机电安装工程冷冻水、热水、工艺冷却水管道施工方案（中英文) 23页

'******（中国）有限公司一期厂房实验楼工程WorkmethodofChilledWaterSystem冷冻水、热水、工艺冷却水系统工程施工方案2013年3月20日22/23 目录1、Overview2工程概况22Reference2编制依据23Worktechnicalprocess3施工工艺程序34．Installationofpipe3管道的安装35.Preparation5施工准备56．Theprocessingtechnologyofprefabricatedpipelines6管道预制的加工工艺67．Theproduction,installationofsupport&hanger8管道支、吊架制作安装98．GeneralStipulationsfortheInstallationofPipelines9管道安装的一般规定99．Valveinstallation10阀门的安装1010．Test,pressure-testingandblowingontheintegralityofpipeline.12管道的完整性检查、试压和吹扫1211．Pressure-testing管道的试压1312．Checkandacceptandmanagementonconstructionmaterials14施工材料的验收及管理1413．Checkandacceptofwelding14焊材验收1414．Examinationonweldingquality17焊接质量检验1715.Paintingofbracketandpipelines18支架、管道的油漆1816.安全技术措施及HSE管理Safetymeasure2222/23 1、Overview工程概况1.1Brief:工程简述：1.1.1C11-2科研楼，冷冻水系统水源来自能源中心提供，提供供回水温度8/14℃，在地下室有冷冻水管引入接口，流量为426m³/h，供MAU,FCU,工艺冷却水以及废水处理机房设备冷却用，冷冻水系统泵为2台交流量泵，一备一用，在供，回水主管之间设有压差电动调压阀，系统设计压力为0.7mpa,设计温度为9℃。1.1.2C11-2科研楼，空调热水系统水源来自能源中心提供，提供供回水温度90/48℃，在地下室有冷热管引入接口，通过管道井至六层设备间，通过板换，供MAU,FCU,RCH用，热水流量为82.0m³/h.热水系统泵为2台交流量泵，一备一用，在供，回水主管之间设有压差电动调压阀，系统设计压力为0.7mpa,设计温度为60℃。1.1.3C11-2科研楼工艺冷却水系统，水源由冷冻水泵供二到五层的机械室，冷冻水从管道井结出，其中供给每层的冷冻水流量7.2m3/h,冷冻水经过一台50KW的板换，供工艺设备用，冷却水供回水温度9/15℃，工艺冷却水系统泵为2台交流量泵，一备一用，在供，回水主管之间设有压差电动调压阀，系统设计压力为0.7mpa,设计温度为9℃。1.1.4冷冻水、热水、工艺冷却水系统中管道材料，管径DN15至DN50（包括DN50）采用无缝钢管（螺纹连接），管径大于DN50采用焊接钢管（焊接），管径小于等于DN50阀门采用螺纹连接，使用闸阀或者球阀，管径大于DN50阀门采用蝶阀，阀门类型可参照（诺华关于设备材料技术要求标准201016管道表），工艺冷却水管道采用镀锌焊接钢管，螺纹连接，无缝钢管弯头为管径的1.5倍。1．2PipeList主要工程实物量一览表名称Name规格Spec.材质Material数量QuantityFreezepipe冷冻，热水管DN300、DN350、DN250、DN200、DN150、DN125、DN100、DN80、DN65carbonsteelpipe焊接钢管About2000m约2000mFreezepipe冷冻管，热水，工艺冷却水DN50、DN25无缝钢管About3000m约3000m2Reference编制依据2.Engineeringconstruction&Acceptancespecificationforindustrialmetallicconduit《工业金属管道工程施工及验收规范》GB50235-2010Engineeringconstruction&Acceptancespecificationforsitefacilityandindustrialpipewelding《现场设备、工业管道焊接工程施工及验收规范》GB50236-2011《气焊、手工电弧焊及气体保护焊焊缝焊缝坡口的基本型式与尺寸》GB985-88《埋弧焊焊缝坡口的基本型式与尺寸》GB986-88《钢熔化焊接接头射线照相和质量分级》GB3323-87；《施工现场临时用电安全技术规范》JGJ46-88；《机械设备安装工程施工及验收通用规范》GB50231-2009；《压缩机，风机，泵安装工程施工及验收规范》GB50275-2010；《脱脂工程施工及验收规范》HG20202-2000；诺华对管道材料，焊接的施工标准以及施工设计图纸。22/23 3Worktechnicalprocess施工工艺程序Thesteelpipeinstallationshallbecarriedoutstrictlyaccordingtorelatedstandards,andatthesametimeconformstocertaintechnicalprocessandsanitationmeasures.对于金属管路的施工必须严格按照相关的标准进行，同时需遵循一定操作工艺流程和保洁措施4．Installationofpipe管道的安装操作工艺流程22/23 施工准备Operationprocess竣工验收配合吹扫气密试验管道完整性检查管道焊接施工检查竣工资料整理两漆两道管道系统试压仪表安装现场组对焊接管内的清洁度处理底漆两涂管道预制、组对焊接预制制作与单线图复核焊口编号按照单线图材料表检验材料和配件编制施工方案静电接地管材标识图纸会审焊接工艺评定持证焊工培训、考核22/23 5.Preparation施工准备Theconstructionofthisprojectshallconformstothedrawingsandinstructions.Ifnodesignrequestexists,itshallconformstocriterionandstandardsandthealterationshallfirstgettheapprovalofdesigners,i.e.,thespecificationandtype.本工程的施工应按照设计图纸和施工说明的要求进行，无设计要求时，应符合规范标准，修改部分必须经过设计单位的批准，核定材料的规格与型号。Allthoseworkerswhowilljointheinstallationshall:befamiliarwiththedrawingsandstandards,mastertheoperationrequirements,fullyawarethecharacteristicsofconstruction,assurethesafetyandquality,.Besides,theauditingandexplanationworkregardingtodrawingsandtechniquesshouldbedonewell,thetrainingforspecialworksshallbearrangedwell,thosemeasureapparatusandmachinesintheprojectshallbereadyandvariousprocessedpartsshallbecheckedandconsignedinatimelymanner.参加施工安装的人员，都必须熟悉图纸和标准，了解工程的性质，全面掌握操作要求，对施工的特点有明确的认识，确保安装的安全和质量。及时做好施工图纸的会审和技术交底工作，组织好特殊工种的资格培训，项目中所需用的机械和计量器具应齐全，各类加工件经过审核及时委托。