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).doc

*（中国）有限公司一期厂房实验楼工程 Work method of Chilled Water System 冷冻水、热水、工艺冷却水系统工程施工方案 2013年3月20日目 录1、Overview2工程概况22 Reference2编制依据23 Work technical process3施工工艺程序34Installation of pipe3管道的安装35. Preparation5施工准备56The processing technology of prefabricated pipelines6管道预制的加工工艺67The production, installation of support & hanger8管道支、吊架制作安装98General Stipulations for the Installation of Pipelines9管道安装的一般规定99Valve installation10阀门的安装1010Test, pressure-testing and blowing on the integrality of pipeline .12管道的完整性检查、试压和吹扫1211Pressure-testing管道的试压1312 Check and accept and management on construction materials14施工材料的验收及管理1413Check and accept of welding14焊材验收1414Examination on welding quality17焊接质量检验1715. Painting of bracket and pipelines18支架、管道的油漆1816.安全技术措施及HSE管理 Safety measure221、Overview工程概况 1.1 Brief: 工程简述：1.1.1 C11-2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426m/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。1.1.2 C11-2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82.0m/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。1.1.3 C11-2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20 10 16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。 12 Pipe List主要工程实物量一览表 名 称Name规 格Spec.材质 Material数量QuantityFreeze pipe冷冻，热水管DN300、DN350、DN250、DN200、DN150、DN125、DN100、DN80、DN65carbon steel pipe焊接钢管About 2000m约2000mFreeze pipe冷冻管，热水，工艺冷却水DN50、DN25无缝钢管About 3000m约3000m2 Reference编制依据 2. Engineering construction & Acceptance specification for industrial metallic conduit 工业金属管道工程施工及验收规范GB50235-2010Engineering construction & Acceptance specification for site facility and industrial pipe welding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。3 Work technical process施工工艺程序 The steel pipe installation shall be carried out strictly according to related standards, and at the same time conforms to certain technical process and sanitation measures.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4Installation of pipe管道的安装操作工艺流程施工准备Operation process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 5. Preparation施工准备The construction of this project shall conforms to the drawings and instructions .If no design request exists, it shall conforms to criterion and standards and the alteration shall first get the approval of designers, i.e., the specification and type.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。All those workers who will join the installation shall: be familiar with the drawings and standards, master the operation requirements, fully aware the characteristics of construction, assure the safety and quality,. Besides, the auditing and explanation work regarding to drawings and techniques should be done well, the training for special works shall be arranged well, those measure apparatus and machines in the project shall be ready and various processed parts shall be checked and consigned in a timely manner.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。 The construction sequence of pipelines shall be arranged reasonably and in the spirit of fully understand the design purpose of drawings and carry out work based on the following principles :ground before underground, prefabrication before installation, first main pipe then sub-pipe, tackle easy, higher ones before hard ,lower ones, first clean systematically then pass embalmment, heat preservation and concealment process.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”。 For those pipelines installation with special requirement, we shall follow the check and accept standards of construction .If different types of workers overlap, the following shall be followed: electricity gives way to water, and water to wind, and then to drainpipe.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”All the preparation work should be finished ahead of time, such as the lay out of large equipment, water usage on site and the smoothness of roads as well as the site. All materials for pipeline construction ,no matter supplied by A or B, shall have the quality certificate, and its indexes shall conform to technical standards of state or relevant agencies and workers shall recheck its specifications and types in accordance with the design requirement before usage. All the accessories i.e. pipelines, connections shall be painted in order not to be mixed for their materials and rates .As for those materials that have been using ,they shall be piled up in terms of nature, specifications and rates with a sign to differ and the antisepsis and safety work shall be done well.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。 The piling up of all materials shall be carried out in line with its nature, pressure grade and specification .Ordinary piping materials can be put on flat dry warehouse in the open air while for special materials, protective actions shall be taken. Piping connections and valves should be put in designated shelves with obvious signs. Such accessories as instrument shall be protected differently to free from pressure and dampness.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。The preparation of mechanical equipment on site shall conform to actual need and statistical quantity. The selection of location shall meet the drawings and be done when conditions are ready with protective measures.