CONTENTS 目录

　1.0 Scope 范

　围 2.0 Specifications, codes and standards 规范标准

　3.0 general 总

　述 4.0 Installation of instruments 仪表安装

　 1.0 Scope 范 围

　This procedure applies to the installation of instrumentation on PP+HDPE PLANT of CSPC NANHAI PETROCHEMICAL PROJECT. 本程序适用于 CSPC 南海石化项目 PP+HDPE 装置仪表安装。

　2.0 Specifications, Codes and Standards 3163-KK-WR-101 Instrumentation work requisition 3163-KK-SC-101 Instrumentation works specification 3163-KK-SG-021

　 Symbols & Identification for instruments erection 3163-TM840.01/94E Instrumentation Erection 3163-TM840.02/96E Instrumentation Verification at plant site 3163-KK-PQ-101

　 Instrumentation works-Site Inspection Plan 63-8550-6500-0001

　Instrument field earthing philosophy 65-8550-6500-0001

　Installation details for High Pressure Instruments NH-HDPE+PP-QPL-06

　 Instrument Quality Plan OTHERS Instrumentation work-Drawings, Specification, Standards etc. 3.0 General

　总 述 3.1 All checks shall be done by instrument engineer or technician responsible for the instrument installation. 所有检查应由负责仪表安装的仪表工程师或技术员进行。

　3.2 Instruments shall be installed as per all relevant drawings, standards and specifications. If there are no specified requirements in these drawings, the installation shall comply with API RP551 and this procedure. 仪表应按有关图纸，标准和规格进行。如果图纸中没有具体要求，执行 API RP 551和本程序。

　3.3 Check all instruments removed from packing cases against design requirements for model,

　material , range ,tag number, accessories and electrical (air) rating, etc. and report immediately any damages or shortages in accordance with Procedure for Material"s Loading, Unloading, Storage and Distribution on Site. Document no: MBOD/EPC.1-RP-CTRU-21. 按照材料装卸，现场存放和发放程序 MBOD/EPC1-RP-CTRU-21 开箱检查，对照设计文件核对仪表的型号、规格、材质、测量范围、位号、附件、电气（空气）)额定值等，如有损坏或短缺，立即报告。

　3.4 Ensure, prior to installation in the field, that instruments have been bench pre-calibrated in accordance with the Vendor"s requirements. The cables shall be run only after piping and its" supports have been installed. Firstly install interior instruments, then exterior instrumentation. The wiring shall be connected only after the instruments panels have been located and fixed and the cables have been run. 仪表安装前应按制造商的要求进行单体校验，电缆的敷设应在管架管线安装就绪后进行。仪表安装应遵循先室内后室外的原则，先进行室内机柜的就位安装，待电缆引进室内后再进行接线工作。

　3.5 Pressure test and flushing of instruments 仪表的试压和吹扫

　Instrumentation piping and equipment may be pressure tested and flushed together with the process piping or separately, but the instrument piping flushing must be done only after the flushing of the process pipe has been completed. Orifice plates,

　vortex meters, control valves, ESD valves etc. shall be removed and replaced by spools prior to process piping flushing.

　仪表管线可与工艺管线一起或分开进行试压和吹扫，但仪表管线一定要在工艺管线吹扫完后方可进行。工艺管线上的孔板流量计、涡轮流量计、调节阀、ESD阀等在吹扫前要拆下，用短管代替。

　3.6 While waiting for installation and after installation, instruments such as control and ESD valves shall be protected from ingress of sand and dust. 等待安装和安装后仪表，如调节阀、ESD阀等，要采取保护措施，防止沙尘侵入。

　3.7 Before the installation of instruments, a joint checkup on drawings and data shall be made by the CP6CC’s and TCM’s inspector. All installation workers must be trained, qualified and competent.仪表安装前要由施工队与 TCM 代表联合检查图纸和资料。所有安装工人必须经过培训并具备资格。

　4 Installation of instruments 仪表安装

　4.1 Installation of instruments cables 仪表电缆敷设 4.1.1 The following preparation shall be taken before the installation of cables.

