管道阀门维护检修规程(上)

管道阀门维护检修规程（上）二○○七８７４目录1总则···························································································8752完好标准·····················································································8783管道阀门的维护···········································································8793.1维护····················································································8793.2常见故障和消除方法·······························································8814检验、检修周期和内容··································································8835检修方法及质量标准·····································································8855.1检修前的准备工作和检修中的注意事项·······································8855.2管道、阀门及管道附件的质量检验·············································8875.3管道的检修及质量标准····························································8915.4阀门的检修及质量标准····························································9266试压、吹洗与验收········································································9286.1试压····················································································9286.2吹扫与清洗···········································································9336.3验收····················································································9397维护检修中的安全注意事项······························································940附件一：阀门的型号和选用····································································942附件二：TDI界区常用材料、管线代号的含义·············································948附件三：常用橡胶密封圈的性能和使用范围···············································952附件四：管道设备涂漆的有关规定···························································955附件五：管道涂色规定(HG25043－91)······················································957８７５1总则1.1适用范围参照原化学工业部颁发的《管道阀门维护检修规程》(HG25002－91)以及其他有关资料，编制本规程。本规程适用于最高工作压力低于35MPa、工作温度为－20～＋450℃的碳钢、低合金钢、不锈钢、耐热钢、铸铁和有色金属工业管道的维护和检修。工作温度低于－20℃或高于450℃的工艺及热力管道，需遵守低温或高温管道的设计规定。本规程不适用于仪表管道和非金属管道。1.2工艺管道的分类1.2.1按管道材质、温度、压力为参数的管道分类如表1。表1．材质工作温度℃工作压力MPaⅠⅡⅢⅣⅤ碳素钢≤37032＞10.0～32＞4.0～10.0＞1.6～4.0≤1.6＞37010.0＞4.0～10.0＞1.6～4.0≤1.6合金钢及不锈钢≤－70或≥450任意－70～450＞10.0＞4.0～10.0＞1.6～4.0≤1.6铝及铝合金任意≤1.6铜及铜合金任意＞10.0＞4.0～10.0＞1.6～4.02≤1.61.2.1.1剧毒介质的管道按Ⅰ类管道。1.2.1.2有毒介质和甲、乙类火灾危险物质的管道均应升一级。1.2.1.3有毒介质、剧毒介质及甲、乙类火灾危险物质的分类情况如下：1.有毒介质：是指进入人体量≥50克时即会引起人体正常功能损伤的介质，如二氧化硫、氨、一氧化碳、氯乙烯、甲醇、氧化乙烯、硫化乙烯、二硫化碳、乙炔和硫化氢等。2.剧毒介质：是指进入人体量＜50克即会引起肌体严重损伤或致死作用的介质，如氟、氢氟酸、氢氰酸、光气、氟化氢和碳酰氟等。1.2.1.4甲类火灾危险物质：1.硝化棉、硝化纤维胶片、喷漆棉、火胶棉、赛璐璐棉、黄磷；2.金属钾、钠、锂、钙、锶、氢化锂、四氢化锂、氢化钠；3.赤磷、五硫化磷；4.己烷、戊烷一、石脑油、环戊烷、二硫化碳、苯、甲苯、甲醇、乙醇、乙醚、蚁８７６酸、甲酯、醋酸甲酯、硝酸、硝酸乙酯、汽油、丙酮、丙烯腈、乙醛；5.