1/73
Nanjing Wujiazui Shipbuilding Co.,Ltd.
STEEL SHIP PIPING GENERAL
MANUAL
钢质船舶管系通用手册
Number编号
DRAW UP：编制＿＿＿＿＿ TRANSLATION：翻译＿＿＿＿＿ VERIFY：核对＿＿＿＿＿
EXAMINE：检查＿＿＿＿＿
AUTHORIZE：批准＿＿＿＿＿
2/73
CATALOG目录
1. Scope of application适用范围………………..... ..... ..... ..... ..... .. 1 2. Piping name and code管子名称和编码.….…………………..... .... 1 3. Pipe classes、 material and size管子类型、材料和规格………..... ..... ...2 4. Principles and requirement to piping管子原理和要求………..... .....4 5. Technical requirement for pipe processing管子处理的技术要求.... ..9 6. Pipe connection type and requirement管接形式和要求……….... ..16 7. Pipe treatment管子处理………………………………..... ..... . ....24 8. Material of gasket in pipeline管路垫圈材料 ………………….... 24 9. Arrangement and mounting of fittings in pipeline管路附件布置和安
装.... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ...25
10. Requirement for installing AC ducts &refrigerating pipe安装空调
和冷却管路的要求.... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .28
11. Pipe supporter管子支架………………………….... ..... . .... .... .30 12. Installation of pipes管子安装………………. ..... ..... ..... ... .... ..42 13. Requirement for pipe passing through hull Structure管路贯穿船体
结构的要求……..... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .44
14. Testing of pipe管子的测试 ………..…..... ..... ..... ..... ..... .. .... ..50 15. Insulation绝缘……………………………………......... .... .... 52 16. Paint color & insignia of pipeline管子油漆和铭牌……………...55
3/73
1. Scope of application适用范围2
This manual specifies the requirements of processing、arrangement and mounting for pipes、 fittings and supports.
本手册规定了船舶管系、管系附件、管子支架的加工、布置、安装要求及检验规则。
This manual is suitable for pipe-laying design, and pipe processing、arrangement and mounting for ships which will be built at our shipyard. For special required pipes, the processing and mounting should be according to special drawings or special workmanship for the single vessel.
本手册适用于我厂建造船舶的管系设计和管子加工、布置、安装。对有特殊要求的管子加工、安装以图纸要求为准或另编单船专用工艺。
This manual isn't suitable for plastic pipes processing and mounting. 本手册不适用于塑料管的加工和安装。
2. Pipe system name and code number系统名称与编码代号
2．1 Pipe system name and code number see Table 1. 管路系统编码代号见表1
Table1 Pipe system name and code number
表1系统名称与编码代号
Code No.编码代号 AC AL AO AS AW BF BL BP CA CF CH CL CS DA DC DW EP EM FB FC FD
Name名称 Air Conditioning Duct空调风管 Acetylene Pipe乙炔管 Air Pipe, Oil Tank油舱透气 Compressed Air, Starting 起动空气 Air Pipe, Water tank水舱透气 Boiler Feed Water锅炉给水 Bilge Line全船舱底水 Ballast Piping全船压载水 Compressed Air, Control & Service低压(杂用及其他)压缩空气 Cooling , Fresh Water淡水冷却 Cargo Tank Heating System货油舱加热系统 Condense Line蒸汽回汽凝水 Cooling , Seawater海水冷却 Drainage, Over All全船疏排水 Draining, Condensed Water凝水排放 Deck Washing System甲板冲洗 Exhaust Piping 排气(烟)管 Extinguishing, Machinery Space机舱化学灭火 Fuel for Boiler锅炉燃油 CO2 System二氧化碳管 Fuel Oil Drainage燃油泄放 4/73
FE FF FL FO FP FT HC HO HY LC LD LM LO LP LT OF OX PC RP RW SA SC SO SP SS SW VP VS WD WF WH WS Fire-Extinguishing System消防水 Foam Fire Extinguish Line泡沫灭火 Filling Line , Oil Tank油舱注入 Fuel Oil Supply燃油供给 Fuel Oil Purifying燃油净化 Fuel Oil Transfer燃油输送(驳运) Heat Oil Coil燃油加热 Heat Oil热油系统 Hydraulic oil pipe液压管 Cargo Loading Manifold输油(货油装卸) Lubricating Oil Draining滑油泄放 Level monitoring pipe液位遥测管 Lubricating Oil Supply滑油供给 Lubricating Oil Purifying滑油净化 Lubricating Oil Transfer滑油输送 Overflow pipe溢流管 Oxygen PIPE氧气管 Cable Pipe电缆管 Refrigerant pipe制冷剂管 Refrigerated water pipe冷冻水管 Drainage ,over all soil全船粪便污水排放 Cargo Stripping System货油舱扫舱 Sounding Tube, Oil tank油舱测深 Steam Piping蒸汽 Sprinkle System洒水 Sounding Tube, water tank水舱测深 Voice pipe传话管 Ventilation System通风 Drinking water system饮用水 Fresh water supplying system淡水供给 Hot water system热水 Sea water supplying system海水供给 Explanatory notes:说明 XX AO 13 一 01