Theconstructionsequenceofpipelinesshallbearrangedreasonablyandinthespiritoffullyunderstandthedesignpurposeofdrawingsandcarryoutworkbasedonthefollowingprinciples:groundbeforeunderground,prefabricationbeforeinstallation,firstmainpipethensub-pipe,tackleeasy,higheronesbeforehard,lowerones,firstcleansystematicallythenpassembalmment,heatpreservationandconcealmentprocess.需要合理安排管道的施工顺序，贯彻在充分理解和消化施工图纸设计意图的情况下，应本着如下的原则进行管道施工：“先地下，后地上；先预制，后安装；先主管，后支管；先难后易，先高后低；先系统吹洗，后防腐、保温、隐蔽验收”。Forthosepipelinesinstallationwithspecialrequirement,weshallfollowthecheckandacceptstandardsofconstruction.Ifdifferenttypesofworkersoverlap,thefollowingshallbefollowed:electricitygiveswaytowater,andwatertowind,andthentodrainpipe.对于有特殊要求的管道的施工工序按照设计施工验收规范标准执行，多工种交叉相碰时，应按照下述原则进行管道空间分配：“电让水，水让风，风让排水管”Allthepreparationworkshouldbefinishedaheadoftime,suchasthelayoutoflargeequipment,waterusageonsiteandthesmoothnessofroadsaswellasthesite.Allmaterialsforpipelineconstruction,nomattersuppliedbyAorB,shallhavethequalitycertificate,anditsindexesshallconformtotechnicalstandardsofstateorrelevantagenciesandworkersshallrecheckitsspecificationsandtypesinaccordancewiththedesignrequirementbeforeusage.Alltheaccessoriesi.e.pipelines,connectionsshallbepaintedinordernottobemixedfortheirmaterialsandrates.Asforthosematerialsthathavebeenusing,theyshallbepiledupintermsofnature,specificationsandrateswithasigntodifferandtheantisepsisandsafetyworkshallbedonewell.施工前的大临设施的规划，现场用水，用电的配备，道路畅通，场地的平整等应事先做好。管道工程的材料，无论甲方还是乙方供给，都应具有制造厂产品合格证，其指标应符合国家或部颁发的技术标准，使用前按照设计要求核定其规格、型号并进行外观复查验收。对本装置所使用的管材、管件等附件，按照要求进行着色标志，防止不同材质、不同等级的混淆，对已经领用的材料按照材质、规格、等级分别堆放，标牌显示。Thepilingupofallmaterialsshallbecarriedoutinlinewithitsnature,pressuregradeandspecification.Ordinarypipingmaterialscanbeputonflatdrywarehouseintheopenairwhileforspecial22/23 materials,protectiveactionsshallbetaken.Pipingconnectionsandvalvesshouldbeputindesignatedshelveswithobvioussigns.Suchaccessoriesasinstrumentshallbeprotecteddifferentlytofreefrompressureanddampness.对于所有材料的堆放，应根据材质、压力等级、规格，严格区分，一般管材可以堆放到平坦干燥的露天仓库，下边要垫枕木，对特殊材料要采取保护措施。管件、阀门要设置专用的料架，并有明显的标志，对仪表器具等附件要特殊保管，以防受压受潮。Thepreparationofmechanicalequipmentonsiteshallconformtoactualneedandstatisticalquantity.Theselectionoflocationshallmeetthedrawingsandbedonewhenconditionsarereadywithprotectivemeasures.施工现场的机具配备，根据实际需要，统计数量，使用的位置设置范围按平面图要求继续，在条件成熟的情况下进行准备，并做好机具防护措施。6．Theprocessingtechnologyofprefabricatedpipelines管道预制的加工工艺Prefabricatedpipelinesincludesthefollowingsteps,theinvestigation,cut-offofpipelines,thegrooveandbendingofscrewthread，themakingofbracket.Mindthesepointsbelow:管道预制一般包括管子的检查、切割、坡口或螺纹加工、弯制、管道支吊架制作以及管段组装等工序。预制时，需要注意如下的几点：Flangeshallbeputinplaceswhereit’seasytoscrewboltdown.法兰应置容易拧紧螺栓的位置。lTheweldingpointonpipeshallkeepfromshelvesinordertoweldandcheckl管段上的焊口应避开管架，并便于施焊与检验。lComplexpipesectionsshallfirstbemeasuredthenmakedrawingsl复杂管段应经实测后再绘制加工图。lChooseonlythosethatareeasyhandledsiphonasclosuresection.l选择易于现场调整的平面弯管作为封闭管段。lFortheprecision,correctandcompletenessofdimension,thedrawingisbettermadewithsingleline.l加工图应清楚正确，尺寸齐全，宜以单线绘制。22/23 Generalprocessingtechnologyofprefabricatedpipelines管道预制的一般工艺流程如下：防锈涂漆不合格返修焊缝检验焊接管子编号预装配管子、管件组对管子切口、坡口或螺纹加工管子调直核对材质、规格和标式Foreachstepoftheprefabricationprocess,wewillcheckcarefullythesignofpipelines,andmarktherelocatedplace.AllthosethathavepassQCshallhaveonesignbutsteelseal.对于管道预制加工的每道工序，均应该认真核对管子的有关标记，并做好材质及其它标记的移置工作，管道预制加工合格后，应有检验印记，但不得使用钢印。Whenprefabricationfinished,theinsideshallbecleanedwithoutanydust,ironscrapandothersundries.Besides,thetwoendsshallbeblockedanddepositedappropriately.