4.1 管段应受到保护以避免其它安装工作的影响，特别是加热工作和打磨工作。
Piping shall be protected from other installation works especially hot works and grinding
by the use of fire protect material.
4.2 应保护非铁管不受铁管操作与焊接的影响。在完成安装之前，所有的开口处应密封以防进入污物。
Special precautions shall also be taken to protect non-ferrous pipework during carbon steel
pipe installation and welding, on completion of installation all openings shall be sealed
to prevent the dirt and moisture.
5. 错误清单 Punch Listing
在管路安装完成后，应准备一份错误清单，以报告管路是否按照最新的车间用图、设备布置图、其它
相关图纸和检查进行了安装，合格后才能按照 ABS 规范做冲洗和压力试验。
On completion of the erection of piping. A punch listing exercise will be carried out to
ascertain that the line has been erected to the latest revision shop drawings, equipment
arrangement drawing, other relevant drawing and inspection. All aspects of the work have been
carried out to the latest isometric and specifications the line shall be passed for flushing
and pressure testing acc. to ABS rules .