管道油漆修补方案

1、table of content目 录一、 project general introduction工程概况二、 references 编制依据三、 preparations 准备工作四、 painting process 涂漆工艺1、 confirm the regions that need to repair and repair method确认油漆损伤部位和修补方法 2、surface preparation method表面处理方法3、painting涂漆五、 quality control and inspection 质量控制及检查六、 safety 安全七、 paint pr

2、otection油漆保护一 二 references 编制依据三 preparations 准备工作1、the design and other technical document is ready; the construction drawing is reviewed.设计及其他技术文件齐全，施工图纸业经会审；2、 construction procedure and technical instructions are completed; the safety training and technical training from international company ha

3、ve been provided.完成施工方案和技术交底，进行了安全技术教育和国际公司技术培训；3、 pipe and fittings shall have qualifications.管段应具备出厂合格证；4、 material, tools, apparatus for test and inspection, construction facility and space are ready.材料，机具，检测仪器，施工设施及场地已齐备；5、 inspection must be done during the course of anticorrosion construction,

4、 and perform the acceptance immediately after anticorrosion is completed.防腐蚀工程施工过程中，必须进行中间检查；防腐蚀工程完工后，应立即进行验收；6、 the coating shall have qualification from its manufacturer 油漆应有制造厂的质量证明书；7、 painting environmental condition shall be in accordance with the information on the product sheet. the surface

5、temperature to be 30c.above dew point relative humidity shall be less than 85%.涂装环境条件必须和产品说明书的信息一致。表面温度至少大于露点30c.。相对湿度最大植为85%。8、 selection of paint 油漆选用dc has provided the painting system suitable for this project. the selection of paint shall strictly follow dc construction painting system. paint t

6、ype, finish paint color and paint repair color should be chosen in accordance with the line list. the specific painting systems are as follows.本项目dc已经给出了适合本项目的油漆系统，油漆选择严格按照dc油漆系统进行选择施工 。油漆种类、面漆和油漆修补的颜色按照line list规定选用，主要有如下种类。详细油漆系统对照表如下：painting systemdc201a油漆系统dc201a dc201a：new steelwork，piping and

7、 fabricated equipments，shop prepare（-20 to 1200c）location 部位dc201asurface reparation表面处理abrasive blast cleaning to iso8501-1 sa2.5, (roughness 40-75microns)喷砂处理至 iso8501-1 sa2.5，粗糙度达到rz=40-75 微米coating system 涂层配套coat name涂层名称product name 产品名称dft: microns干膜厚度：微米prime coat底漆inorganic zinc-rich, inter

8、zinc 22 greenish grey, matt无机富锌底漆 interzinc 22 绿灰色，平光60-75mid-coat中间涂层mio epoxy intergard475hs gray环氧mio 中间漆 intergard 475hs, 灰色100-150top coat面漆polyurethane color：meet specs requirements聚氨酯面漆 颜色：符合规范要求60-75typical minimum/maximum dft range典型最小/最大干膜厚度范围220-300pipe supports sand blasting, painting re

9、quirement should be the same as piping,.管道支架的喷砂、涂漆与管道要求相同。dc201b：site work and repairs of steelworks,piping and fabricated equipments (-20 to 1200c)location 部位dc201bsurface preparation表面处理abrasive blast cleaning to iso8501-1 sa2.5, (roughness 40-75microns)喷砂处理至 iso8501-1 sa2.5，粗糙度达到rz=40-75 微米coatin

10、g system 涂层配套coat name涂层名称product name 产品名称dft: microns干膜厚度：微米prime coat底漆surface tolerant epoxy intergard670hs低表面处理环氧漆 intergard670hs100-150mid-coat中间漆surface tolerant epoxy intergard670hs低表面处理环氧漆 intergard670hs100-150top-coat面漆polyurethane color:meet spec”s requirements 聚氨酯面漆 颜色：符合规范要求50-75typical

11、 minimum/maximum dft range典型最小/最大干膜厚度范围250-375dc202a：galvanized surface,handrais(-5 to 600c).(can not use abrasive basting).location 部位dc202surface preparation表面处理清理基层表面油污到sspc-sp1标准要求。coating system 涂层配套coat name涂层名称product name 产品名称dft: microns干膜厚度：微米prime coat底漆蚀刻底漆 interprimer53910-25mid-coat中间漆