管道预制加工后，应清理内部，不得留有沙土、铁屑及其它杂物，封闭两端并妥善存放。Thosewithalowcamberabilityshallbestraightenedbeforeprocess.Thecuttingofpipelinesshallconformtothedesignedsizeandmorelengthbeleftwhenre-cuttingisneeded.弯曲度差的钢管，应在加工前进行调直。钢管切削前应按照设计尺寸，如还需要切削加工时，则应留有切削余量。Pipelineshouldbecutinthisway:钢管的切割方法如下：22/23 CaliberseamlesssteelpipelineshouldbematchedwithjointtypeI;theslopeofthosewithacalibermorethanorequalstoDH80andathicknessmorethan3.5mmisbettercutwithagrindingwheelwhilewithacalibermoreorequalstoDN150shouldbetreatedwiththeblazeofacetylene.Beforetheusingofblaze,theoxidationlayerandunevenareasofslopingisbetterpolishedwithgrindingwheel.DoublepipelinesshouldbematchedwithV-shapejoint.口径无缝钢管采用Ⅰ型对接缝组对；口径大于等于DN80，壁厚在3.5mm以上的无缝钢管宜用砂轮机削坡口；口径大于等于DN150时用氧乙炔火焰打坡口，火焰打坡口的宜用砂轮机打磨氧化层和凹凸不平处，两管道用V型对接缝组对无缝合线的lThosepipesthatwillgetharderwhenquenchingcanbepolishedwhenthesaw-bedandlathearecooled.l有淬硬倾向的管子应用锯床、车床等机械表面热影响区除去，采用打磨即可。lOtherpipelinescanbecutbyacetylenel其它钢管可用氧乙炔焰切割。Theweldingofpipelines’slopingjointshallbedoneasfollows:钢管的焊接坡口按照如下方法加工：lThosepipesthatwillgetharderwhenquenchingshallbetreatedinamechanicalwayl有淬硬倾向的管子，必须用机械方法加工。lOrdinarypipescaneitherprocessedbymechanicalwayoracetylene,inwhateverwaythesurfaceshouldbepolishedfirst.l一般管道的管子，宜用机械方法加工，亦可采用氧乙炔焰加工，但必须将其表面打磨平整。Thepackagingofpipelinesshallconsiderthetransportationandinstallation,.Thebindingshallpossessenoughhardnessandstrengthen,ifnot,temporaryreinforcingmeasureshallbepreparedwiththesuspendingpointmarkedwhennecessary.管道预组装应方便运输和安装，组合件应有足够的刚度与强度，否则应有临时加固措施，必要时应标出吊装索具捆绑点的位置。Duetothelargeworkload,whenprefabricationworkfinished,signsshouldbemadeaccordingtounit,system.Thepipelinescannotoverlapinordernodistortionhappens.Thejointsshallbesealedbyplasticcover.Thepilingplacesshallhavedamp-proofandantisepsismeasures.Thosewithdifferentmaterialscannotbemixedtopreventqualitativechanges.由于管道预制工作量大，预制后管道的堆放，按照单体、系统分别放置，编好标记，不能重叠防止管道的几何变形。而且预制好的管口必须塑料管套封口，堆放的部位有防潮、防腐措施。各种材质的预制件不能混淆堆放，以防止影响材质变化。7．Theproduction,installationofsupport&hanger22/23 管道支、吊架制作安装Pipelinesupport:thebulksupportshallbefabricatedwithprofilesteelandtreatedbyhot-dipping;othersupportsshallbecombinedtype.管道支架：大型支架采用型钢制作，热镀锌处理，其它支架采用成品组合式支架。Thesizeanddimensionofthepipelinesupport&hangershallconformtodesignrequirementandtheinstallationwarpshallbewithin3mm.Theprefabricationisintheformofpiecesandrawmaterialswithdrawingsasthestandards.Marksshallbemadewithpaintorpens.管道支吊架的型式、加工尺寸等应符合设计要求，并组装的尺寸偏差不得大于3mm。支吊架的预制主要以散件、原材料的形式提供，加工以支架图集为标准，制作后在预制件上用油漆或记号笔标上支架的位号。Thescrewholeofsupport&hangershallbemadeinmechanicalwayinsteadofacetylene.Thewarpoftheholesshallbewithinthefreetolerance.Thematerialsshallbeassured.Thecoordinateswarpsshallbenomorethan10mm,elevationshallhavenopositivewarpsandthenegativewarpsshallbewithin10mm.支吊架的螺孔应采用机械钻孔，不得使用氧乙炔焰割孔。孔的加工偏差不得超过其自由公差。管道支吊架应保证其材质的正确，坐标偏差不得超过10mm，标高不宜有正偏差，负偏差不应超过10mm。Theweldinglineofsupport&hangershallbefullandthosedebrisaroundweldinglineshallberemoved.Theweldinglineofthecornershallbefullandsmoothwithitsthicknessnolessthan1.5timesofthethinpieces.Weldingdistortionshallbecorrected.支吊架的制作、安装焊缝应满焊，不得漏焊、欠焊和裂纹等缺陷，焊缝附近的飞溅物应予以处理；支吊架的角焊缝应焊肉饱满，过度圆滑，焊脚高度不低于薄件厚度的1.5倍，焊接变形必须予以矫正。Thefixingandrelocationofsupport&hangershallfollowthedrawingrequirementsstrictly.Esp.thosethatwillmovewiththetemperaturearenotallowedtomovecasually.heform,materialandlocationofthesebracketsshallbecheckedwhentheinstallationisover.支吊架的固定和支架的调整位置按照施工图纸的严格要求，特别是有冷热位移的管道固定更不能随意设置。管线安装完毕后，要按照设计要求核对支吊架的形式、材质和安装位置。8．