-陜煤集團東鑫垣煤化工項目PSA制氫/脫硫工程工藝管道焊接方案施工單位：監理單位：建設單位：編制人：審核人：審核人：審核人：批準人：批準人：批準人：日期：日期：日期：四川省華川安裝工程有限責任公司一、概述（一）、為了確保陜煤集團東鑫垣煤化工項目PSA制氫/脫硫項目安裝工程工藝管道焊接施工質量，特編制此方案，施工及相關人員應嚴格遵照執行。（二）、編制依據：1、施工圖紙；2、GB50236-2011《現場設備、工業管道焊接施工及驗收規范》；3、GB50235-2010《工業金屬管道工程施工及驗收規范》；4、GB50184-2011《工業金屬管道工程施工質量驗收規范》；5、JB4730-94《壓力容器無損檢測》。（三）、本工程工藝管道的主要材質為奧氏體不銹鋼0Cr18Ni9和碳素鋼20#與Q235B等，主要介質代號及名稱如下表：代號介質名稱操作壓力（MPa）操作溫度（℃）規格材料管道（起）管道（止）708AFG-01～04混合解吸氣0.0340?1220x10.0Q235B氫氣提純工序來界外708AFG-05～06凈化氣0.0340?1220x10.0Q235B氫氣提純工序來界外708AFG-07～09含硫氣0.0340?108x3.00Cr18Ni9界外708AT02708APL-01a～01b脫硫液0.0540?630x4.00Cr18Ni9708AT01708APL-03b-450708APL-02脫硫液0.0540?530x4.00Cr18Ni9708APL-01a/b-600708APL-03c-450708APL-03a～3c脫硫液0.0540?480x4.00Cr18Ni9708APL-01a-600708AP02708APL-04a～-04c脫硫液1.240?426x4.00Cr18Ni9708AP01708APL-06a/b-450708APL-05a～05b脫硫液1.240?480x6.00Cr18Ni9708APL-04a-400708APL-07b-350708APL-06a～06b脫硫液1.240?480x6.00Cr18Ni9708APL-04c-400708APL-05b-450708APL-07a～07b脫硫液0.540?377x5.00Cr18Ni9708APL-05a-450708APL-08b-80-1~32708APL-08a～08b脫硫液0.540?89x3.00Cr18Ni9708APL-07a-350708AV02708APL-09a～09b脫硫液0.540?25x2.00Cr18Ni9708APL-07a-350708AV02708APL-10a～10b硫泡沫0.0240?219x4.00Cr18Ni9708AV01708AV04708APL-11硫泡沫0.0240?159x3.50Cr18Ni9708AV04708APL-12abc-100708APL-12abc硫泡沫0.0240?108x3.00Cr18Ni9708APL-11-150708AP04A/B/C708APL-13abc硫泡沫0.540?89x3.00Cr18Ni9708AP04A/B/C708APL-14-80代號介質名稱操作壓力（MPa）操作溫度（℃）規格材料管道（起）管道（止）708APL-14硫泡沫0.540?89x3.00Cr18Ni9708APL-13abc-80708APL-17ab-50708APL-15硫泡沫0.540?32x2.50Cr18Ni9708APL-14-80708AV04708APL-16硫泡沫0.540?89x3.00Cr18Ni9708APL-14-80708APL-23-80708APL-17ab硫泡沫0.540?57x3.00Cr18Ni9708APL-14-80708AC01A/B708APL-18清液0.0260?159x3.50Cr18Ni9708AC01A/B708AV09708APL-19硫膏0.0260?108x3.00Cr18Ni9708AV05708APL-20abc-80708APL-20abc硫膏0.0260?89x3.00Cr18Ni9708APL-19-100708AP05A/B/C708APL-21abc硫膏0.560?57x3.00Cr18Ni9708AP05A/B/C708APL-23-80708APL-22硫膏0.560?32x2.50Cr18Ni9708APL-23-80708AV05708APL-23-硫膏0.560?89x3.00Cr18Ni9708APL-21abc-50708APL-23ab-50708APL-23ab硫膏0.560?57x3.00Cr18Ni9708APL-23-80708APL-24abc-50708APL-24abc硫膏0.560?57x3.00Cr18Ni9708APL-23ab-50708AE01A/B/C708APL-25abc清液0.280?45x2.50Cr18Ni9708AE01A/B/C708AV08708APL-26abc清液0.280?45x2.50Cr18Ni9708APL-25abc-40708APL-27-80708APL-27清液常壓80?89x3.00Cr18Ni9708APL-26abc-40708AV05708APL-28清液常壓80?108x3.00Cr18Ni9708AV08708AV05708APL-29清液常壓80