XX ------- Part I of system code number : two numbers , stand for pipe area. 区域代号-----系统编号代码第一部分(二位): 数字码,代表管件区域代号； AO------- Part II of system code number : two letters, stand for pipe system. 系统代码---系统编号代码第二部分(二位): 字母,代表管件系统代码； 13-------- Part III of system code number : two numbers, stand for pipe item. 管件代号----系统编号代码第三部分(二位): 数字码,代表管件代号； 01-------- Part Ⅳ of system code number : two numbers , stand for pipe item. 管件序号----系统编号代码第四部分(二位): 数字码,代表管件序号。
5/73
3. Pipe grade 、material and size管子等级，材料，规格
3.1 Pipe grade管子等级
3.1.1 Normally, pipes are divided into I、 II、 III three grades based upon the pressure and/or temperature the pipes need to undertake, see table 2
船舶耐压管系按其设计压力和温度，一般分为I、II、III三级见表2。具体管子等级应根据所入级船级社规范而定
Table 2 Pipe grade
管系等级 grade I grade II grade III 一级 二级 三级 Design Design Design Design Design Design Pipe system管系 pressure tempera. pressure tempera. pressure tempera. 设计压设计温度 设计压设计温度 设计压设计温度 力 ℃ 力 ℃ 力 ℃ Mpa Mpa Mpa Steam and thermal >1.6 or>300 ≤1.6 and≤300 ≤0.7 and≤170 oil蒸汽和热油 Fuel oil燃油 >1.6 or>150 ≤1.6 and≤150 ≤0.7 and≤60 Other medium >4.0 or>300 ≤4.0 and≤300 ≤1.6 and≤200 其他介质 Note:注 1. Other medium means air、 water、 lubrication oil and hydraulic oil, etc. 其它介质指空气、水、滑油和液压油等 2. Open-ended pipes i.e. drainage、overflow and vent pipes of boiler are grade III pipes. 不受压的开式管路，如泄水管、溢流管、透气管和锅炉放汽管等为III级管系。 3.2 Material and size材料和规格
3.2.1. Pipe material, for grade I & II pipe, 10# steel to be chosen (stander number: GB5312-87); And for class III pipe, 10# steel to be chosen (stander number: GB8163-87).
管子材质：I 、II级管选用10#、20#（标准号：GB5312—87），III级管选用10#、20#（标准号：GB8163—87)。
Seamless steel pipe will be chosen mainly according to Table 3. If conflicting occur, rules of class society to be obeyed.
无缝钢管的规格优先选用表3。若特殊系统管子外径、壁厚按规范要求与表3不符合时，则以规范要求为准。
Table3 Seamless steel pipe 表3 无缝钢管规格优先选用表 Nominal Outside Thickness厚度 diameterDiameter管A B C 管径 子外径 10 17 2.5 2.5 3.2
6/73
15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 22 27 34 42 48 60 76 89 114 140 168 219 273 325 377 426 2.5 2.5 2.5 3.5 3.5 3.5 4.5 4.5 5.0 5.5 5.5 6.5 6.5 7.5 9.0 9.0 3.5 3.5 3.5 3.5 4.0 4.0 5.5 5.5 6.0 7.0 7.5 8.5 9.5 11.0 12.0 13.0 4.0 4.0 4.5 4.5 7.0 7.0 7.0 7.0 8.5 8.5 9.5 11.0 13.0 15.0 15.0 15.0 3.2.2 Copper pipe will be chosen mainly according to table 4 紫铜管的规格优先选用表4。
Table4 Copper pipe
表4 紫铜管规格优先选用表 Outside diameter Pipe which will prior to be chosen (mm) Copper pipe Alloy pipe 8-10 1.0 0.8 12-20 1.2 1.0 25-44.5 1.5 1.0 50-76 2.0 1.5 3.2.3 All pipes upon arrival in the yard should have makers’ certificates of qualification, and all pipes which will be used as grade I & II should have certificate of class society、 heat number and batch number.
到厂的各种管材必须具有制造厂质量保证书，所有I级和II级管子应具有船检证书及制造生产罐号，并按管子的材料、级别、规格分类妥善保管。
3.2.4 Upon arrival in the yard, before stowing, visual inspection is to be conducted to the pipes against technical documents.
For seamless steel pipe, the faults of crack、 clinker-built 、folding 、rolling and delaminating etc are not allowed on pipe internal and external surface, if there are above-mentioned faults, they should be cleaned up. The pipe thickness reduction caused by cleaning up should not exceed value that rule and/or standard permitted. For seam steel pipe internal and external surface, the faults of crack、undercutting、 splash and depression etc which may caused by welding are not allowed. And for the non-ferrous pipe surface, it should be smooth and clean , and the faults of crack、 pin holes、 air-bubble、 delaminating and corrosion etc are not allowed.
7/73
管子入库前，应对管材内外表面质量进行检查。无缝钢管内外表面不得有裂缝、裂纹、折叠、结疤、轧折、分层等缺陷存在，如有上述缺陷应予清除，清除部位的壁厚减薄量不得超过材料标准允许的负偏差；有缝钢管内外表面不允许存在由于焊接引起的裂纹、咬口、飞溅、凹陷等缺陷；有色金属管子表面应光滑清洁，不应有针孔、裂缝、气泡、离层、锈蚀等缺陷。
3.2.5 When ordering carbon steel pipe、 Stainless steel pipe、 copper pipe and aluminum pipe, the requirement of annealing treatment should be forwarded to the maker.
碳素钢管、不锈钢管、铜管、铝管在订货时，应向制造厂提出退火处理要求。
3.2.6 The connecting fittings, e.g. pre-fabricated bends and reducers etc. refer to GB12459-90, should be supplied makers’ certificates of qualifications before stowing in warehouse.