GeneralStipulationsfortheInstallationofPipelines管道安装的一般规定Thefollowingrequirementsshallbemetwhenconductinginstallation进行管道的安装，需要满足如下的通用规定：lCivilengineeringconstructionhasfinishedandhaspassedtheco-examinationofcivilengineer,inspecting,constructionandinstallationagencies.22/23 l有关的土建工程已经施工完毕，并经过土建、监理单位、建设单位和安装单位的有关人员共同检查合格。Afterrevision,theequipmentsattachedtopipelinesarequalifiedandfixed,meetingthetubingrequirement.l与管道联结的设备经过校正合格，固定完毕，具备配管的要求。Pipelines,accessories,valves,matsareallcheckedaccordingtodesignrequirements,assuringthenatureandspecificationsaswellastypesareallcorrect.l管子、附件、阀门、垫片等已按照设计要求进行核对，其材质、规格和型号无误。Composingandsupportingpiecesofpipelinesallpassedtheexam.l管道组成件及管道支撑件等已经检验合格。Theinsideofpipelines,sections,connectionsandvalveareallcleaned,withoutdirtandsundries.l管子、管段、管件和阀门等内部已经清理干净，不留污物和杂物。Ifslopingisneededintheinstallation,itshallbedesignedaccordingtodesignrequirements.l管道安装如需要坡度，则坡度应符合设计要求。Thelocationsofflange,weldinglineandotherconnectionsshallbeconvenientforrepairandwithcertainspaceleft.l法兰、焊缝及其它连接的设置方位便于检修，其周围留有一定的空间。Allthepre-formedholesshallbedoneonceandforallandkeptclean.所有管道上的预留孔在预制中一次完成，不宜在安装后开孔，保证管腔清洁。Duringintervalsofinstallation,theopeningnozzleshallbesealedtimelyandbeforere-installation,recheckoftheinsideofthepipelines,makingsurenoproblemsexist.l管道安装工作间断时，应及时封闭敞开的管口，为继续安装对前期已经安装好管道内部进行检查，确认管内无疑问后再继续安装。9．Valveinstallation阀门的安装●Priortopurchasethevalve,weshallsubmitpertinentdocumentationapproval,andplacethepurchaseorderifapprovedby。Thevalveshallbeinstalledafterapprovalandacceptance.l所有阀门采购前向管理公司提供相关资料进行审核，得到批准后进行采购订货。阀门进场经业主及管理公司验收合格后方可安装。●TagandmarkallvalveaccordingtorequirementsofPID,single-linedrawing。l安装前根据业主和管理公司要求，针对PID图及单线图，对每个阀门进行编号挂牌。Beforeinstallation,testingofpressure,intensityanddensityshallbefinishedandqualified.Wheninstallingscrewthreadvalve,firstcleanthescrewthreadwithsteelwirebrushandpaintleadoiland22/23 enlacehempsilkorstraponit,thenusemonkeywrenchtoscrewittight.Andatthesametimemindthefollowingpoints:阀门安装前的试压、强度试验和严密性试验必须完毕，且合格。对于丝扣阀门安装丝接时，先用钢丝刷将丝口清刷干净，管螺纹上涂上铅油，缠绕上麻丝或生料带，用手将阀门拧在管道上，然后再用活动扳手把阀门上紧。同时注意如下的几点内容：Beforevalveinstallation,checkifthefillingisenrichedandifthebolthasenoughadjustingsurplus.l阀门安装前应检查填料是否充实，其压盖螺栓是否有足够的调节余量。Beforevalveinstallation,checkthetypeaccordingtodemandsanddirectionmarkerandmediumflow.l安装前应按照设计要求核对型号，并按照阀门指示标记及介质流向，确保其安装方向正确。Thehandleofvalveonlevelpipelineshallbeinstalledontheabovehalfcircle.l水平管道上的阀门，其阀杆一般宜安装在上半周范围之内。Theanglebetweenvalvehandleandaxesshallbewithin30degreeandthetie-inshallbeagile.ThepoleofThosevalveswhichhavedisplacementwithheatshallhaveequalizedmeasurestomakesureit’ssmooth.Afterinstallation,weshallchecktomakesurethatit’sagileandtheswitchiscorrect.l阀门传动杆（伸长杆）与阀门的轴线夹角不应大于30度，其接头应转动灵活。有热位移的阀门，传动杆应有补偿措施，并伸缩自如。阀门安装后，应以其操作机构和传动装置进行调整与试验，使之动作可靠，开关灵活指示准确。Wheninstallingthevalveofflange,firstpre-matchtheflangeandvalve,thenfixvalveonthepipelineinlinewiththeinstallationrequirement,andthenweldflangeonthepipe,unloadthevalve,andhaveembalmment.Atlast,assemblythevalveandflange,haveboltandnuton,adjustthelocationofmatandvalveandscrewtightincatercornerdirection.l法兰阀门安装，将配套的法兰与阀门预安装在一起，按照阀门的安装方向要求，将阀门在管道上定位，随后把法兰点焊在管道上，卸下阀门，将配套法兰与管道焊牢，并作好防腐处理。最后把阀门与配套法兰对装起来，串上螺栓，带上螺母，调整好垫片和阀门位置后，以对角线方向进行顺序紧固。Requirementsonthequalityofvalveinstallation阀门的安装质量要求：Beforevalveinstallation,firstvisualexaminationtocheckwhetheraccessoriesareready,whetherthereissigns.ie.spec.,pressureanddirection,whethertheon-offofhand-wheelisagileanddependable,whetherthesurfaceisrusted,thepaintisofforthereisadjust-roomforbolt.l阀门安装前，应进行外观检查。