　电缆敷设前应进行下列准备工作：

　 The cable to be run shall be of sufficient length as shown in the cable lay out, plan or drawings. 敷设电缆长度应足够，符合电缆布置，平面图或其它图纸。

　 Keep extra length to anticipate relocation of instrument. 留有长度余量供仪表改变位置用。

　cable No. Panel No. Received Length Type &

　Size of cable Distribution Reference drawings Cable Numbering or schedule no. Length

　Staring Point Ending Point

　  Prepare an installation sequence plan with reference to site conditions and the above table. It is preferable to run & terminate the longest cable first then followed by shorter cables. 用上面表格准备电缆敷设计划表，实施时先敷设长电缆，后敷设短电缆。

　4.1.2 Inspection Items 检查项目：

　 Where cables are laid on trays or racks, the trays or racks shall be inspected to ensure the routing is complete and free from any sharp edges and foreign debris. 汇线槽或桥架应安装完毕，无脏质杂物，无尖角毛刺。

　 The cable shall comply with design specifications and requirements and shall be free from mechanical damages.

　电缆型号、规格等应符合设计要求，无机械损坏。

　 Test cable for continuity and insulation to ensure they are satisfactory (with certificates). 电缆连续性和绝缘性试验，确保合格。

　 Tag the cables on both ends. 电缆两端做标志。

　 Visual test. 目测检查。

　4.1.3 Cables ends shall be sealed to prevent from the ingress of moisture. 密封电缆的两端，以防潮湿空气侵入 4.1.4 Cables must be laid on cable tray or in conduits as per specifications. 电缆必须按规格敷设在电缆桥架导线管中 4.1.5 Throughout the cable installing process, an individual must be responsible for observation, and prevention of other construction work above the racks and trays that can damage the cables. As soon as the cables have been installed the conduits must be closed to prevent the cables from damages. 电缆敷设过程中，必须由专人监督，防止在桥架上方施工可能损坏电缆。电缆安装后导线管必须封闭防止电缆损坏。

　4.1.6 The cables ends shall be sealed using rubberized tape and the ends of cables in intrinsic safety loops shall be sealed with blue rubberize tape. In high fumes and oily areas the sealed ends shall be painted with a coating of epoxy. 电缆端部应用带密封，本安回路用蓝色胶带密封。高烟和油污区密封端涂环氧树脂层。

　4.2 Installation of Junction Boxes 安装接线盒 4.2.1 Check the junction box for dimensions and type, explosion proof sealing, corrosion proof painting and drains, tagging, number of termination points and number of holes for cable termination. 检查接线盒的规格尺寸，防爆密封，防腐涂漆，排液孔，端点数和电缆端子孔数。

　4.2.2 Junction boxes and supports shall be properly grounded and very firm design. 接线盒及支架应适当牢靠接地。

　4.2.3 Proper conduit fittings shall be installed with threads fully engaged and the proper sealing compound used. 安装导线管固定件，螺纹充分啮合并对用合适的密封剂密封。

　4.2.4 Wiring 接线  Ensure that the percentage of spare terminals and terminal blocks are as per construction drawings(Termination drawing). 按施工图的要求留备用接线板、接线柱  Ensure that the proper type of glands and sealing compounds are used and that there is no damage to the cables. 压盖和密封料正确，不损伤电缆。

　 The cables screens shall be correctly connected and multicore cables and branch cables cores are correctly labeled and tagged. 屏蔽电缆接线正确，多芯电缆、分支电缆及其电缆芯位号标注正确  All screws, bolts shall be properly tightened.

　拧紧螺丝螺栓。

　 All terminal block shall be tagged. 所有端子板作标标志 4.3 Installation of Instruments 仪表安装 4.3.1 In-line instruments 在线仪表 4.3.1.1 In-line instruments such as orifice plates, control valves, flow meters, flow switches etc. shall be installed by the Process Discipline Department and supervised by the site instrument engineer. 孔板、调节阀、流量仪表、流量开关等在线仪表应由工艺专业安装，由现场仪表工程师监督检查。

　4.3.1.2 The instruments shall be removed and replaced by spools prior to flushing. 吹扫前，应将在线仪表取下，用短管取代。

　4.3.2 Instruments directly mounted on process piping or equipment. 直接安装在工艺管线或设备上的仪表 4.3.2.1 The instruments shall be mounted directly on to process piping or vessels when all flushing and pressure testing is completed. 在线仪表安装须在管道和容器吹扫试压完成之后进行。

　4.3.2.2 Where instruments are to be flange mounted, the following shall be checked prior to installation. 对于法兰连接的仪表，安装前应检查以下内容：

　 Orientation of flanges and instruments are correct. 法兰仪表的方位正确  Mating faces of equipment, piping, vessel flanges and instrument"s flange match. 设备，配管，容器的法兰与仪表法兰结合面匹配  Gaskets, nuts and washers are of correct material length and diameter 垫片(圈)、螺栓、螺帽的直径、材质、长度正确。