定型弯头、异径接头等连接件，可参照GB12459—90，必须有材料质量保证书方可入库。
4. Principles and requirements of piping layout管系布置原则与要求
4.1The pipeline should try to keep straight and reduce the bends at most possible. Anyway, the piping layout should be compliance with the requirement of international ship building rules 、 regulations and also the authority requirement of the country which the flag is flied. The pipeline should have enough reliability and easy operation for the crews.
管路尽可能直线布置，弯头尽可能少，同时要符合有关船舶建造规范、国际公约、国际规则以及挂旗国港口法规，并应有足够的可靠性和经济性，力求满足船员使用要求。
4.2 The spacing of parallel pipes i.e. adjacent two pipes (including pipe fittings) or pipe and hull construction normally should exceed 20mm, shown as Fig .1, but the smallest spacing (after pipe being insulated)is not less than 10mm . At some places where the space is very tight, it’s allowed that the spacing exceed 2mm.
并行管或交叉管或邻近的二根管子（包括管子附件）或与船体结构间距宜在20mm以上，图1所示，但最小间距（管子包扎后）不少于10 mm，在空间非常紧的位置上，允许间距2 mm以上
fig.1图1
4.3 The distance between following pipe and cable should exceed 100mm. 下列管子与电缆的距离应在100 mm以上
8/73
1）Outside surface of insulation for steam pipe. 蒸气管绝热层外表
2）Outside surface of insulation for exhaust pipe. 排气管绝热层外表
4.4 The arrangement of pipeline and its fittings should ensure operation, maintenance and repair conveniently during the period of servicing, and also to avoid collision and influence people passing through.
管路及其附件的布置，应保证在营运期间能方便地操作和维修，同时能有效地避免碰撞，不影响人通过。
4.5 According to the requirement of each equipment, the necessary free space for the equipment dismantling、 maintenance、 repairing and checking should be considered . Pipes are not allowed to arrange inside these spaces.
应根据各设备的要求考虑其拆装、维修、检查等必要的空间，在此空间内不宜设置管路。
4.6 When cables、 pipes and vent ducts go through the same vertical cross section, it should be arranged from up to down according to the sequence of cables-pipes-vent ducts, when pipes are over cables unavoidably, it’s not allowed to have removable connectors .
当电缆、管子、风管位于同一垂直位置时，一般应由上而下按照电缆——管子——风管的顺序布置，当管子不可避免地穿过电缆上方时，不得有可拆接头。 4.7 For the pipes which may endure expansion or other strengths, the necessary compensation steps e.g. bending pipes or adding expansion joints or flexible joints are always taken.
对承受热胀冷缩或其它应力的管子，应采取管子弯曲或加膨胀接头或伸缩接头等必要的补偿措施。
When the pipelines are arranged in long distance straight line, e.g. thermal oil pipe、exhaust pip、 boiler smoke exhaust pipe、 steam pipe、 cargo oil pipe、 stripping pipe and ballast pipe etc, the expansion / shrinking of pipes and hull deformation etc are to be taken into consideration, and the grade of connecting bolts are also need to be considered.
尤其要注意热油管、排气管、锅炉排烟管、蒸气管、货油管、扫舱管、压载管等长距离直线布置时，管子的热胀冷缩、船体的变形等，同时要考虑到连接螺栓的强度等级。
4.8 Generally, it is not allowed that fresh water pipes pass through oil tanks or that oil pipes pass through fresh water tanks. If it’s unavoidable, the pipes should go through the pipe tunnel or the jacket pipe. If other pipes except fresh water pipes pass through oil tanks, the pipes should be thickened, and removable connectors should be avoided at most possible.
淡水管不得穿过油舱；油管不得穿过淡水舱。若不可避免时，应在密封通道或套管内通过，其它管子通过油舱时，管壁应加厚，并不得有可拆接头。 4.9 Arrangement of sewage pipes 粪便管的布置
4.9.1. Sewage pipes are not allowed to pass through fresh water tanks. 粪便管不得穿过淡水舱。
9/73
4.9.2 When sewage pipe being horizontal arranged, it should have 50:1 slope along
flow direction
粪便管水平布置时应按流向50：1的斜度。
4.9.3 At special position when the sewage pipes can only be horizontal, the length
should be short as far as possible and short socket for cleaning need to be added at necessary positions.
特殊部位只能平直时，管子长度应尽量短，在必要位置增设疏通接头
4.9.4 Sewage pipes can not arranged above the beds inside the cabin, if unavoidable,
it can not have removable connectors.
粪便管尽量不布置在床铺上方，若需布置时不应有可拆接头。
4.10 The fuel oil tank、 vent pipes、overflow pipes、sounding pipes and filling pipes
of tanks should not pass through cabins generally. If unavoidable, removable connectors can not be fitted inside the cabins.
燃油舱、柜的空气管、溢流管、测深管、注入管应避免通过居住舱室。不可
避免时则通过该舱室时，不得有可拆接头。
4.11 In the range of appropriate distance around the switchboard、electric control
boxes、electric motors and important instruments, the steam pipes、 exhaust pipes、boiler smoke exhaust pipes、water pipes、 oil pipes and their fittings are not to be fitted. If it’s unavoidable, the removable connectors can not be fitted, or the effective protection steps should be taken.