乙炔、氢、甲烷、乙烯、丙烯、丁二烯、环氧乙烷、水煤气、硫化氢、氯乙烯、液化石油气、电石；6.氯酸钾、氯酸钠、过氧化钾、过氧化钠。1.2.1.5乙类火灾物质：1.硫磺、镁粉、铝粉、赛璐璐板(片)、樟脑、萘、生松香、硝化纤维漆布、硝化纤维色片；2.煤油、松节油、丁烯醇、异戊醇、丁醚、醋酸丁酯、硝酸戊脂、乙酰丙酮、环己胺、溶剂油、冰醋酸、樟脑油、蚁酸、糠醛；3.硝酸铜、铬酸、亚硝酸钾、重铬酸钠、铬酸钾、硝酸、硝酸汞、硝酸钴、发烟硫酸、漂白粉；4.氧气、氟气；5.氨气；6.桐油漆布及其制品、漆布及其制品、油纸及其制品、油绸及其制品、浸油金属屑。1.2.1.6本表分类的管道类别即为该管道的焊缝等级。表2．1.2.2按公称压力分级管道分类如表2。1.2.3不同材质管道在不同温度下最高工作压力如表3～9。1.2.3.1碳钢管子、管件的公称压力和最大工作压力如表3。表3．公称压力PgMPa介质工作温度℃≤200250300350400425450最大工作压力MPa0.10.10.10.10.070.060.060.050.250.250.230.200.180.160.140.110.400.400.370.330.290.260.230.180.600.600.550.500.40.380.350.271.001.000.920.820.730.640.580.451.601.601.501.301.201.000.900.702.502.502.302.001.801.601.401.104.004.003.703.303.002.802.301.806.406.405.905.204.704.103.702.9010.0010.009.208.207.306.405.804.50级别名称压力PMPa真空管道P＜0低压管道0≤P≤1.57中压管道1.57＜P≤9.81高压管道P＞9.81８７７1.2.3.2含钼不少于0.4％的钼钢及铬钼钢制管子、管件的公称压力和最大工作压力如表4。表4．520公称压力PgMPa介质工作温度℃≤350400425450475500510520最大工作压力MPa0.100.10.090.090.080.070.060.050.040.250.250.230.210.200.180.140.120.110.400.400.360.340.320.280.220.200.170.600.600.550.510.480.430.330.300.261.001.000.910.860.810.710.550.500.431.601.601.501.401.301.100.900.800.702.502.502.302.102.001.801.401.201.104.004.003.603.403.202.802.202.001.706.406.45.805.505.204.503.503.202.8010.0010.009.108.608.107.105.505.004.301.2.3.31Cr18Ni9Ti不锈钢管子、管件的公称压力和最大工作压力如表5。表5．520公称压力PgMPa介质工作温度℃250300350400425450475500最大工作压力MPa0.250.250.220.210.190.180.170.160.150.600.600.530.490.460.440.410.390.361.001.000.880.820.760.730.690.660.591.601.601.401.301.201.151.101.050.952.502.502.202.001.901.801.701.601.504.004.003.503.303.102.902.752.602.406.406.405.605.304.804.604.404.203.8010.0010.008.708.207.807.306.906.505.901.2.3.4灰铸铁及可锻铸铁管子、和管件的公称压力和最大工作压力如表6。表6．公称压力PgMPa0.100.250.400.601.001.602.504.00介质工作温度℃≤120最大工作压力MPa0.100.250.400.601.001.602.504.002000.100.250.380.550.891.502.303.602500.100.200.360.500.801.402.103.403000.100.200.320.500.801.302.003.201.2.3.5纯铝(压延铝)制管子、管件的公称压力和最大工作压力如表7。1.2.3.6青铜、黄铜及紫铜管子、管件的公称压力和最大压力如表8。８７８表7．表8．1.2.3.7软铅的强度折减系数如表9。表9．介质温度℃≤306080100120140强度折减系数10.640.560.500.400.321.3阀门分类表10．阀门按公称压力为主要参数分类如表10。1.4本规程与国家或上级有关部门的规定相抵触时应遵循国家或上级有关部门规定。2完好标准2.1零、部件2.1.1管道、阀门的零部件完整齐全，质量符合要求。2.1.2仪表、计量仪器、信号联锁和各种安全装置、自动调节装置等齐全完整，灵敏、可靠。2.1.3管道、管件、管道附件、阀门、支架等安装合理，牢固完整，各种螺栓连接紧固；无异常振动和杂音。2.1.4防腐、保温、防冻设施完整有效，符合要求。2.2技术资料2.2.1技术档案：检修及验收记录齐全；高压管道及阀门还应有质量证明书和安装质量验收记录。2.2.2运行时间统计、记录。2.2.3高压管道、阀门应有易损件图纸。2.2.4维护检修规程齐全。2.3设备及环境管道、阀门布置合理，环境整洁，无跑、冒、滴、漏。公称压力PgMPa介质工作温度℃≤80120150最大工作压力MPa0.250.250.200.160.600.600.500.401.001.000.800.62公称压力PgMPa