　 Where dual installation is required, the two flanges are correctly spaced and their alignment is correct. 安装双法兰时，法兰的距离对中合适  Bolts shall be tightened in sequence 顺序拧紧螺栓。

　 Process flow direction to be shown. 标明工艺流方向 4.3.3 Support mounted instruments 架装仪表 4.3.3.1 Attention shall be paid to the following:

　注意事项  The instruments and impulse points elevation are as per approved drawings 严格按批准图的要求确定仪表与脉冲点的标高。

　 The orientation of instrumentation is such that process connections can be made with a minimum amount of bends. 仪表的安装方向应使连接管路弯头最少  When the installed instrument has a local indicator, it shall be positioned so that it can be easily observed by operator from the corresponding control valve. 就地显示仪表的安装位置应处在从调节阀处便于观察仪表示值的位置  Pressure or differential pressure instruments shall be provided with isolation valves. 压力或压差仪表应安装有隔离阀

　4.3.3.2 When installing instruments with capillary tubing connections, attention shall be paid to the following: 毛细管连接仪表的安装注意事项  The capillary tubing shall be fixed and supported to ensure it has a minimum number of bends. 为使毛细管的弯头最少，毛细管应适当固定和支撑  Make an alignment, to ensure that the flange and pipe at a same central line. 法兰的轴线应与管道的中心线一致  Mating faces of equipment, piping or vessel flanges and instrument"s flange should match. 仪表与管道或容器结合面匹配  Gaskets, nuts and washers are of correct material, length and diameter. 垫片(圈)、螺栓、螺帽的直径、材质、长度正确  Bolts shall be tightened in sequence to ensure gaskets remains centered. 顺序拧紧螺栓，确保垫片(圈)居中  Tubing tray should be installed if necessary. 如必要，应安装桥架 4.3.4 Installation of skid mounted instruments 橇装仪表安装 4.3.4.1 Check the Tag No. and Name plate in accordance with relevant approved drawings. 按施工图检查设备的位号和铭牌 4.3.4.2 Inspect all skid mounted instruments and accessories, name plates, test reports, mounting locations, connections, electrical power supply wiring and air tubing connections, to ensure that they are as per specifications. 检查各橇装仪表及部件，名牌，安装位置，测试报告，连接及电源接线和风管的连接是否符合规格 4.3.4.3 All parts of skid mounted instruments shall be fixed, secured and vibration free. 橇装仪表各部件固定牢固，无震动 4.3.4.4 Install ground wires, signal cables, power cables and other tubing. 安装接地线、信号线、电源线以及其它管路 4.4 Installation of control valves 安装调节阀

　Attention shall be paid to the following:

　注意事项  Control valves shall be installed vertically and in the same direction of process flow as the piping. There shall be enough space around valves for the installation of positioners and tubing. 调节阀安装应垂直，阀体上箭头的指向应与介质流向一致，阀体周围 要有足够的空间以便于安装定位器及配制管线。

　 Positioners shall be fixed on to the support of the control valve and easy accessible for reading and maintenance, the connection joint of spindle (valve stem) and feedback lever shall be secured. 带定位器的调节阀，应将定位器固定在调节阀支架上，并便于观察和维修，定位器的反馈连杆与调节阀阀杆接触要紧密牢固  The valve stem and regulator lever shall be connected and move freely (free of obstruction), positioner limits shall be secured at correct positions. 阀杆与调节器杆连接，活动自如，止挡限位应在正确的位置  Pneumatic and hydraulic signals to actuators shall be adjusted accordingly and accurately so as to ensure that the valves move correctly. 至气动及液动执行机构的信号应相应调节并要精确，以确保阀门活动正确

　 Control valve with flange body refer to section 4.3.2.2. 调节阀的法兰要求参照 4.3.2.2款进行。

　4.5 Installation of instrument pressure piping and tubing (impulse lines)

　仪表压力管（脉冲线）的安装 4.5.1 Instrument pressure piping and tubing includes pressure, flow, level instruments, analyzers, and actuated valves, instrument control panels, local control panels, gauges and skid-mounted instruments. Valve "fittings and vessels that are used in pressure lines are also included. 仪表压力管压力、流量、液位仪表，分析仪表和驱动阀，仪表控制盘，就地控制盘，压力表及橇装仪表。也包括管路系统中使用的阀门配件和容器等附件 4.5.2 All materials used for pipes and fittings shall meet the design requirements, and shall have quality certification. 管路和配件的材质和规格应符合设计要求，并应有质量合格证 4.5.3 The insides of all piping and fittings shall be cleaned and free from debris or grease. Flush the process line before the instrument installation. 管子及配件内部面应清洁干净，无赃物油脂。安装前吹扫工艺管线。