配电板、电控制箱、马达及重要仪表的上方或前后适当距离的范围内，不得设置蒸气管、排气管、锅炉排烟管、水管、油管及其附件。不可避免时，则不得设置可拆接头，或采取有效的防护措施。
4.12 Above the boiler smoke ducts、steam pipes、 exhaust pipes and silencer ,the oil pipes or oil tanks should be avoided. If it’s unavoidable, the removable connectors can not be fitted, or the effective protection steps are to be taken.
锅炉、烟道、蒸气管、排气管及消音器上方，应避免设置油管或油柜。不可避免时，则不得设置可拆接头，或采取有效的防护措施
4.13 For the vent pipes, generally condensed water block should be avoided. And when the vent pipes are arranged on freeboard deck or deck of superstructure, the heights see Fig.2.
空气透气管，一般应避免冷凝水滞留现象产生。对于海船空气透气管布置在干舷甲板或上层建筑的船楼甲板上时，其高度应符合图2要求。
Fig.2图2
4.14 The pipes of double bottom tanks and deep tanks leading upward to free board
10/73
deck, can not be arranged inside cabins/tanks.
双层底舱及深舱的空气管，必须向上引至干舷甲板上，不得布置在室内 4.15 The overflow pipes and drainage pipes are generally cline downward, and the vent pipes are always cline upward.
溢流管，甲板疏排水管等应向下倾斜，对于空气管则应向上倾斜。
4.16 When the scuppers are arranged, the thickness of deck covering and heat-insulating layer are to be noted.
甲板漏水口的布置应便于排出积水，其安装要注意甲板敷料和隔热层的厚度。
4.17 Domestic water pipes and drainage water pipes etc. generally can not have removable connectors inside the cabin, except which connect to the WC-module and washing-basin.
生活管系在居住舱室内布置时，除与卫生单元和洗池连接处外一般不宜用可拆接头。特殊情况，应征得船东同意
4.18 The pipes and ducts for superstructure cabins are generally arranged in the corridors. If it’s difficult to put all these pipes and ducts together, the AC ducts and ventilation ducts can layout inside cabins, and the water pipes and steam pipes should avoid passing through the cabins at most possible.
上层建筑的管系、风管尽可能布置在内走道，内走道空间位置有困难时，优先将空调管布置在居住舱室内，压力管、蒸汽管尽可能避免穿过居住舱室。 4.19 The pipes, which pass through the cabins vertically, should avoid passing through the places where the windows will be mounted.
上下穿过居住舱室的管子，应注意隐蔽，沿舷边上下的管子应避免通过有舷窗的位置。
4.20 The pipes, which pass through the cabins’ insulation, should not have removable connectors.
绝缘层内不得布置可拆接头的管子
4.21 The pipes, which pass through the cargo holds, should be protected. 穿过货舱区的管子应加以保护。
4.22 The pipes, which are arranged near the man holes, should not influence opening the man hole covers and passing through for peoples.
人孔附近布置管子时，不得影响人孔盖的打开，也不能影响人的通过
For the pipes inside the double bottom tanks and other hull structure tanks, the pipes can pass through the light-weighted holes, but the enough space for people passing through should be considered.
对于双层底或各种船体结构舱柜内管子，可利用减轻孔布置，但要考虑到人能较方便地通过。
4.23 When the pipes are arranged, the technical characters of pipes fabricating、grinding、galvanizing and mounting should be considered. E.g. the pre-fabricated bends are generally not used in the pipes DN≤100, except some special crowded places. And the spaces between the end of vent pipes and shell should ensure the possibility of double welding etc.
管路布置时，应考虑管子制作、打磨、镀锌和安装的工艺性，如DN≤100的管子一般不用定型弯头拼接，特殊部位才选用定型弯头。透气管的端部距舷边
11/73
（或船体结构）应保持一定的距离，以保证双面焊接的可能性。
4.24 Laying the pipes above the bilge wells should be avoided , if it’s unavoidable, necessary operating spaces for cleaning the bilge wells should be ensured.
污水井上方避免布置管路，不可避免时，应保证清洁污水井所需要的操纵空间
4.25 The distance between the returned pipe and suction pipe for lubrication oil circulation tank should be laid as far as possible so as not to suck the air and impurities into the M/E.
滑油循环舱中的回油管和吸入管，应尽可能相互远离，以免气泡和杂质进入吸入管内
4.26 About the mounting positions of overboard drainage valves, some factors e.g. ship’s draft、draft mark、ship’s name、 accommodation ladder、 lifeboat davit 、 the shell plate welding seam and block connection seam should be considered.
舷外排出阀的安装位置，应考虑到船舶吃水、外板水尺、船名、舷梯、救生艇升降，船体外板拼板板缝，大合拢缝等因素。
4.27 The pipes except which belong to the refrigerating system should be away from the refrigerated room as far as possible.
非冷藏装置的管子应尽可能避开冷库。
4.28 It should be avoided that pipes go through the provision stores and clothing store, if it’s unavoidable, the removable connectors can not be fitted inside these area.