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。 6The processing technology of prefabricated pipelines管道预制的加工工艺 Prefabricated pipelines includes the following steps, the investigation ,cut-off of pipelines, the groove and bending of screw thread，the making of bracket. Mind these points below: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：Flange shall be put in places where its easy to screw bolt down.法兰应置容易拧紧螺栓的位置。l The welding point on pipe shall keep from shelves in order to weld and checkl 管段上的焊口应避开管架，并便于施焊与检验。l Complex pipe sections shall first be measured then make drawingsl 复杂管段应经实测后再绘制加工图。l Choose only those that are easy handled siphon as closure section.l 选择易于现场调整的平面弯管作为封闭管段。l For the precision, correct and completeness of dimension, the drawing is better made with single line.l 加工图应清楚正确，尺寸齐全，宜以单线绘制。General processing technology of prefabricated pipelines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For each step of the prefabrication process, we will check carefully the sign of pipelines, and mark the relocated place. All those that have pass QC shall have one sign but steel seal.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。When prefabrication finished, the inside shall be cleaned without any dust, iron scrap and other sundries. Besides, the two ends shall be blocked and deposited appropriately.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。Those with a low camber ability shall be straightened before process. The cutting of pipelines shall conform to the designed size and more length be left when re-cutting is needed.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。 Pipeline should be cut in this way:钢管的切割方法如下：Caliber seamless steel pipeline should be matched with joint type I; the slope of those with a caliber more than or equals to DH80 and a thickness more than 3.5mm is better cut with a grinding wheel while with a caliber more or equals to DN150 should be treated with the blaze of acetylene. Before the using of blaze, the oxidation layer and uneven areas of sloping is better polished with grinding wheel .Double pipelines should be matched with V-shape joint.口径无缝钢管采用型对接缝组对；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l Those pipes that will get harder when quenching can be polished when the saw-bed and lathe are cooled.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。l Other pipelines can be cut by acetylenel 其它钢管可用氧乙炔焰切割。The welding of pipelines sloping joint shall be done as follows:钢管的焊接坡口按照如下方法加工：l Those pipes that will get harder when quenching shall be treated in a mechanical wayl 有淬硬倾向的管子，必须用机械方法加工。l Ordinary pipes can either processed by mechanical way or acetylene, in whatever way the surface should be polished first.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。The packaging of pipelines shall consider the transportation and installation ,.The binding shall possess enough hardness and strengthen ,if not, temporary reinforcing measure shall be prepared with the suspending point marked when necessary.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。 Due to the large work load, when prefabrication work finished, signs should be made according to unit, system. The pipelines cannot overlap in order no distortion happens .The joints shall be sealed by plastic cover. The piling places shall have damp-proof and antisepsis measures. Those with different materials cannot be mixed to prevent qualitative changes.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。 7The production, installation of support & hanger管道支、吊架制作安装 Pipeline support: the bulk support shall be fabricated with profile steel and treated by hot-dipping; other supports shall be combined type .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。The size and dimension of the pipeline support & hanger shall conform to design requirement and the installation warp shall be within 3mm.The prefabrication is in the form of pieces and raw materials with drawings as the standards. Marks shall be made with paint or pens.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。 The screw hole of support & hanger shall be made in mechanical way instead of acetylene. The warp of the holes shall be within the free tolerance. The materials shall be assured. The coordinates warps shall be no more than 10mm, elevation shall have no positive warps and the negative warps shall be within 10mm.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。 The welding line of support & hanger shall be full and those debris around welding line shall be removed. The welding line of the corner shall be full and smooth with its thickness no less than 1.5 times of the thin pieces. Welding distortion shall be corrected.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。 The fixing and relocation of support & hanger shall follow the drawing requirements strictly. Esp. those that will move with the temperature are not allowed to move casually. he form, material and location of these brackets shall be checked when the installation is over.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。 8General Stipulations for the Installation of Pipelines管道安装的一般规定 The following requirements shall be met when conducting installation进行管道的安装，需要满足如下的通用规定： l Civil engineering construction has finished and has passed the co-examination of civil engineer, inspecting, construction and installation agencies.