　4.5.4 Prior to installation, the CS piping shall be given protective coating. If it is required, some parts shall be prefabricated in workshop at site. 安装前应将碳钢管材进行防腐处理，部分部件管路应在现场车间预制 4.5.5 Sectional prefabricated piping must be cleaned and proper handling shall be provided to protect from sand and dust. 预制制好的管段内部必须清洗干净，并采取措施防止杂物进入 4.5.6 Arc welding shall not be used to cut impulse pressure piping. Thickness up to 25 mm of carbon steel piping shall not be flame cut. Non-ferrous metal and alloy piping etc. shall not be flame cut. 脉冲压力管不得用电弧焊切割。厚度至 25mm 的碳钢管不应用火焰切割，有色金属管、合金钢管等不得用火焰切割。

　4.5.7 Impulse lines shall not be buried directly. If the installation locations are not specified in the design, the installation shall be according to the site conditions and shall be where applicable, and secured with a minimum number of bends or crossovers, and there shall not be any critical bends or complex bends. 脉冲管线不宜直接埋地敷设。如设计没有明确规定安装位置，应按现场情况合理安装，固定尽量减少弯头和交叉，尤其不得有急剧和复杂的弯头。

　4.5.8 Impulse lines shall be installed in a position that is easy for operation and maintenance to minimize the possibility of mechanical damage corrosion and vibration. 脉冲管线应安装在便于操作和维修的地方，以减少机械损伤，腐蚀，振动的可能性。

　4.5.9 The impulse lines for measuring shall be short as stipulated; the maximum length shall be not more than 6m. 用于检测的脉冲管线在满足测量要求的条件下应尽量缩短，最大长度不宜大于6米。

　4.5.10 When pressure lines run across walls or floors, protective tubing (sheathing) shall be installed. If it runs from an explosion-proof or toxic area to a non-explosive or nontoxic area, any openings crossed must be sealed. 压力管线在穿墙和过楼板时，应安装保护管(罩)。管线由防爆厂房或有毒厂房进入非防爆或无毒厂房时，在穿墙或过楼板处应进行密封。

　4.5.11 When pressure lines connects to hot process lines or equipment, the connection joints shall have offsets for expansion or insulation.. 压力管线与高温工艺设备、管路连接时应考虑补偿或保温 4.5.12 Installation of pressure lines shall meet the following requirements: 压力管线安装应符合下列条件  Check and ensure the primary elements mounted on process equipment and piping are installed correctly, satisfying the requirements of installation of measurement impulse lines. 工艺设备、管道上安装的一次元件满足测量脉冲管线要求  Check tubings, fittings and valves in accordance with approved drawings. 管子、管件、阀门符合图纸  Check pipes to ensure that the surfaces are free from cracks, rust and damage, and fittings and valves are free from mechanical damages, and all threaded connections shall be tightened properly. 管子外观检查无裂纹、伤痕和严重锈蚀等缺陷。管件阀门机械损伤，螺纹连接紧固合适。

　 Check the valves to ensure that they meet the quality requirements, and their seats are in proper condition. 阀门符合质量要求，阀座状态良好  Check that the procedures and methods for the installation of pressure lines conform to the design drawings. 压力管线安装程序和方法符合设计图纸 4.6 Installation of Instrument Air Lines and Signal Tubing 仪表风管线和信号管线的安装 4.6.1 Air line 风管线 4.6.1.1 Before installation, the piping, fitting and valves of instrument