粮食库、被服舱应避免管子任意穿越，凡穿过该类舱的管子，不允许有可拆接头。
4.29 When laying pipes, it should be noted to prevent from generating air block in the water cooling system. It also should be noted to avoid siphon phenomenon occurring between the tanks and their pipes. 在布置管路过程中，应注意防止冷却系统和与热交换器连接的管子产生气囊现象，各种箱柜及其管路布置中，应注意避免虹吸现象的产生
4.30 Filling pipes are normally arranged close to board side and bulkhead and convenient to operate.
注入管应尽量布置在靠近舷边和舱壁便于操作的地方。
4.31 When laying the pipes, the possibility of fitting the pipes’ supports is to be considered. The pipes’ supports should be fitted on the hull structural components at most possible. If the supports have to be fitted on deck and bulkhead , shown as Fig.3, the supports’ pads should be added, indicated as table 5.
管路布置时，应考虑管子支架布置的可能性，应尽可能布置在船体构件上，若布置在非肋位甲板、壁板上如图3，一律加焊支架垫板如表5。
12/73
Fig 3图3
Table5 support pad 表5 支架垫板规格 No.Support angle steel side length 序号 支架角钢边长 1 L30*30*3，L40*40*4 2 L50*50*5，L65*65*6 3 L75*75*8 4 L100*75*8 Pad垫板 Φ60*8 Φ100*8 Φ110*8 Φ130*8 4.33 When pipes being arranged near the position where ship’s form changs sharply, some distance should be pre-left in order not to hit the hull structure caused by hull building tolerance.
在船体线型变化较大部位附近布管时，应预留一定距离，以防船体建造误差引起管子与船体相碰
4.34 It should be noted to avoid the collision that the pipe connecting pieces and hull bracket
plates.
应注意管路连接件与船体肘板折边的相对位置，避免相碰。
4.35 The sounding pipes should be arranged vertically with deck, and specially for the oil tanks the sounding pipes should be led to the safe places on open deck. The upper part of the sounding pipes see table 6, the anti-hitting plate or closing plate in oil tank should be made of copper plate.
测量管布置力求与甲板垂直，而对油舱应引至露天甲板上的安全位置，其下端 结构形式分别见A型图4和B型表6，油舱内防击板或封板均需用铜板制。
13/73
图4
Table 6 sound 表6 B型测量管
Antihitting Distance of Sounding plate sounding pipe pipe nominal dimension bottom end and diameter DxT anti-hitting plate 测量管通经 防击板 测量管下端与尺寸 DxT 防击板距离L ≤40 120x14 20～35 Sketch简图 Type B sounding pipe B型测量管 >40～65 120x16 15～20 4.36 The slope of steam piping and the quantity and location of drain valves or cocks are so arranged that the condensing water can be effectively drained under the condition of ship’s normal trim, zero rim (upright top up) or list not exceed 5?. 蒸汽管布置的斜度和放水阀或旋塞的数量、位置、应在船舶处于正常纵倾、正浮或横倾不超过5０时，能使蒸汽管系任何段有效地泄放凝水。
4.37 The steam piping is not allowed to go through the electric store and paint store, and also not allowed to go through cargo holds generally.
蒸汽管不得穿过灯具间和油漆间，一般也不得穿过货舱。
14/73
a) 弯模半径R b) 定型弯头半径R*
图5
4.38 For the grade III pipes which people are not easy to access or very difficult to fit and dismantle, welding sleeves to be used as connectors, and butt welding for class I and class II pipes.
对人不易到达，或拆装非常困难的III类管子，应使用焊接套管连接，I、II类管子采用对接焊。
a) The radius R of cold bent pipe 冷弯管的直径R
b) the radius R* of pre-fabricated bend 定型弯头的直径R*
5 Technical requirement of pipe processing管子加工技术要求
5.1 Specification of the equipment 设备规格
5.1.1 The pipe-bending machine should in good working condition. 弯头机械为完整状态
5.1.2 For DN≤150mm steel pipe, it’s normally cold bent by bending machine, but the pipes in special narrow places on board can use pre-fabricated bends. And for DN≥175mm seamless steel pipe, the pre-fabricated bends butt welding are normally used. 通径DN≤100mm的钢管一般情况采用冷弯机弯制，在管子安装空间狭小时可采用定型弯头焊接。通径DN≥125mm的无缝钢管应选用定型弯头对接焊。 The radius R of cold bent pipe and the radius R* of pre-fabricated bend are shown as table 7 and fig 5.
弯模半径R和定型弯头半径R*见表7和图5所示。
Table 7 The radius R of cold bent pipe and the radius R* of pre-fabricated bend
表7 弯模半径R和定型弯头半径R* Outside Cold pre-fabricated bend Nominal Remark Diameter Bent 定型弯头 Diameter 备注 管子外径 冷弯 直径 Long长 Short短 15 22 60 / / 20 27 85 / / 25 34 100 38 25 32 42 125 48 32 40 48 150 60 40
15/73
50 65 80 100 125 150 200 250 300 350 400 450 500 60 76 89 114 140 168 217 273 325 377 402 457 530 180 210 270 340 / / / / / / / 75 98 120 150 190 225 300 375 450 525 / / / 50 65 80 100 125 150 200 250 300 350 400 450 500 5.2 Technical requirement for bending pipe 管子弯制技术要求
5.2.1 Before bending the pipe, the pipe’s material should be checked if it is compliance with the drawing. The pipe should be bent and rectified according to part drawings.
管子弯制前，必须核对管子材料是否符合图纸要求。然后按管子零件图弯制校正
5.2.2 Pipe is normally bent by the way of cold bending, special cases hot bending is permitted.
管子的弯制一般采用冷弯，特殊情况允许采用热弯。 5.2.3 Water-gas pipe isn’t allowed to be hot-bent.