?108x3.00Cr18Ni9708AV08708APL-28-100708APL-30清液常壓80?108x3.00Cr18Ni9708AV08708APL-32ab-100708APL-31清液0.0280?108x3.00Cr18Ni9708AV09708APL-32ab-100708APL-32ab清液0.0280?108x3.00Cr18Ni9708APL-30/31-100708AP09A/B708APL-33a清液0.580?57x3.00Cr18Ni9708AP09A708APL-35-80708APL-33b清液0.580?57x3.00Cr18Ni9708AP09B708APL-35-80708APL-34清液0.580?32x2.50Cr18Ni9708APL-33a-50708AV09708APL-35清液0.580?89x3.00Cr18Ni9708APL-33a-50708APL-41-80708APL-37清液0.580?32x2.50Cr18Ni9708APL-33a-50708APL-38-25708APL-38清液0.580?32x2.50Cr18Ni9708APL-33b-50708APL-40abc-25708APL-39清液0.540?32x2.50Cr18Ni9708APL-33b-50708AV08708APL-40abc清液0.540?32x2.50Cr18Ni9708APL-38-25708APL-24abc-50708APL-41清液0.540?89x3.00Cr18Ni9708APL-35-80708AE02708APL-42清液0.540?57x3.00Cr18Ni9708APL-33b-50708APL-50-100708APL-43廢液0.550?45x2.50Cr18Ni9708APL-33b-50界外708APL-44清液0.0240?108x3.00Cr18Ni9708AV09708APL-45-100708APL-45清液0.0240?108x3.00Cr18Ni9708AV09708APL-46ab-100708APL-46a清液0.0240?108x3.00Cr18Ni9708APL-45-100708AT01708APL-46b清液0.0240?108x3.00Cr18Ni9708APL-45-100708AT02708APL-47a排污液0.0240?57x3.00Cr18Ni9708AV01708APL-49a-100708APL-47b排污液0.0240?57x3.00Cr18Ni9708AV02708APL-49b-100708APL-48a排污液0.0240?57x3.00Cr18Ni9708AV01708APL-49a-100代號介質名稱操作壓力（MPa）操作溫度（℃）規格材料管道（起）管道（止）708APL-48b排污液0.0240?57x3.00Cr18Ni9708AV02708APL-49b-100708APL-49a排污液0.0240?108x3.00Cr18Ni9708APL-47/48a-50708APL-50-100708APL-49b排污液0.0240?108x3.00Cr18Ni9708APL-47/48b-50708APL-50-100708APL-50-排污液0.0240?108x3.00Cr18Ni9708APL-49ab-100708AV06708APL-51清液0.540?32x2.50Cr18Ni9708APL-33a-50708APL-53-25708APL-52清液0.540?32x2.50Cr18Ni9708APL-33b-50708APL-53-25708APL-53清液0.540?32x2.50Cr18Ni9708APL-51/52-25708APL-54ab708APL-54ab清液0.540?32x2.50Cr18Ni9708APL-53-25708AC01A/B708APL-55堿液0.0740?159x3.50Cr18Ni9708AV0608APL-56ab-100708APL-56ab堿液0.0740?108x3.00Cr18Ni9708APL-55-150708AP06A/B708APL-57ab堿液0.0740?89x3.00Cr18Ni9708AP06A/B708APL-58-100708APL-58堿液0.540?89x3.00Cr18Ni9708APL-57ab-80708APL-50-100708APL-59堿液0.540?89x3.00Cr18Ni9708APL-58-80708APL-61-80708APL-60a堿液0.540?57x3.00Cr18Ni9708AP07708APL-58-80708APL-60b堿液0.540?57x3.00Cr18Ni9708AP07708APL-61-80708APL-61堿液0.540?89x3.00Cr18Ni9708APL-59-80708APL-41-80708APL-62堿液0.540?89x3.00Cr18Ni9708AE02708APL-63-80708APL-63堿液0.540?89x3.00Cr18Ni9708APL-62-80708APL-02-500708APL-64堿液0.540?89x3.00Cr18Ni9708APL-63-80708APL-02