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。After revision, the equipments attached to pipelines are qualified and fixed, meeting the tubing requirement.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, mats are all checked according to design requirements, assuring the nature and specifications as well as types are all correct.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。Composing and supporting pieces of pipelines all passed the exam.l 管道组成件及管道支撑件等已经检验合格。The inside of pipelines, sections, connections and valve are all cleaned, without dirt and sundries.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。If sloping is needed in the installation, it shall be designed according to design requirements.l 管道安装如需要坡度，则坡度应符合设计要求。The locations of flange, welding line and other connections shall be convenient for repair and with certain space left.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。All the pre-formed holes shall be done once and for all and kept clean.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。During intervals of installation, the opening nozzle shall be sealed timely and before re-installation, recheck of the inside of the pipelines, making sure no problems exist.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。 9Valve installation阀门的安装 Prior to purchase the valve, we shall submit pertinent documentation approval, and place the purchase order if approved by 。The valve shall be installed after approval and acceptance.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。 Tag and mark all valve according to requirements of PID, single-line drawing。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。Before installation, testing of pressure, intensity and density shall be finished and qualified. When installing screw thread valve, first clean the screw thread with steel wire brush and paint lead oil and enlace hemp silk or strap on it, then use monkey wrench to screw it tight. And at the same time mind the following points: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：Before valve installation, check if the filling is enriched and if the bolt has enough adjusting surplus.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。Before valve installation, check the type according to demands and direction marker and medium flow.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。The handle of valve on level pipeline shall be installed on the above half circle.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。 The angle between valve handle and axes shall be within 30 degree and the tie-in shall be agile. The pole of Those valves which have displacement with heat shall have equalized measures to make sure its smooth. After installation, we shall check to make sure that its agile and the switch is correct.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。When installing the valve of flange, first pre-match the flange and valve, then fix valve on the pipeline in line with the installation requirement, and then weld flange on the pipe, unload the valve, and have embalmment. At last, assembly the valve and flange, have bolt and nut on, adjust the location of mat and valve and screw tight in catercorner direction.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。Requirements on the quality of valve installation阀门的安装质量要求：Before valve installation, first visual examination to check whether accessories are ready, whether there is signs .ie. spec., pressure and direction, whether the on-off of hand-wheel is agile and dependable, whether the surface is rusted , the paint is off or there is adjust-room for bolt.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。 General testing of valve shall be selective examined every 1 out of 10(the same production No., spec., type) and be more than 1.If leakage, crack are found ,20% more shall be examed, if still exist unqualified ,then exam one by one .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。Notice when install valve: when match valve and pipeline with flange or bolt, the valve shall be installed when shut while using welding, the valve shall be kept open and the bottom shall be welded with argon.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。10Test, pressure-testing and blowing on the integrality of pipeline .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：Test on the integrality of pipeline is a must before pressure-testing without which, no pressure-testing shall be done. The main reasons are:Photo of ductwork, plane and sectionl 管道系统图、平面图、剖面图l bracket photo of pipel 管道支架图 l SimpleC photol 管道简易试压系统图 Test on the integrality shall be done as follows:管道完整性检查的方法如下：Constructing team check its own pipeline in the light of drawingsl 施工班组对自己施工的管线按照设计图纸自行检查。Technicians check each line of his pressure-testing system.l 施工技术人员对试压的系统每根管线逐条复检。When all lines pass, we shall let QC and owners to recheck and begin operate if again they pass 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Test on the integrality of pipeline includes hardware and software .The former includes the type, spec., nature, elevation of pipe , the flow directio