水煤气管不允许采用热弯。
5.2.4 Stainless steel pipe and alloy pipe normally should be cold-bent, if it needs to be hot-bent, heating stainless steel pipe should avoid carbureting, and it’s not allowed to cool alloy pipe by water which has big harden quench tendency.
不锈钢管和合金管宜冷弯，若要热弯时，不锈钢管加热应避免渗碳，而对淬硬倾向较大的合金钢管不得浇水冷却。
5.2.5 While bending seam pipe, the seam should put at the location where the deformation caused by bending is the smallest.
弯制有缝钢管时，一般应使焊缝处在因弯曲而引起变形最小的方位上。 5.2.6 While bending copper pipe, cold-bending by machine or pre-fabricated bend is normally used for DN≥15mm copper pipe. And for DN<15mm copper pipe, it’s usually bent by small handed tool.
铜管的弯制，通径≥15mm的铜管由冷弯机弯制成型，或在管子安装空间狭小时采用定型弯头。通径<15mm的铜管用手工或轻巧手工工具进行弯曲加工 5.2.7 It should be annealing treated after copper pipe and copper alloy pipe being bent. The annealing treatment temperature is 500~700℃.
铜和铜合金管冷弯弯曲后，应进行退火处理，退火温度为500~700℃。 5.2.8 The shrimp-shell type welded pipes are generally used for big diameter exhaust pipe of ship’s M/E and auxiliary engine、 smoke duct of boiler and other low-pressure
16/73
pipe system. It can be connected by seamless steel pipe or the pipes, which rolled-up with Q235-A steel plate, structural type see fig5.
虾壳式焊接接管，一般适用于船舶主、付机大口径的排气管、锅炉烟道管及其它低压管等，可用Q235—A钢扳卷或无缝钢管拼制，其结构型式为图5所示。
Fig 5图5
5.3 The technical requirement of pipe laying off and welding. 管子下料及焊接技术要求
5.3.1 For non-ferrous pipe, water gas pipe and steel pipe whose outside diameter does
17/73
not exceed 48mm, mechanical cutting is to be adopted. For steel pipe whose outside diameter exceed 48mm, except for mechanical cutting, it’s allowed to be cut and open by gas-cutting way yet. The way of cutting and opening of alloy steel pipe is to be according to material contents. After pipe being open and cut, cut should be trimmed smooth, and iron oxide and burr should be all cleaned up.
有色金属、水煤气管和外径不超过48mm的钢管，应采用机械切割。对外径超过48mm的钢管除用机械切割外，还允许使用气割方法切割和开孔。合金钢管切割和开孔的方法应根据材料成份决定。管子开孔和切割后，切口必须修整光顺，氧化铁和毛剌必须全部清除干净。 5.3.2 After the pipe has to be cut,管子切割后
表8 管端面和管子外表面的垂直公差 mm 公称通径DN DN≤100 100
钢管的对接焊、支管与总管的焊接（直三通和斜三通支管等）优先采用单面焊双面成型。焊接前宜先用亚弧焊打底。管子与法兰焊接或套管焊接应使用埋弧半自动焊或CO2气体保护焊接或手工焊等方法。
5.3.4 The connection of pipe and lap-welding steel flange should be both side welding, the dimension of weld leg should be accordance with the requirement of drawings . For the pipe which DN<15mm, it’s allowed to single side welding after being approved by ship surveying department.
管子与搭接焊钢法兰的连接应采用双面焊，焊脚尺寸应符合图纸要求。通径<15mm的管子，经验船部门同意允许单面焊。
5.3.5 For few galvanized pipe which have to be welded on site, the damaged galvanized layer of pipe outside surface because of welding should be cleaned at once and brushed by zinc-rich paint.
对少量不得不在现场焊接的镀锌管，因焊接而引起的管子外面镀锌层破坏部分应及时清理并涂上富锌漆。
5.3.6 The part of pipe welded should be smoothed before being welded, the welding slag 、 electrode coating and spraying particle should be cleaned up after pipe being welded completely, in and out ring of flange and weld seam of branch pipe should be dressed smooth.
管子焊接部位施焊前应光顺，管子焊接完工后，应清除焊渣、药粉及飞溅粒子，法兰内外圈、支管焊缝均应打磨光顺。
5.4 Pipe processing dimension allowance and inspecting specification. 管子加工尺寸公差及检查规定
18/73
5.4.1 Exterior quality at part of pipe bend 管子弯曲处的外观质量
It’s not allowed to have obvious depression formed by chafe, flute or collision on the pipe surface, for the important usage pipe, if there is flute at the bent part whose depth is less than 10% of pipe thickness, and depression depth is less than 5% of pipe outside diameter, the pipes are allowed to be used, it’s not allowed to have some defaults of clinking, mapping, folding and delaminating, it’s to be cleaned away if there are above mentioned defaults, the thinning down quantity of being cleaned part thickness should be accordance with the specification of 5.4.2 .