12、环氧底漆 intergard26930-50top-coat面漆polyurethane color: meet spec”s requirements 聚氨酯面漆 颜色：符合规范要求50-75typical minimum/maximum dft range典型最小/最大干膜厚度范围90-150painting systemdc203 油漆系统dc203dc203：steel piping and fabricated equipment under insulation （-30 to 1550c）location 部位dc203surface preparation表面处理abrasiv

13、e blast cleaning to iso8501-1 sa2.5, (roughness 40-75microns)喷砂处理至 iso8501-1 sa2.5，粗糙度达到rz=40-75 微米coating system 涂层配套coat name涂层名称product name 产品名称dft: microns干膜厚度：微米prime coat底漆phonolic epoxy intertherm228环氧酚醛高温漆 intertherm22890-120top coat面漆phonolic epoxy intertherm228环氧酚醛高温漆 intertherm22890-120t

14、ypical minimum/maximum dft range典型最小/最大干膜厚度范围180-240painting system dc204 油漆系统dc204steel piping and fabricated equipment under insulation （155 to 4000c）location 部位dc204surface preparation表面处理abrasive blast cleaning to iso8501-1 sa2.5, (roughness 40-75microns)喷砂处理至 iso8501-1 sa2.5，粗糙度达到rz=40-75 微米coa

15、ting system 涂层配套coat name涂层名称product name 产品名称dft: microns干膜厚度：微米prime coat底漆inorganic copolymer intertherm751csa冷喷铝高温漆 intertherm751csa90-120top coat面漆inorganic copolymer intertherm751csa冷喷铝高温漆 intertherm751csa90-120typical minimum/maximum dft range典型最小/最大干膜厚度范围180-2409 main equipment & tools 主要机具a

16、、主要施工工具description机具名称qty.数量wheel grinding machine砂轮磨光机as necessary按需manul blasting machine 手动喷砂机as necessary按需internal grinding machine内磨机as necessary按需power blender动力搅拌机as necessary按需scraper刮刀as necessary按需file锉刀as necessary按需wile brush钢丝刷several若干abrasive cloth铁砂布several若干paint bucket油漆桶as necess

17、ary按需brush刷子as necessary按需 b、main inspection facility 主要检测工具编号noname 名称use 用途remarks 备注1thermometer 温度计test temperature检测温度-1550, need tobe calibratedtermly 需定期校准2sling psychrometer 手摇湿度计test temperature and humidity 检测温度和湿度need to becalibrated termly需定期校准3dew point calculator 露点计算表calculate dew poi

18、nt计算露点need to becalibrated termly需定期校准4超生波测厚仪测量涂层厚度need to becalibrated termly需定期校准5holiday tester 漏涂检测仪check holidays ofcoatings 检测涂层漏涂点need to becalibrated termly需定期校准6replicate tape profile tester 复膜胶带法粗糙度检测仪check the anchorprofile of substrate检测底材表面粗糙度7tape for test cleaning 清洁度测试胶带cleaning test

19、 检测清洁度8flash magnifier 放大器9knife 刀四、 painting process 涂漆工艺local area touchup for piping 管道局部损伤及焊缝修补工艺confirm damaged positions and exact location of site weld确认油漆损伤部位以及现场焊口的具体位置inspection with pachometer & record检查：漆膜测厚仪检测并记录finish coat touchup面漆修补intermediate touchup (if needed)中间漆修补(若需)primer touc

20、hup底漆修补manual surface preparation or sandblasted 表面手工处理及喷砂处理1、 确认油漆损伤区域 confirm damage regions need to repair a、 areas need to repair需要进行涂层修补的区域area of welding seam where welding has been done after painting and unqualified local coating area caused by every kind of reason need to be repaired. gener

21、ally components shall be repaired include:对于涂装后进行焊接的焊缝区域和各种原因造成的不合格局部涂层，应进行修补，一般情况下需要进行修补的构件为：welding seam area: area after construction coating finished.焊缝区域：主要针对主要涂层已施工完毕的焊缝区域。damaged coating area: damaged by hot working transportation, lifting and loading etc. damaged local part of coating.涂层损坏区域

22、：由于热工作业和运输，吊装，装卸等原因造成的涂层损伤或损坏局部涂层部位。over thickness coating cause crack on inorganic zinc silicate coating.由于涂层厚度超厚，而导致无机硅酸锌涂层龟裂部位。local coating with defects: sagging, omission, pin hole caused by unsuitable construction.有涂层缺陷的局部涂层：由于施工过程中施工不当造成的流挂，漏涂，针孔等局部涂层的位置。seriously polluted part of coating: an