-500708APL-65a堿液0.540?57x3.00Cr18Ni9APL-06b-450708APL-63-80708APL-65b堿液0.540?57x3.00Cr18Ni9708APL-06a-450708APL-64-80708APL-66清液0.540?25x2.00Cr18Ni9708APL-53-25708AV03708APL-66ab清液0.540?32x2.50Cr18Ni9708AV03708APL-46ab-100708AAV-01排空氣0.0340?325x7.020#各排空點低壓放空氣管網708AAV-02排空氣0.0440?159x6.020#708AFG-01-1200708AAV-01-150708AAV-03排空氣0.0440?159x6.020#708AFG-01-1200708AAV-01-150708AAV-04排空氣0.0440?159x6.020#708AFG-06-1200708AAV-01-150708AAV-05排空氣0.0440?57x3.020#708AFG-07-100708AAV-01-150708AAV-05a排空氣常壓40?630x10.020#708AV01就地排空708AAV-05b排空氣常壓40?630x10.020#708AV02就地排空708AAV-06a排空氣0.0440?159x6.020#708AT01就地高點排空708AAV-06b排空氣0.0440?159x6.020#708AT02就地高點排空708AAV-07排空氣0.0440?57x3.520#708AS101就地高點排空708AAV-08排空氣常壓40?219×6.020#708AV06就地高點排空708AAV-09排空氣0.0440?159x6.020#708AV04就地高點排空708AAV-10排空氣常壓40?159x6.020#708AV07就地高點排空708AAV-11排空氣常壓40?159x3.50Cr18Ni9708AV05就地高點排空708AAV-12排空氣常壓40?159x6.020#708AV09就地高點排空代號介質名稱操作壓力（MPa）操作溫度（℃）規格材料管道（起）管道（止）708AAV-13排空氣常壓40?159x6.020#708AV08就地高點排空708AAV-14ab排空氣常壓40?108x3.00Cr18Ni9708AC01A/B708AAV-15-100708ADR-01a排污液0.0240?159x3.50Cr18Ni9各排污點708AV07708ADR-01b排污液0.0240?108x3.00Cr18Ni9各排污點708AV07708ADR-02a排污液0.0240?57x3.00Cr18Ni9708APL-01b-600708ADR-01a-150708ADR-02b排污液0.0240?57x3.00Cr18Ni9708APL-01b-600708ADR-01a-150708ADR-03abc排污液0.0240?57x3.00Cr18Ni9708APL-03abc-450就地708ADR-04abc排污液1.240?57x3.00Cr18Ni9708APL-04abc-400708ADR-01a-150708ADR-05a排污液0.0440?159x3.50Cr18Ni9708AT01708ADR-01a-150708ADR-05b排污液0.0440?159x3.50Cr18Ni9708AT02708ADR-01a-150708ADR-06排污液0.0440?32x3.020#708AS101就地708ADR-07排污液0.440?32x3.020#708AE02就地708ADR-08排污液0.440?25x2.00Cr18Ni9708AE02708ADR-01a-150708ADR-09排污液0.0440?108x3.00Cr18Ni9708AV06708ADR-01a-150708ADR-10ab排污液0.440?32x2.50Cr18Ni9708APL-57ab-80708ADR-09-100708ADR-11排污液0.0440?108x3.00Cr18Ni9708AV04708ADR-01b-10008ADR-12排污液0.440?32x2.50Cr18Ni9708APL-13abc-80708ADR-01b-100708ADR-13排污液0.0440?108x3.00Cr18Ni9708AV05708ADR-01b-100708ADR-14abc排污液0.440?32x2.50Cr18Ni9708APL-21abc-50708ADR-01b-100708ADR-15ab排污液0.440?32x2.50Cr18Ni9708APL-33ab-50708ADR-01b-100708ADR-16排污液0.0240?89x4.020#708AFG-06-1200708AS01708ADR-17排污液0.0240?108x3.00Cr18Ni9708AS01708ADR-09-100708ADR-18-25-L1E排污液0.0240?25x2.0708AV07就地708ADR-19a排污液0.0440?57x3.520#708AFG-03-1200708ADR-01a-150708ADR-19b排污液0.0440?57x3.520#708AFG-05-1200708ADR-01a-150