管子表面不应有擦伤，沟槽或碰撞形成的明显凹陷，对非重要用途的管子在弯曲处如有沟槽其深度在管壁厚度10%以下，凹陷深度不超过管子外径的5%时可允许使用。管子弯曲处的背部不得有裂纹、结疤、折叠、分层等缺陷，如有上述缺陷存在应完全清除，被清除部位壁厚减薄率，应符合5．4．2规定。 5.4.2 Circularity圆度
Pipe section circularity allowance of bent pipe shall be less than 7% or equal. 弯管所产生的管子圆度应≤7% 5.4.3 Shrinkage.收缩率
Shrinkage allowance of pipe section outside diameter at bent location shall be less than 4% or equal
管子弯曲后，其弯曲处截面外经尺寸收缩率应≤4% 。 5.4.4 Pipe thickness reduction rate after bent. 管壁减薄率 Pipe reduction rate: 管壁减薄率η<(D/3R)x100%
Reduction rate formula of actuality: 实际减薄率计算公式： η=(t-t1)/tx100%
η:---Reduction rate减薄率
D:--- Pipe outside diameter.管子外径 R:--- Bending radius mm弯曲半径mm
t:---Pipe actual average thickness. 弯曲前的管壁实际平均厚度mm
t1:---Pipe thinnest thickness mm after bent弯曲后的管壁最薄处的厚度 mm
5.4.5 Folding height折皱高度
After pipe being bent, it’s allowed even folding existing, but its height isn’t allowed to exceed 4% of pipe reality outside diameter D, it’s not allowed to have clinking, which is visible by eyes at folding part. 管子弯曲后，允许有均匀折皱存在，但其高度不得超过管子实际外径D的4%，在折皱处不得有目测可见的裂纹。
5.4.6 For the branch pipe hole opened on pipe, its location exactness、 opening size、 fairness and the connecting case of branch pipe should be checked.
对于管子开的支管孔，应检查其位置的正确性、开口大小、光顺度及支管的连接情况。
5.4.7Formation dimension of weld should conform to requirement, the height of fillet are same with each other , all weld seam require even, weld seam surface is to be transited tactful to avoid sharp angle.
焊缝成型尺寸符合要求，焊脚高度彼此相同，整条焊缝尺寸要求均匀，焊缝
19/73
表面圆滑过渡避免尖角。
5.4.8 The faults of clinking welding beading blowhole, undercut and crafer without being filled full or depression etc aren’t allowed to exist on the surface of weld seam, its also not allowed to sink down ward on pipe inside surface, if there are above mentioned faults, it’s to be repaired.
焊缝表面不应有裂纹、焊瘤、气孔、咬边及未填满的弧坑或凹陷存在，管内壁不允许塌陷，如有上述缺陷应进行修补
5.4.9 It’s not allowed to have electric arc chafe, if there are some electric arc chafe, it’s to be rooted out and repair welding for dished pocket, and the part being repaired welding should be ground smooth.
被焊接表面，不允许有电弧擦伤，如有电弧擦伤时，必须完全铲除，铲除后凹坑应预以补焊，并将补焊处打磨光顺。
5.4.10 The butt-welded joint of pipe should be processed checking with nondestructive detection or other equivalence inspection way according to rule requirement.
管子的对接焊接头，应根据规范要求进行无损探伤检查，或其它等效检查方法。
5.4.11After flange being welded completely, and before hydrostatic test, the vertical angle of flange face and pipe and the quality of flange surface are to be checked according to the requirement of table 9. 法兰焊接完毕，未进行水压试验前，按表9要求检查法兰平面与管子的垂直角度以及法兰表面质量。
5.4.12 After flange and pipe being welded together, it’s not allowed decreasing the sectional area of pipe nominal diameter, and should checking pipe insertion, welding leg dimension and welding quality.
法兰与管子焊接后，不允许减少管子通径截面积，并应检查管子插入量、焊脚尺寸及焊缝质量
5.5 Pipe processing管子加工
5.5.1 Dimension tolerance of pipe processed in accordance with table 10. 管子加工尺寸公差按表10。
Table 10 Dimension tolerance of pipe processed.
表10管子加工尺寸公差
No.序号 1 Item项目 Straight pipe 直管 Bent pipe △L ±4 L ±4 Tolerance Mm公差 Sketch略图 (1) L、h、a、θare dimensions of sketch. L、h、a、θ为图纸尺△a ±4 Remark标注 2
20/73
弯管 Bent 3 pipe 弯管 Three-dimensional 4 bent pipe 立体弯管 Branch 5 pipe 分支管 △h △L △a △h ∣θ1-θ2∣ △L △a △h △θ1 ±10 ±4 ±5 ±3 ≤20 ±4 ±4 ±4 ±10 寸. (2) △L、△h、△a、△θare tolerance between pipe measured dimensions and sketch’s dimensions. △L、△h、△a、△θ为管子测量尺寸与图纸尺寸的公差值. △θ2 △L △a △h △θ ±10 ±4 ±4 ±4 ±10 ±4 ±4 (3) Angle adjusting value is based on length . 角度校正,以长度 段为基准. Penetra6 tion pipe贯穿管 △L △a △θ ±10 6.1 Pipe connected with a branch has three types: 管子连接型式和要求 Right three-way type, oblique three-way type and bent three-way type see fig 7. 钢管焊接支管型式一般分为：直三通、斜三通、角尺三通三种型式。如图7所示。
Fig 7图7
46/73
100 125 150
114 140 168 225 250 280 170 195 225 114 140 160 10 12 12 16 16 16 -50x5 -50x5 -50x5 L50x50x4 Q235-A L50x50x4 Q235-A L50x50x4 Q235-A 11.1.5 Type E support form and dimensions are shown as fig25 and table 23
E型管子支架的型式，规格和尺寸按图25、表23。
Fig25图25
Table 23? Type E support size?