检查其配件附件是否齐全；有无规格、工作压力、方向等标志；手轮开启是否灵活、可靠；外表面有无锈蚀，油漆是否脱落，压盖螺栓有否留有调节余量。Generaltestingofvalveshallbeselectiveexaminedevery1outof10(thesameproductionNo.,22/23 spec.,type)andbemorethan1.Ifleakage,crackarefound,20%moreshallbeexamed,ifstillexistunqualified,thenexamonebyone.l一般性阀门试压应每批（同生产号、同规格、同型号）数量中抽查10%，且不少于1个，如有渗漏、裂纹等不合格应再抽查20%，如果仍有不合格的则逐个进行试验。Noticewheninstallvalve:whenmatchvalveandpipelinewithflangeorbolt,thevalveshallbeinstalledwhenshutwhileusingwelding,thevalveshallbekeptopenandthebottomshallbeweldedwithargon.l安装阀门注意点：当阀门安装与管道以法兰或螺纹连接时，阀门应在关闭状态下安装。当阀门与管道以焊接方式连接时，阀门不得关闭，焊缝底层宜采用氩弧焊焊接。10．Test,pressure-testingandblowingontheintegralityofpipeline.管道的完整性检查、试压和吹扫管道的完整性检查是管道试压前的必要工作，没有经过完整性检查合格认可的系统一律不得进行试压试验。完整性检查的主要依据是：Testontheintegralityofpipelineisamustbeforepressure-testingwithoutwhich,nopressure-testingshallbedone.Themainreasonsare:Photoofductwork,planeandsectionl管道系统图、平面图、剖面图lbracketphotoofpipel管道支架图lSimpleCphotol管道简易试压系统图Testontheintegralityshallbedoneasfollows:管道完整性检查的方法如下：Constructingteamcheckitsownpipelineinthelightofdrawingsl施工班组对自己施工的管线按照设计图纸自行检查。Technicianscheckeachlineofhispressure-testingsystem.l施工技术人员对试压的系统每根管线逐条复检。Whenalllinespass,weshallletQCandownerstorecheckandbeginoperateifagaintheypass试压系统中所有管线均检查合格后，申报质检、业主进行审检、质检，审检合格后进行操作Testontheintegralityofpipelineincludeshardwareandsoftware.Theformerincludesthetype,spec.,nature,elevationofpipe,theflowdirectionofvalveandhandhold,thetype,locationandslopeofbrackets,whilethelatterincludeswhethertherecord,visaandformofpipe-installationiscorrect.l22/23 完整性检查的内容分硬件和软件部分。硬件是检查现场安装管道型号、规格、材质、坐标标高、阀门的流向、手柄的方向、支吊架的型式、位置、管道的坡度、垂直度、水平度等是否符合设计和规范要求；软件是检查管道安装记录内容是否正确，完整。各种管道安装记录表、签证、记录是否正确。11．Pressure-testing管道的试压8．1Beforethecompletionofinstallation,pressure-testingshallbedonebyQCpersonnel,whichisoverhaul.管道安装完毕以后试验之前需要进行试验前的准备工作，该工作应由施工质检人员按照设计要求进行一次全面彻底的清查核对工作，核查内容包括：lWhetherinstalledinlinewithdesigndemandl管道实物安装工作是否按照设计要求全部完成。lWhetherPipelines,connections,flangesandvalvesaswellasmatsmeetdesigndemandl所安装的管道、管件、法兰、阀门、垫片是否符合设计及规范要求的规格、型号、材质、平面空间布置。lWhetherthedemandedmaterialflowintwodirectionsisinlinewithdesigndemandl在正反方向要求的阀门等介质的流向是否与设计安装方向相符。lIfdefaultsarefound,timelychangeshallbedone.Asforbracketsofpipeline,stillinlinewithdesigndemandwiththekeypointsontheheatline.对检查出来与设计要求不相符合应及时整改，对管道支吊架也按照设计要求进行检查，热力管线上的固定支架更是检查的重点。Overhaulalsogoestotheweldingofpipes,ie,对管道的焊接也应进行全面的检查，其内容包括：lWhetherweldingiscompletel管道焊接工作是否完成。lWhetherno-defectsexamshavepassedl焊口外观检查是否已经合格。Beforetesting,planshallbemadeandapprovedbyrelevantunitsandagencies.管道试验前应编制试验方案，并经过有关单位和部门审查批准以后方可进行管道系统试验。11．2．Blowingofpipelinesystem管道系统的吹扫Pressuretestingpassed,blowingworkbeginwithapreciseplanprior管道在压力试验合格后，即可进行管道吹扫清洗，吹扫清洗管道前应编制详细管道吹扫清洗方案11．3。Pipelinewelding管道的焊接12．Checkandacceptandmanagementonconstructionmaterials施工材料的验收及管理22/23 Allpartsonsiteshallpassthedesigndrawing’sdemandandhavequalitycertificateandguarantee.CheckingshallfollowthestipulationGB50235-97凡进入现场管道组成件及焊材应符合施工图设计要求，并具有产品合格证和质量保证书。必须按照GB50235-97规定对管道组成件进行检验。Whenmaterialreplacementhappensinconstruction,approvalfromdesignunitsifamustandregistertimelywiththedata.施工过程中发生代用材料的，必须取得设计单位同意签证后方可代用，并及时登记，保存好代用材料的见证资料。13．Checkandacceptofwelding焊材验收Forthesakeofweldingquality,strictcontrolandmanagementshouldbedone.为了确保工程的焊接质量，必须对焊接材料严格管理和控制。Havingreceivedsolder,thematerialandweldingengineershallco-checkthequality,andregisterthetype,spec.,outqualityandstore.Weldingmaterialssuchasweldingrod,argon,acetyleneshallpassnationalstandards.l焊材到货后，由材料责任工程师和焊接工程师共同审核质量说明书，并对焊材型号、规格、外观质量等进行验收、登记入库。