23、y contamination has already damaged coating (polluted by cement)or the local area where contamination can be removed by easy cleaning.涂层被严重污染的部位：被污染物严重污染，污染物已造成涂层损坏（被水泥污染），或污染物已无法通过简单的清洗就能除去的局部涂层区域。b、 method of painting repair涂层修补的方法 for weld seam are or damaged area of coating: use power sand paper

24、 disc to grind the weld seam area or damaged area of coating to grade st3(damaged coating has been removed entirely ), the pipe welding joint will be treated by manual blasting machine by a level of sa2.5.damaged area and unbroken area shall have a overlapping slope. overlapping area shall appear ne

25、w and fresh surface of coating to enlarge bonding force between repair coating and raw coating. repair position shall be cleaned adequately after preliminary surface treatment, then repair painting as per the whole set of painting repair system and arrive the designed film thickness. for small area,

26、 brush painting shall be used. but spray coating shall be used for mid-coating and final coating when more coating areas connected together. brushing style will be taken to the touch up works to ensure the appearance of the coating.对于焊缝区域或者涂层损坏区域：应用动力砂纸片将焊缝区域和涂层损坏区域打磨处理到st3级（被损坏的涂层应完全清除），管道焊口采用手持式喷砂

27、机，除锈等级sa2.5。损坏区域与完好区域涂层应的边缘部位应砂磨出搭接坡度，搭接区域的原涂层应砂磨漏出新鲜的涂层表面，以增加修补涂层与原涂层的结合力。修补位置基层表面处理结束后，应充分清洗该表面，然后按修补油漆配套系统进行涂层修补并达到设计要求的干膜厚度。油漆涂层修补采用刷涂，确保修补涂层的外观。 对于涂层缺陷，涂层龟裂，涂层污染的部位修补：先砂纸片，砂布或其他方法清除缺陷涂层和严重污染涂层。然后按照对该部位涂层进行砂磨和清洗，并保证搭接涂层边缘一定的搭接坡度和新鲜的涂层表面。再按照修补涂层系统进行修补，涂层修补的其他要求同上节。 c、由于固化后的无机锌涂层很难进行自覆涂，因此，对于有缺陷和损

28、坏的无机锌涂层应采用环氧富锌进行修补。 d、 被修补的涂层或基层表面应清洗干净，无污染物，如存在油污应充分清洗油污（达到sspc-sp1标准）。e、 为确保修补涂层的外观，建议较大面积的涂层采用喷涂的方法施工。注：l 检查管道外观，对所有在运输、倒运、现场焊接等过程中破坏的涂漆用记号笔做好标记，并标记出打磨处理的范围。l 确定现场焊口，未试压管段焊口以及不锈钢管的具体的位置。做好标记。2、surface preparation 表面处理surface preparation before painting涂漆前的表面处理u surface preparation request: grade.

29、 st3, thorough rust removal by hand or power machine or arrive grade sa2.5 by mechanical rust removal.表面处理粗糙度要求： st3级 彻底的手工和动力工具除锈或者采用机械除锈达到sa2.5级。u treatment by hand: unwound scale, rust and aging coating on pipes can be removed in using wire brush or rubber paper or manual machine or spade.人工处理：管道

30、表面上松散的氧化皮、锈蚀和老化涂层可用钢丝刷刷掉、砂皮纸砂去、用手工工具刮掉或铲除u power treatment: its better to use power machine than manual machine when removing scale, rust or aging coating. but it cant be used to remove the rust or scale attached to pipe surface firmly. normally used power machine includes :wire brush, impulse tools

31、, grinding machine and rubber sharpening machine. pay more attention not to polish the metal surface, especially when using power wire brush, or it will destroy the required surface roughness.动力处理：在清除松散的氧化皮、锈蚀和老化涂层时，用动力工具比用人工效果好，而且省力。但是动力工具不能除去紧紧附着在管道表面的锈蚀和氧化皮。通常采用的动力工具，包括钢丝刷、冲击工具、砂轮机及砂皮磨光机。但是必须注意，不

32、要抛光金属表面，尤其是在使用动力钢丝刷时，否则会破坏涂覆所需的表面粗糙度。u for cracked coats，grind the coat in the crack area comletely to reach required roughness ， and then commerce the repair paint work 。 对于龟裂的涂层，需将龟裂处涂层彻底打磨，并达到规定的粗糙度要求后再进行油漆的修补。 u for cracked and slightly scratched coats，do not grind too hard 。 only grind to the b