表23 E型管子支架的规格和尺寸 Pipe Nominal Dia公称通径 150 Pipe support Dimension管子支架尺寸 D 172 S 6 L 272 C 236 a 50 d 15 h 6 B 250 B1 200 B2 163 B3 200 R δ 6 6
47/73
200 250 300 350 400 223 277 330 382 432 6 6 8 8 8 330 385 440 495 544 295 350 406 460 508 50 50 60 60 60 15 15 7 8 300 350 400 450 500 200 250 300 350 400 207 254 304 350 392 200 250 300 300 300 6 6 8 8 8 6 6 8 8 8 17 10 17 10 17 10 H: Decided at site H根据现场安装高度定
11.1.2 Type standard and dimension of F type pipe support is shown as fig26 table 24
F类型管子支架的规格看图26表格24
Table26 specification and dimension of F type pipe support
表26 F类型管子支架的规格
fig26图26 Pipe Pipe support Dimension管子支架尺寸 Nominal D S L C a d h B B1 B2 B3 r1 r2 δ Dia. 150 172 6 280 244 50 15 6 250 79 163 200 40 40 6
48/73
200 250 300 350 400 223 277 330 382 432 6 6 8 8 8 330 385 440 495 544 295 350 406 460 508 50 50 60 60 60 15 15 17 17 17 7 8 10 10 10 300 350 400 450 500 90 207 200 40 40 6 110 254 250 40 40 6 130 304 300 50 50 8 140 350 300 50 50 8 160 392 300 50 50 8 Table 24? Type F support size
表24 F型管子支架的规格和尺寸
H: Decided at site
H：根据现场安装高度定
11.1.7 11.7 Type U pipe clamp form and dimensions are shown as fig 27 and table
25.
U型管夹形式，规格和尺寸按图27、表25
Fig27图27
Table 25 Type U clamp size
表25 U型管夹的规格和尺寸
Pipe dimension 管子尺寸
U clamp dimension U型管夹尺寸 49/73
Main dimension主尺寸 Nominal Outside Dia.公Dia.外径 P R d? d2 称外径 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400
Clamp type and size 管夹和尺寸 U2型 U3型 H 20 25 32 42 E 27 27 27 27 H 33 45 59 75 93 119 148 194 248 293 345 396 E 34 34 40 36 49 49 49 58 58 70 70 70 22 27 34 42 48 60 76 89 114 140 168 219 273 325 377 426 34 40 46 56 62 74 92 12 15 18 23 26 32 40 10 10 10 10 10 10 12 12 16 16 16 20 M10 M10 M10 M10 M10 M10 M12 M12 M16 M16 M16 M20 M20 M24 M24 M24 104 46 134 59 160 72 188 86 244 112 298 139 20 356 166 24 408 192 24 458 217 24 11.8 Copper pipe support form and dimensions are shown as fig 28 and table 26
铜管支架的形式，规格和尺寸按图28、表26
fig28图28
50/73
Table 26 Copper pipe support form and size
表26 铜管支架的形式，的规格和尺寸 Pipe dimension管子尺寸 Support dimension支架尺寸 Nominal Dia.公称通经 Outside Dia.外径 20 24 30 38 45 60 76 K 94 99 106 128 134 146 174 C 64 69 76 86 92 104 126 R 10 12 15 19 22.5 30 30 t 2 2 2 2 2 2 2 D 10 10 10 14 14 14 16 B x b -30x3 -30x3 -30x3 -40x4 -40x4 -40x4 -50x4 A x B Q235-A L30x30x3 L30x30x3 L30x30x3 L40x40x4 L40x40x4 L40x40x4 L50x50x4 15 20 25 32 40 50 65 11.2 Support layout principle支架布置原则
11.2.1Supports is as possible mounted on adjacent girder beam, frame, bracket etc Hull strength structural component, or its back, or face plate of solid floor, or face plate of horizontal web. Or solid floor on double bottom, If the supports aren’t mounted on above mentioned place, it need add doubling plate at the leg of support, see 4:31.
支架尽可能装焊在就近的纵桁、横梁、肋骨、肘板等船体加强构件或其背面或实肋板面板或水平桁面板或双层底实肋板上，若未落就上述情况，其支架脚需增加复板，见4．31。
11.2.2The supports of branch pipe are fitted at the location nearby main pipe as far as possible, and not effect main pipe flexible.
支管的支架尽可能设置在主管附近的地方，且不应影响主管的伸缩。
11.2.3It’s prohibited that pipe supports are directly welded on hull outside plate and within 50mm range of strength deck weld seam.
严禁将管子支架直接装焊在船体外板上和强力甲板焊缝周围50mm以内。 11.2.4Pipe support under engine room floor plate could be welded on the support leg of grating as far as possible.
机舱花钢板下的管子支架尽可能利用格栅撑脚来装焊。
11.2.5When fitting long walk bridge on the weather deck .pipe support could be welded on the constructor of long walk bridge, as far as possible.
露天甲板上设有步桥结构时，其支架尽可能装焊在步桥结构上。
11.2.6For steam pipe, exhaust pipe and heating pipe etc. which telescopic quantity is more bigger, at their telescopic part, it’s not allowed to fit rigid supports, ship clamps or strap bolt with two nuts fastening are to applied.
对蒸汽、排气和加热管等伸缩量较大的管系在其伸缩段不应设置刚性支架，应采用滑动箍或U型管夹带双螺母紧固。