焊接材料焊条、焊丝、氩气、乙炔等质量应符合国家标准或有关标准。lWeldingrodshallhavethequalitycertificate.焊条、焊丝均应有制造厂的质量合格证。lArgon,oxygenandacetylenegasshallhavequalitycertificatewiththepuritydegreeofArgonmorethan99.99%andoxygen98.5%。l氩气、氧气、乙炔气应有合格证，氩气纯度≥99.99%，氧气纯度≥98.5%。Whenstored,thesematerialsshallbearrayedinlinewiththetype,spec.,andbatchNo.,andsignsbemade.l焊材入库后，焊材保管员要按照焊材的型号牌号、规格、批号分类存放在现场焊材货架上，并做好标识牌。Thewarehouseshallhavecrediblefacilitiesi.e.,rain-proof,damp-proof.Thetemperatureshallbecontrolledabove5℃andtherelativehumiditybelow60%.Besides,onethermometer,5infra-redraylight,onefananddamp-plumingmachineshallbeequipped.l焊材库必须具有可靠的防雨、防潮条件和必备的设施。室内温度应该控制在5℃以上，相对湿度控制在60%以下，室内挂有干湿球，顶装红外线灯泡5只左右，备电扇一台，抽湿机一台。22/23 13．1．Firingofweldingrod焊条烘烤lBeforeusage,theweldingrodshallbefired:l焊条在使用前应进行烘烤，焊条烘烤如下表所示。焊条类别type烘烤温度（℃）temperature烘烤保温时间（H）heatpreservationtime恒温箱温度（℃）constanttemperature酸性焊条acidity100~1501~250碱性焊条basicity350~4002150不锈钢焊条stainlesssteel100~1251~1.550Lowhydrogenweldingrodshallbere-firedafter4hsinnormaltemperaturel低氢型焊条一般在常温下超过4小时应重新烘干。lThoseunfinishedrodsshallberecycledandusedagainwhenbaked.Thefiringtimeshallbewithin2times.l当日未用完的焊条应回收，并重新烘烤后才能使用，焊条重复烘烤次数不得超过两次。lWhenbakingtherods,suchsituationsshouldbeavoided,suddenlyputintohightemperatureorvice-virsa.烘烤焊条时禁止将焊条突然放在高温烘箱内，或从高温烘箱内突然取出冷却，防止焊条因骤冷骤热而产生药皮开裂脱皮Recordsshouldbemadeduringbaking.l焊条烘烤时应做好记录。13．2．Materialhandingandrecycling焊材发放与回收Whenhandlingtherods,solderershouldsignwith“LetterofCreditforRods”(trademark,spec,numberandpurpose)andcheckcarefullyl焊材发放时，焊工凭焊接责任师《焊条信用卡》（注明焊材牌号、规格、数量和用途）履行登记签字手续；焊工应仔细核对，防止错领。Whenreceivingrods,heatpreservationcanistermustbecarriedorwe’llrefusetogive.Thesamecanistercannotbeusedtostoredifferentbrandedrods.l焊工领用焊条时，必须携带焊条保温筒（筒内干燥无异物）否则拒绝发给，每一个焊条保温箱内不得装入两种不同牌号的焊条。Thehandingmustberecordedandtherecordsmustbetureandre-traceablel焊条发放必须有记录，记录必须真实，可追踪。Theonetimehandedrodscannotbetoomuch,thatcanbeusedupin4hours.l一次发给焊工的焊条数量不宜太多，一般控制在4小时内用完。22/23 Intheafternoon,theunusedrodsshallbereturnedexactlyandstoredseparately.Recordsshouldbemadeandafterre-bakingtheserodscanbehandedoutagainl焊条每天工作结束时剩余的焊条应如数退回，并单独分类存放，并做好回收记录，回收的焊条经重新烘烤后发出。13．3．Processrequirementsofthewelding焊接工艺要点Theseamshallbetreatedbyargon-arcweldingatfirst,thensucceededwitharcwelding.焊缝焊接采用氩弧焊打底，电焊盖面的焊接工艺方式TheweldingobjectsshallnotbebruisedbyArc.It’snotallowedtolightorendArc.Thearc-holeshallbefull.焊件表面严禁电弧擦伤，不得在坡口外的管壁上任意引弧和熄弧；焊缝的接头弧坑应填满，层间接头应错开。Afterthewelding,thedebrisandsplashingshallbecleanedandafterexamination,marksshallbemadeattheend.焊接完毕后应将熔渣、飞溅清理干净，经外观检查合格后在焊缝的最终接头附近打上焊工钢号。Environmentalrequirement：thetemperaturecan’tbelessthan-5℃,whenusingarcwelding,thewindspeedshouldbewithin8m/s.Whenthetemperaturecan’tmeetthedemands,effectivemeasuresshallbetaken.施焊环境要求：环境温度不低于-5℃，手工电弧焊时风速不大于8m/s。当环境温度不符合要求时应采取有效防护措施后施焊。lWeldinglinereturnforrepairl焊缝返修Weldinglinereturnforrepairshallbedoneastheformertechnicsandrepairpartsshallbeexamedasbefore.Thoseneedre-treatingshallbetreatedbeforereturning.焊缝的返修应按照原焊接工艺进行，返修部位按照原检验方法进行，质量要求与与焊缝相同。要求焊后处理的管道，焊缝的返修应在焊接处理前进行，若焊后处理还需要返修，返修后应再作处理Weldingtestl焊接检验Whenweldingfinish,weshallfirstexamtheweldingseam;cosmeticoftheseamshallcomplywithpertinentrequirements;quantityandqualityoftheseamshallmeetthedesignstipulationandinspectionrequirements;inaddition,weshalldrawoutthesingle-linedrawing,tagwithweldingno.,welderno.,andweldingdateandtakerecords.焊接完毕后首先应对焊缝外观检查；焊缝的外观质量应符合相关的规定；数量和质量标准应按照设计规定执行，且符合业主和管理公司提供的焊接检验要求，绘制单线图，标上焊口号、焊工编号、焊接日期，并做好焊接记录。