33、ase coat for repairing with interthane 990 top-coat 。对于轻微损伤的涂层，不需打磨过深，只需要适度打磨即可进行修补，可直接用interthane 990 面漆。 u the repairing area should have 3050mm adjoining area with the pre-existing coat 。 the grinding should have some gradient to insure the repaired coat connects well with the pre-existing coat。修

34、补区域与原有涂层有3050mm 的搭接，要求打磨成一定的坡度，用于修补涂层与原有涂层平滑过渡。3、painting涂漆 painting must be done in a nice weather; doing in raining, fogging, snowing and heavy dust is forbidden.涂料须选择在晴好天气的条件下施工，在雨，雾，雪和较大灰尘的条件下禁止施工。 ensure the surface to be painted is clean. the surface can be cleaned with dust collector or brush

35、 etc. the same treatment shall be done again after each film is dry. then next coating can be applied.涂料表面必须保证清洁干净。涂漆前用吸尘器，刷子等清理干净，每层涂膜干燥后需经同样处理后，方可涂下一层涂料。 ensure the seperation from other components around in the event that any contamination occur prior to painting, and especially much attention to

36、 ground pretection shall be taken in case of any soil pollution. separateing material can use tape (small range),color clothing and wood board. 涂漆前必须对周围其它部件进行隔离以免造成周围部件的污染，特别注意对地面的保护以免造成土壤的污染。隔离材料可采用胶带（小范围）、彩条布、木板等. the painting surface must be dry. the next paint can be applied only when the last p

37、aint film is complete dry.涂漆表面必须干燥。前一道涂膜实干后，方可涂下一道漆。不同温度条件下interseal 670 hs 重涂间隔时间 interseal 670 hs re-coat interval time under different temperatures温度 temp.表干 touch dry硬干 hard dry自重涂间隔re-coat by self最小 min.最大 max.108小时 hrs32小时 hrs32小时 hrs无 extended157小时 hrs26小时 hrs26小时 hrs无 extended255小时 hrs18小时 h

38、rs18小时 hrs无 extended402小时 hrs6小时 hrs6小时 hrs无 extended不同温度条件下interthane 990 表干、硬干和覆涂间隔时间：touch dry ， hard dry and re-coat interval time of interthane 990 under different temperatures温度 temp.表干 touch dry硬干 hard dry自重涂间隔re-coat by self最小 min.最大 max.55小时 hrs24小时 hrs24小时 hrs无 extended1525小时 hrs10小时 hrs10

39、小时 hrs无 extended2515小时 hrs6小时 hrs6小时 hrs无 extended401小时 hrs3小时 hrs3小时 hrs无 extended不同温度条件下interzinc22重涂间隔时间 surfacetemp 温度计touch dry表干温度hard dry硬干时间over-coating interval with recommended top-coat 推荐面漆覆涂间隔时间minimum 最短时间maximum最长时间50c30min 分钟3hrs 小时36-48hrs 小时extended 无限制150c20min 分钟90min 分钟24-36hrs 小

40、时extended 无限制250c10min 分钟60min 分钟16-24hrs 小时extended 无限制400c5min 分钟30min 分钟8-12hrs 小时extended 无限制不同温度条件下intertherm228、intergard475hs重涂间隔时间touch dry, hard dry and over-coating interval 表干，硬干，覆涂间隔时间：surfacetemp 温度计touch dry表干温度hard dry硬干时间over-coating interval with recommended top-coats 推荐面漆覆涂间隔时间mini

41、mum 最短时间maximum最长时间50c1.5 hrs16hrs 小时16hrs 小时extended 无限制150c1 hrs10 hrs10 hrs 小时extended 无限制250c1 hrs5 hrs5 hrs 小时extended 无限制intertherm 228 and 751csa layer application interval under different temperature conditions不同温度条件下intertherm228、intertherm751csa重涂间隔时间surfacetemp 温度计touch dry表干温度hard dry硬干时

42、间over-coating interval with recommended top-coat 推荐面漆覆涂间隔时间minimum 最短时间maximum最长时间100c8 hrs 小时16hrs 小时36hrs 小时5 days 天150c7hrs 小时12 hrs 小时24hrs 小时4 days 天250c5hrs 小时8 hrs 小时16hrs 小时3 days 天400c3hrs 小时6 hrs 小时16hrs 小时2 days 天五 quality control and inspection 质量控制及检查project manager项目经理qa/qc manager质检经理