708ADR-20a排污液0.0440?89x3.00Cr18Ni9708AV01下降管708AT01708ADR-20b排污液0.0440?89x3.00Cr18Ni9708AV02下降管708AT02708AS04-01蒸汽0.4143.4?108x5.020#界內總管來界內各用氣點708AS04-02蒸汽0.4143.4?57x3.520#708AS04-01-100708AS04-02a~f-50708AS04-02a~f蒸汽0.4143.4?57x3.520#708AS04-02-50708AT01708AS04-03蒸汽0.4143.4?57x3.520#708AS04-01-100708AS04-03a~f-50708AS04-03a~f蒸汽0.4143.4?57x3.520#708AS04-03-50708AT02708AS04-04蒸汽0.4143.4?32x3.020#708AS04-01-100708ADR-16-80708AS04-05蒸汽0.4143.4?57x3.520#708AS04-01-100708AV07708AS04-06蒸汽0.4143.4?89x4.020#708AS04-01-100708AS04-07abc-50708AS04-07abc蒸汽0.4143.4?57x3.520#708AS04-06-80708AE01A/B/C708AS04-08abc蒸汽0.4143.4?18x2.00Cr18Ni9708AS04-07abc-50保溫截止閥708AS04-09abc蒸汽0.4143.4?57x3.00Cr18Ni9硫磺下料管熔硫釜筒體代號介質名稱操作壓力（MPa）操作溫度（℃）規格材料管道（起）管道（止）708AS04-10abc蒸汽0.4143.4?57x3.00Cr18Ni9708AS04-07abc-50安全閥就地排空708AS04-11蒸汽0.4143.4?89x4.00Cr18Ni9708AS04-01-100各伴熱點708AS04-12ab蒸汽0.4143.4?18x3.020#708AS04-11-80708ASC-06ab-15708AS04-13ab蒸汽0.4143.4?25x3.020#708AS04-11-80調節器降液管708AS04-15蒸汽0.4143.4?25x3.020#708AS04-11-80708AV06708AS04-16蒸汽0.4143.4?25x3.020#708AS04-11-80708AV04708AS04-18蒸汽0.4143.4?25x3.020#708AS04-11-80708AV09708AS04-17蒸汽0.4143.4?25x3.020#708AS04-11-80708AV05708AS04-14ab蒸汽0.4143.4?18x3.020#708AS04-11-80708APL-46ab-100708ASC-01冷凝水0.2120.2?57x3.520#各冷凝液排放點界外08ASC-02冷凝水0.2120.2?18x3.020#708AS04-01-100708ASC-01-50708ASC-03abc冷凝水0.2120.2?32x2.50Cr18Ni9708AE01A/B/C708ASC-01-50708ASC-04abc冷凝水0.2120.2?18x2.00Cr18Ni9708AS04-09abc-50就地708ASC-05abc冷凝水0.2120.2?18x2.00Cr18Ni9保溫截止閥就地708ASC-06ab冷凝水0.2120.2?18x3.020#708AS04-12ab-15708ASC-01-50708ASC-07ab冷凝水0.2120.2?18x3.020#708AS04-13ab-15708ASC-01-50708ASC-09冷凝水0.2120.2?18x3.020#708AV06708ASC-01-50708ASC-10冷凝水0.2120.2?18x3.020#708AV06708ASC-01-50708ASC-12冷凝水0.2120.2?18x3.020#708AS04-16-20708ASC-01-50708ASC-11冷凝水0.2120.2?18x3.020#708AS04-17-20708ASC-01-50708ASC-08a冷凝水0.2120.2?18x3.020#708AS04-14a-15708ASC-01-50708ASC-08b冷凝水0.2120.2?18x3.020#708AS04-14b-15708ASC-01-50708ADW-01脫鹽水1.240?45x2.50Cr18Ni9803ADW-101各用水點708ADW-02脫鹽水1.240?45×3.520#708ADW-01-40708AV06708ADW-03脫鹽水1.240?32x3.020#708ADW-01-40708AS01708ADW-04脫鹽水1.240?25x3.020#708ADW-01-40708AV03708ADW-05脫鹽水1.240?32x3.020#708ADW-01-40708APL-19-100708ADW-06脫鹽水1.240?32x3.020#708ADW-01-40708ADW-06ab-25708ADW-06ab脫鹽水1.240?32x3.020#708ADW-06-32708AC01AB708ADW-07脫鹽水1.240