13．4。Solderercompetence22/23 焊工资格AllthosesoldersonsiteshallhaveQualityCertificateforSolderofPressureVesselorStandardQualityCertificateforWeldersGB50236-98.参加施工的焊工，必须持有劳动部门颁发的《锅炉压力容器焊工合格证》或《GB50236-98标准的焊工合格证》，杜绝无证上岗。.Competencyexaminationshallbedoneforonsitesolderers,ie,hisweldingvariety,weldingmethodandlocationshallmatchthecertificateorwilldeemedasnocertificate.上岗焊工施焊前，应进行焊工资格审查，其施焊钢种、焊接方法和焊接位置均应与焊工本人持有的焊工合格证相符合，否则按照无证上岗论处。ForthoselowCompetencywelders（onetimeeligibilityratelessthan80%）,theircertificateshallbepausedandreturnonsiteonlyafterre-trainingandexamination对于焊接质量连续不佳的持证焊工（焊接一次合格率低于80%），应暂停该焊工作业资格，经过重新培训、考试合格后方可上岗施焊。14．Examinationonweldingquality焊接质量检验14．1．Checkoftheoutsideslot缝外观检验Thefigurationoftheslotshallbegoodandsmoothlytransitstothemainpartl焊缝成形应良好，焊缝边缘应圆滑过渡到母材。lTheoutsizeandqualityoftheslotshallconformsto:l焊缝外形尺寸及表面质量应符合下表的规定序号sequencenumber项目Item质量等级QualitygradingⅠⅡⅢⅣ1表面裂纹、气孔、夹渣、凹陷及熔合性飞溅Outsidecrack,airhole,dregs,hollowsandsplashes不允许Notallowed22/23 2咬边Projectionparts不允许Notallowed深度≤0.5mm，连续边长≤100mm，咬边总长≤10%焊缝总长Depth≤0.5mmContinuumlength≤100mm，Lengthlessthan10%ofweldingline3焊缝余高weldinglineheighte≤1+0.10b且最大为3mm≤1+0.10bandthemaximum3mme≤1+0.20b且最大为5mm4接头错边Shifting不超过壁厚的10%且不大于2mmBetween10%oftotallengthand2mm15.Paintingofbracketandpipelines支架、管道的油漆lRust-removingshallbedonebeforepainting,withthestandardreachingST3andtimelimitedwithin4hours(noovernight).l管架、管子在油漆前，其表面进行除锈处理，除锈等级达到ST3，除锈不超过4小时（且不过夜），涂刷底漆。Actionsshallbedonewhenairishugeandpartstemperaturelowerthanthecircumstancetopreventre-rustingoftheexterior.Ifrustreturns,removeit.l空气中湿度大，工件温度低于环境温度时应采取措施，防止被处理的金属表面再度生锈，如有锈迹，需要重新除锈。Beforepainting,theownershallaffirmtheworkersl上漆前应经过业主有关对口人员的确认。Theconfectingofpaintingshallbedonebyprofessionalpersonnelaccordingtotheintroductionandnorandom.MixequallyandIfcoagulationexists,firstremovethenuse.l油漆的配制要由专业人员按照油漆说明书严格进行控制，不得随意配制，使用油漆前应搅拌均匀，如果有结皮或其它杂物必须清除后方可使用。●Method:Adoptepoxyzinc-richpaint,onelayerforbottompainting,zmiddlepaintingandtoppaintingrespectively.油漆方式：采用环氧富锌漆，底漆一道、中层一道、面漆一道。管道保温绝热22/23 heatpreservationandpreventingofpipelines一、目的Aimat本指导书适用于管道绝热工程，以规范施工程序，保证施工质量。Thisinstructionisapplicabletoheatpreservationandpreventingofpipelines二、编制依据basis工业设备及管道绝热工程施工及验收规范GBJ126-89ConstructionandnodesonthecheckandacceptanceforindustrialequipmentandpipelineheatpreventingGBJ126-89三、施工步骤process绝热层施工Heat-preventingconstruction金属外保护层施工Metalprotectinglayerbuilding材料验收checkandaccepting技术交底Technicexplanation设计交底Designexplanation审图examination四、施工操作程序及技术要求：constructionprocessandtechnicaldemands序号No.施工工序Process控制要点Mainpoints技术要求及质量标准technicalandqualitydemands控制类别types1技术交底Technicexplanation技术人员应对操作人员进行技术交底，使施工人员熟悉技术要求和施工工艺TechniciansmakeworkersfamiliarwithtechnicalandqualitydemandsBR2材料验收checkandaccepting资料filesl保温材料应具备产品合格证HeatpreservationmaterialsshallhavecertificateAR22/23 绝热层材料的质量Qualityofprotectinglayer保温采用福乐斯橡塑制品B1级，导热性≤0.033w（m.k）20°c，真空吸水性≤5%，产品密度不超过55kg/m3。InsulationmaterialshallbeclassB1Armaflexplastic&rubberproduct,withthermalconductivity≤0.033w（m.k）20°c，vacuumwaterabsorption≤5%,anddensity≤55kg/m3.富乐斯橡胶保温专用520粘合剂，符合GB18583有害物质的限制要求。The520bondingagentmeetrequirementsofGB18583.Forinsulationthickness:DN15~DN25采用30mm,30mmforDN15~DN25DN32~DN65采用40mm,40mmforDN32~DN65DN80~DN200采用50mm,50mmforDN80~DN200DN250以上采用70mm,70mmforDN250andover支承件Supportsl支承件的材质,应根据管道材质确定。Thenatureofsupportsdependsonpipelinesl支承件的宽度，应小于绝热层厚度10mm，但最小不得小于20mm。