　air systems shall be cleaned and to ensure that they are free from oil, water, rust and dirt etc. 仪表风系统的管子、阀门、管件等，在安装前均应进行清洗，不应有油、水、铁锈等污物 4.6.1.2 As air supply piping is galvanized, pipe tubing, fitting and connections shall be threaded and the threads shall be sealed with an approved sealant, no materials shall be remained in the pipe. When using seamless steel pipe, the connection joints can be welded, but no welding slag can remain in the pipe. 供气管道采用镀锌管，管子，配件和接头带螺纹，螺纹用合适密封剂密封，管内不应留有物质。采用无缝钢管时可以焊接，但焊渣不得留在管内 4.6.1.3 Branch lines are installed from the top of the main header and spare connection nipples or tie-in shall be installed on the main header. 支管应从总管顶部引出，总管上应留有备用接头 4.6.1.4 A filter regulator shall be provided between instruments and the instrument air supply line. Where instruments are concentrated, a larger filter can be shared, and the installed location of the filter regulator shall be chosen for easy operation, and easy removal. 仪表风管与仪表间，应装过滤调节器。在仪表集中处，可以采用大的过滤器，其安装位置应选择在操作和拆装方便的地方 4.6.1.5 If a central pressure regulation strainer is used on the airlines, pressure gauges shall be mounted on the upstream and downstream sides of the regulator. A local single filter regulator and pressure gauge shall be mounted on downstream.

　如果风管采用中心过滤调压粗滤器时，调节器的上游和下游侧应安装压力表。下游应装一台单过滤调节器和压力表。

　4.6.1.6 For large flowing air pipes, two strainers are required to be installed in parallel with isolation valves for easy maintenance removal. 大流量风管应并联安装用两台粗滤器和隔离阀，以便保养拆卸。

　4.6.1.7 All airlines systems shall be laid and installed in a neat, tidy and workmanlike manner. Correct drain valves shall be installed on the specified locations and drainpipes shall be installed far away from instruments, electric equipment and terminal blocks. There shall be sufficient space between strainer drain point and the ground, for operational purposes. 供气系统的敷设应整齐美观，在规定的位置安装排污阀，排污管应远离仪表、电器设备及接线端子。排污点与地面之间，应留有便于操作的空间。

　4.6.2 Air Signal tubing

　空气信号管线 4.6.2.1 Air signals tubing shall be grouped together and be secured. Single signal tubing shall be installed along piping and not individually slung. Airlines shall be as short as possible, vertical or level as needed, with minimum number of bends or crossovers. 空气信号管线应集中敷设，并固定牢固。单根信号管线应附管敷设，不得单独悬空安装。管线要短，横平竖直，尽量减少弯曲和交叉。

　4.6.2.2 Metal air signal tubing must be cold bent by bending machine, the minimum number of radii at bends shall be not lower than three times the number of the tube"s outer diameter (OD). tubes bending shall be carried out with the correct type of bender. 金属空气信号管线必须采用弯管机冷弯，弯曲半径不得小于管子外径的 3 倍 4.6.2.3 Installation of airlines shall avoid the use of joints. If unavoidable, pipe expanders shall be used and connected by welded bell and spigot sleeve type couplings. Union that can be dismounted shall be installed between instruments and air tubing. 空气信号管线敷设时，应尽量避免接头，如无法避免时,应用胀管器，用焊接的钟口套套筒接头连接。管线与仪表相接处，应装可拆卸的活接头 4.6.2.4 Before the installation, all pipe tubing shall be pressurized and tested at the maximum allowable working pressure. No damages and deformation shall be allowed. 安装前，所有管道应打压，用最大允许工作压力试验。不得有损伤及变形 4.6.2.5 Air signal line shall be installed away from hot radiation. During installation, attention shall be paid to following: 空气信号管线应避免热源辐射，安装时注意以下几点  Any mechanical damages and wear at crossings. 防止机械损伤及交叉磨损  Specified spare tubing (including No. and length), maintaining its position and the minimum number of radii at bends shall be not lower than 8 times the number of the tube"s outer diameter . 留有适当的备用管数和备用长度。固定时应保持其自然度，弯曲半径不小于管缆外径的 8倍。

　 100mm deep sand shall be filled above and below the underground airlines and covered with one (1) ply of tiles above the sand. Conduits shall protect the air tubing where road crossings and piping surface at ground level. 埋地敷设时，管线上下均应填充 100mm 的砂子，上部盖一层砖。穿越道路和出地面部位应加保护套管。

　 A coupling shall be used at the air tubing branch connections.

　管道的分支处连接应用连接节 4.6.2.6 The tubes shall be cut with correct sized tube cutters, and the cut ends shall be square and properly reamed when shield copper or nylon tubes are cut. 管线应用合适尺寸的割管刀切割，切割带保护套的紫铜管或尼龙管子时，管端应切割整齐。

　4.6.2.7 The joints and piping exposed to corrosive areas shall be appropriately protected. 暴露在腐蚀性大气中的管线，接头应采取保护措施。