43、doc. clerk资料员construction team manager施工队长quality inspector质检员construction teams各施工班组materials inspector材料员dispatcher收发员6.2 technical requirement for painting 油漆施工的技术要求为保证涂装质量，油漆的调配必须由专人操作，严格依照说明书进行调配。 the sort, color, film layer applied, thickness and the mark of the coating shall be as per the des

44、ign document.涂料的种类，颜色，涂敷的层数、厚度和标记应符合设计文件的规定； quality of coating shall according to following requirements:涂层质量应符合下列要求：a) coating shall be uniform and with identical color.涂层应均匀，颜色应一致；b) coating shall be integrity without damage and dripping.涂层应完整，无损坏，流淌；c) film applied shall firmly adhere to and fre

45、e of scale, wrinkle, porosity, pinhole and other defects.涂膜应附着牢固，无剥落，皱纹，气泡，针孔等缺陷；d) the color ring shall be applied with uniform space and identical width.涂刷色环时，应间距均匀，宽度一致。qc procedure:质量控制步骤： 1、treatment of damaged surface of pipe: qc inspector and supervision engineer shall inspect the damaged pip

46、e surface after treatment. then the next final painting can be done. the time of final painting shall be controlled in 4 hours.管道损伤面的处理：管道损伤面处理后由质检员及监理工程师检查合格后才能进行下一步底漆的涂装。并控制在4小时之内完成底漆的涂装。 2、painting choosing and ratio: it shall be done as per guideline of manufacturer and manual strictly. tag numb

47、er of paint and process of mixing shall be traced by inspector. control the mixing using life of paint.油漆的选用及配比：油漆的选用及调配严格按照厂家的指导及说明书进行，质检员需对油漆的牌号及调配过程进行跟踪，并控制油漆的混合使用寿命。3、the next painting shall only be done after the last painting finished and dried.在上一层涂层完成后必须在涂层干硬后经行下道涂层的涂装。 4、protection of paint

48、ing position: strictly prohibit other people to pollute or damage and un-dried position of painting.涂装部位的保护，严禁其他人员对未干部位的损坏及污染。六、safety 安全 obey the site regulations of dow corning. apply for fire permit before grinding works. apply for painting permit before painting work. 严格执行道康宁施工现场的管理要求，打磨工作前需办理动火

49、作业许可，油漆涂装前办理油漆涂装工作许可。 the coating shall be stored in a special warehouse which has good ventilation and be equipped with firefighting device; a warning plate “no smoke/fire”shall be set up; and no body is allowed to live in it. 涂料应在专门的仓库内储存，库房应通风良好，并应与配置消防器材，设置“严禁烟火”警示牌；库房内严禁住人。 when enter into the

50、painting site, all workers shall wear their badge, safety helmat, safety shoes, goggles, gloves and other necessary protection articals.工作人员进入油漆现场必须整齐佩带胸卡、安全帽、安全鞋、防护眼镜、防护手套等必备防护用具。 the painting site must have good lighting, the temporary wiring shall be safe and reliable and with good insulation.油漆现

51、场必须有良好照明,临时电器线路架设，要安全可靠，绝缘好。 the sandblasting tank usd for sandblasting work shall receive hydro test regularly, all pressure gauge, safety valve and etc. shall be calibrated regularly.喷砂作业用的喷砂罐应定期进行液压试验，所用的压力表安全阀等均应定期校验。 painting in a confined space, it must have a good ventilation and with designa

52、ted personnel to watch. 在封闭空间内涂漆，必须保证良好的通风，并有专人监护。 all painters should wear special mask to prevent poisoning. 所有涂装人员必须佩戴专用的口罩，以防油漆中毒。 original scaffold will be used for the painting at height, if not , elevator or ladder will be given instead as well as safety belt.登高油漆工作尽量使用原有的脚手架作业，若无脚手架采用升降机或梯子并

53、正确佩戴安全带。 strictly apply to the elevator and ladder procedure.严格遵守升降机及梯子的使用程序。七、油漆保护paint protectioninternatinal paint system is applied for steel structures, and the fabrication work will be done in the workshop and later installed on site. before entering into site, all ready products are done with

54、 primer, intermediate and finishing paint. effective protection measures will be performed for the painting works.to decrease site touch-up。本项目钢结构采用国际油漆系统，并且都在工厂预制现场安装。成品件进场前底漆、中间漆、面漆已经完成。现场的油漆保护做好有效的控制，才能减少现场油漆的修补。paint protection will be performed in three steps:油漆保护可分为三部分进行跟踪：first step: transportation a