Thewidthshallbe10mmlessthanheat-preventinglayersandwiththeminimum20mmCRl垂直管道的环向接缝，应为上搭下，水平管道的纵向接缝位置，应在两侧搭接，缝口朝下。Exteriorslotofverticalpipelinesshallconnectfromupperandtheverticalslotofhorizontalonesshallbeconnectedintwoendswiththeslotdownwards.l管道阀门，支、吊架支座处防潮层的作法，应按设计文件规定进行。Thevalves,brackets,hangingframesalsomustmeetthedemands.3保护层的施工Constructionofprotectinglayers外保护壳按照诺华要求，高度小于3m管道和室外管道采用外保护壳（铝皮保护壳）.l直管段金属护壳的外圆周长下料，应比绝热层外圆周长加长30-50mm，护壳环向搭接一端应压出凸筋，较大直径管道的护壳纵向搭接也应压出凸筋，其环向搭接尺寸不得小于50mm。Theexteriormetalshieldshellofstraightpipelineshallbe30-50mmlongerthantheoneofheat-preventinglayer,thejointingendofwhichshallhaveatendon.Thebiggerpipelineshallhaveatendonlengthways,nolessthan50mml水平管道金属保护层的环向接缝应沿管道坡向，搭向低处，其纵向接缝宜布置在水平中心线下方14-45°处，缝口朝下。CR22/23 Thecirclejointofhorizontalmetalshieldlayershallleadtothelowerdirectionanditslengthwaysjointshallbeatthe14-45°areabelowthehorizontallinewiththecommissuredownwards.l垂直管道金属保护层的敷设，应由下而上进行施工，接缝应上搭下。Thepavementofverticalmetalshieldlayershallbeginfromthelowersideswhilethejointfromtheupperside.l管道金属保护层的接缝除环向活动缝外，应用抽芯铆钉固定，保温管道也可用自攻螺丝固定，固定间距宜为200mm，但每道缝不得小于4个，当金属保护层采用支撑环固定时，钻孔应对准支撑环。Exceptforthecirclemovablejoint,otherjointofmetalshieldlayershouldbefixedbynail(heat-preservingpipelinecanbefixedbysnail).Thereshallbenolessthanfourineachlineandwhenmetalshieldlayerisfixedbysupportingloop,theboreshallaimatsupportingloop.质量控制点等级定义如下：GradingofqualitycontrolA-----政府质量监察部门、业主质量检查部门、工程监理部门和本施工单位质量检查部门人员到现场检查确认；Thegovernmentalqualitysupervisionagent,owner’squalitysupervisionagent,projectsupervisionunitandourqualitysupervisiondepartmentshallexamandaffirmonsiteB----本施工单位质量控制人员到现场专检确认；OurQCpersonnelexamandaffirmonsiteC----本施工单位质量控制人员到现场巡检监控；OurQCpersonnelpatrolandsupervisethesiteR----见证点，专指在实行A、B、C类检查中本公司应呈办的施工记录资料等。Witnesspointreferstotheconstructionrecordsofusintheexams,A、B、C16.安全技术措施及HSE管理Safetymeasure16.1Carryoutnationallaborlawsandregulationsandadheretocompanypoliciesandtheexisting22/23 securityrulesandregulations,totakepracticalprecautionstopreventsecurityincidents,accesstotheconstructionsitemustwearuniformandhelmet.坚持贯彻国家劳动法规政策和公司现行安全规章制度，采取切实可行的预防措施，杜绝安全事故发生，进入施工现场必须统一着装，正确使用个人劳保用品（劳保鞋、反光背心、保护眼睛、安全帽）16.2Toimplementcertifiedoperatingsystem,specialtypesofworkmusthaveapermittooperate,andcontinuouslyimprovetheworkingconditions.实行持证上岗操作制度，特殊工种操作人员必须持有特殊工种操作证，严禁无证操作，并及时做好登记。不断改善劳动条件，认真做好每个施工人员的劳动保护措施。16.3Electricityonsiteinaccordancewithuniformstandardswillbetheuseofthree-phasefive-wiredistributionbox,allelectricalequipment,andmachinerymustbegrounded.现场施工用电一律按统一标准使用三相五线制配电箱，所有电动设备、机械均需接地接零。16.4Projectteamhasafull-timesecuritystaff,thedailypatrolsofthesitesafetyhelmet,suchasprotectiveequipmentandsafetyoperationsoastoenforcethesafetyrulesandregulations.项目部设专职安全员一名，每天巡各施工点的安全帽等安全防护用品的佩带及安全操作，严格执行各项安全规章制度。16.5Hotworkpermit,electricitypermitmustbeobtainedpriortoworking.Portablefireextinguishersmustbeequipped.Ifoutsidethefirewall,thefirewallinadditiontotemporaryerection,italsoneedstobescentingaroundthewells,leakingvalvesbranchwellseasilycoveredwithstonecotton.施工现场需要动火或用电时，要动火证，用电证齐全，并备有手提式灭火器，在有明火作业时，如果在防火墙外，除要搭设临时防火墙外，还需要将周围的窨井、阀门井等容易泄露处用石棉布覆盖。16.6Wearprotectiveglasseswhilepolishinggrinders.打磨砂轮机时，要戴防护镜。16.7Assignpersonneltosupervisewhiletrialpressure,nopersonisallowedtostandinfrontofblindingplate.试压时设专人临护，严禁超压，盲板前禁止站人。16.8Nosmokingandalcoholduringworkingperiod.现场禁止吸烟，班前班中严禁饮酒。Note:Fortheliftingandinstallationworkofequipmentsrelatedtothechilledwatersystem,weshallsubmitdetailworkmethodsseparately.备注：涉及冷冻水系统的设备吊装、安装施工方案；另行编制详细的专项施工方案。22/23'