?32x3.020#708ADW-01-40708APL-11-150708ADW-08脫鹽水1.240?45×3.520#708ADW-01-40708AV07708ARW-01工業水0.428?108x5.020#界外各用水點708ARW-02工業水0.428?89x4.020#708ARW-01-100708APL-01a-600708ARW-03工業水0.428?89x4.020#708ARW-01-100708AV06708ALN-01氮氣0.440?108x5.020#803ALN-01-150-L1B708ALN-02/03-100708ALN-02氮氣0.440?108x5.020#708ALN-01-100708AFG-02-1200708ALN-03氮氣0.440?108x5.020#708ALN-01-100708AFG-04-1200708ACWS-01循環上水0.432?159x6.020#803ACWS-001-350-L1B708AE02代號介質名稱操作壓力（MPa）操作溫度（℃）規格材料管道（起）管道（止）708ACWR-01循環回水0.442?159x6.020#708AE02803ACWR-001-350-L1B708AIA-101儀表空氣0.440?25x3.020#803AIA-01-150LV72006708AVT-101a/b排空氣0.0350?219×6.020#708AFG-01-1200708AVT-102a/b-250708AVT-102a/b排空氣0.0350?273×7.020#708AVT-101a/b-200708AAV-01-300（四）、本方案僅適用于煤集團東鑫垣煤化工項目PSA制氫/脫硫項目安裝工程工藝管道焊接。二、焊工（一）、焊工需具備《鍋爐壓力容器壓力管道焊工考試與管理規則》合格證與陜西石化站考試合格并取得陜西石油化工建設工程項目焊工上崗證方可參加煤集團東鑫垣煤化工項目PSA制氫/脫硫項目安裝工程工藝管道焊接。（二）、具有合格證的焊工，連續六個月沒有從事該項目的焊接工作，應重新進行技能復試，合格者方準許進行該項目的焊接工作。（三）、焊工必須按照自身的合格項目進行施工。三、焊接方法（一）、DN＜200mm壁厚＜4mm的不銹鋼管道采用全氬弧焊焊接，DN＜200mm壁厚＞4mm的不銹鋼管道采用氬弧焊打底電焊蓋面焊接。（二）、DN＜32mm碳素鋼管壓力管道采用氬弧焊，當DN＞32mm時，采用手工電弧焊施焊。（三）、所有法蘭的制、安均采用手工電弧焊。（四）、所有支架的制、安均采用手工電弧焊。四、焊接材料及設備（一）、工藝管道焊接材料的選用見下表：序號材質氬弧焊電弧焊氬電聯焊120#TIG-J50J422TIG-J50/J42220Cr18Ni9E308A102E308/A102320+0Cr18Ni9E309A302E309/A302（二）、氬弧焊使用的氬氣純度要求在99.96%以上，鎢絲選用鈰鎢棒。（三）、支架的焊接材料選用J422焊條。（四）、焊接材料及輔助材料應具有材質合格證及質量證明書。（五）、焊條J422應按說明書要求進行烘干，如說明書無明確要求，按照烘干溫度150℃，時間1小時,保溫溫度100（六）、焊條烘干需專人負責，焊條烘干次數不得超過2次。（七）、焊接設備采用直流焊機ZX7-400N。五、焊接環境（一）、工藝管道預制應在清潔、避風的場所進行，本工程工藝管道的預制安排在容器制作場內。（二）、風速：氬弧焊＜2m/s，手工電弧焊＜8m/s，否則應采取相應的防護措施才能進行焊接工作。（三）、若相對濕度大于90%及室外施工下雨天氣應停止焊接工作。六、焊接工藝（一）、焊前準備1、施工員、施工班組及相關人員熟悉施工圖紙，進行圖紙自審。2、凡公司焊接工藝評定經有關部門確認后所覆蓋到的施工前可不做焊接工藝評定，如沒有覆蓋到，施工前先做焊接工藝評定，然后按焊接工藝評定的參數編制焊接工藝卡，報有關部門審批后，焊工嚴格按焊接工藝卡進行施焊。3、施工員對施工班組進行技術交底，填寫《技術交底記錄》。4、管道焊接之前需開設V型坡口，坡口型式及參數如下：壁厚(mm)坡口角α鈍邊P(mm)間隙b(mm)2～1055～65°0～21.0～3.05、碳鋼管道坡口用火焰切割與手工角磨機加工制備，不銹鋼管道坡口用等離子切割與手工角磨機加工制備；焊接接頭組對前，應確認坡口加工形式、尺寸，其表面不得有裂紋、夾層等缺陷。6、焊接接頭組對前，應用手工或機械方法清理其內外表面，在坡口兩側20mm范圍內不得有油漆、毛刺、氧化物及其他對焊接過程有害的物質。7、正式焊接前對焊縫進行點固,定位焊有如下幾點要求：⑴、定位焊應由焊接同一管口的焊工進行施焊。⑵、定位焊所用焊材與正式焊接時相同。⑶、定位焊的工藝條件與正式焊接的工藝條件相同，必須焊透。⑷、定位焊的焊縫長度為10～15mm、點數2～6，焊縫厚度不超過壁厚的2/3。⑸、點固焊的焊肉如有裂紋等缺陷，應處理后再進行正式焊接。（二）、正式焊接1、正式焊接前，必須檢查點固焊點，確認無缺陷后方可施焊。2、引弧應在焊接坡口內進行，不得在管道母材上引弧或將熄弧點引向焊道以外。3、焊接時應注意起弧和收弧處的質量，收弧時應將弧坑填滿，多層焊的層間接頭應錯開。4、不銹鋼管道打底焊接時，焊縫內側應充氬氣保護，防止內側焊縫金屬被氧化。5、不銹鋼管道在保證焊透及熔合良好的條件下，應選用小的焊接工藝參數、采用小電流、