精品文檔精品文檔精品文檔精品文檔精品文檔精品文檔目錄Contents一、目的Objective………………2二、編制依據(jù)Compilationbasis.………………2三、保溫施工準備及工序Insulationconstructionpreparationandprocess....2四、巖棉保溫施工程序Insulationofmineralwoolconstructionprocedure..…3五、PIR/PUR玻璃纖維的保溫施工程序PIR/PURorcellularglassconstructionTOC\o"1-5"\h\zprocedure5\o"CurrentDocument"六、保冷發(fā)泡類施工程序Foamupcoldinsulationmethodstatement7\o"CurrentDocument"七、施工質(zhì)量及安全措施Constructionqualityandsafetymeasures8八、施工機具計劃Constructionequipmentprogram12一、目的Objective為保證EOEG管道設(shè)備的保溫保冷工作的工程質(zhì)量，特編制此方案。Thisprogramiscompiledtoensuretheconstructionqualityaboutinsulationcold/heatworkofEOEGpiping.本工程主要工作量如下：管線保溫87.75m3,管線保冷32.19m3,設(shè)備保溫，0.53m3,設(shè)備保冷，&36m3二、編制依據(jù)CompilationbasisSP-8440-0000-6102SpecificationforHotInsulationSP-8440-0000-6103SpecificationforColdInsulationDEP31.46.00.31ACOUSTICINSULATIONFORPIPINGCSPC下發(fā)的施工用圖TheconstructiondrawingsissuedbyCSPC《工業(yè)設(shè)備及管道絕熱工程及驗收規(guī)范》(GBJ126-89)TheacceptancenormsofIndustrialequipmentandpipeinsulationworks(GBJ126-89)《石油化工隔熱工程施工工藝標準》(SH/73522-2003)ConstructionTechnologyforPetrochemicalinsulationstandards(SH/73522-2003)《石油化工設(shè)備和管道隔熱技術(shù)規(guī)范(SH/3010-2000)”InsulationtechnicalspecificationsforOil-chemicalequipmentandpipe"(SH/3010-2000)《石油化工施工安全技術(shù)規(guī)程》(SH3505-1999)The"constructionsafetytechnicalregulationsforoil-chemicalindustry"(SH3505-1999)《石油化工有毒，可燃介質(zhì)管道工程施工及驗收規(guī)范》(SH3501-2002)"Theacceptancenormsoftoxic,flammablemediumaboutPetroleumandChemicalpipeconstruction"(SH3501-2002)三、保溫施工準備及工序ConstructionpreparationandprocessforInsulation1、本裝置保溫工作作業(yè)時間短，合理利用施工時間是保證施工工期的關(guān)鍵。由于工藝管道大部分在預(yù)制車間內(nèi)預(yù)制，保溫工作擬根據(jù)圖紙進行提前下料。Theoperatingtimeofheatinsulationisshort,thereasonableuseofworkinghoursisthekeytomeetingtheconstructionschedule.Astheprefabricationofpipeisintheworkshop,theinsulationworktobecarriedoutaccordingtodrawingsinadvance2、施工準備Constructionpreparation絕熱所用材料，必須按設(shè)計文件的規(guī)定進行檢查驗收。絕熱材料及其制品，必須具有產(chǎn)品質(zhì)量證明書出廠合格證、理化檢測報告原件，其規(guī)格、性能應(yīng)符合設(shè)計要求。然后把符合要求的質(zhì)保書提交給PMTQC部門。Theinsulationmaterialsmustbeinspectedandacceptedaccordingtothedesigneddocuments.TheInsulationmaterialanditsproductsmusthaveanoriginalcertificateofproductqualityandfactorycertification,physicalandchemicaltestreport,itsspecifications,performanceshouldmeetthedesignrequirements,thensubmitthematerialdocumenttoQCofthePMTforapprove.對產(chǎn)品質(zhì)量有懷疑時，供貨商應(yīng)進行復(fù)驗，并提交復(fù)驗結(jié)果。Whenthereisdoubtaboutthequalityofproducts,suppliersshouldcarryoutre-inspection,andsubmittheresultsofre-inspection絕熱工程施工應(yīng)在設(shè)備及管道的強度試驗、氣密試驗合格后及防腐工程完工后進行。Theinsulationconstructionshouldbecarriedoutafterpassingthegas-tightandcorrosiontestsoftheequipmentandpiping絕熱施工前必須具備下列條件:Theinsulationmustmeetthefollowingconditionsbeforeconstruction設(shè)備管道的附屬結(jié)構(gòu)均安裝完畢。Equipmentandpipelinesubsidiarystructuresareinstalled電伴熱或熱介質(zhì)伴熱管安裝就位，并通電或試壓合格。Electrictraceheatingorhotmediumwithheat-pipeinstalledinplace,andpassthepowerorpressuretest清除被絕熱設(shè)備及管道表面的油污、鐵銹。Removeoftheoil,rustonthesurfaceofequipmentandpipeinsulation現(xiàn)場施工機具、水源、消防器具及保護用品都應(yīng)準備完畢。Theconstructionequipment,water,fireapparatusandProtectiveDevicesshouldbereadyOn-site涂層若有脫漏或劃傷應(yīng)重新除銹和涂刷。Ifthereislacunaorscratchonthecoat,itshouldbere-rustandBrushing四、巖棉保溫施工程序Insulationofmineralwoolconstructionprocedure1、施工工序：Constructionprocedure材料及機具準備topreparematerialandtoolsb．確認設(shè)備具有保溫條件后即可安裝保溫層toinstalltheinsulationlayerafterchecktheconditionofequipmentinsulation保護層預(yù)置及安裝topre-fabricationandinstalltheprotectionlayer如有拆除部分也應(yīng)按現(xiàn)場情況進行保溫恢復(fù)toreplacetheinsulationlayerifdismantleexistinginsulationlayer外保護層縫隙進行防水處理，打密封膠todowaterproofforprotectionlayerandtodosealglue清理現(xiàn)場。Todohousekeeping.2、施工工藝constructiontechniques材料準備preparematerial＞工程認定后按工程任務(wù)單準備材料topreparematerialfollowtheconstructionsheet＞核對購買材料的品種、規(guī)格、數(shù)量、有效期、確認無誤、分類存放，并做好防潮措施。Tocheckthevariety,standard,quantity,periodofvalidityofthematerial.Andconfirmallarecorrect,thenkeepthemanddampproofforthem.保溫層安裝。Installationtheinsulationlayer＞保溫層的安裝要按照圖紙要求的類型及厚度進行安裝。Toinstalltheinsulationlayerfollowtherequirementofthestyle,thickness.＞安裝時應(yīng)做好防雨防潮措施。Todowaterproofwhentoinstallationinsulationlayer.＞保溫層安裝要做到無縫隙，厚薄均勻。并與設(shè)備固定緊密。Itisrequirenogap,thicknessuniformitytoinstalltheinsulationlayer.Andfixitclosewiththeequipment.C.保護層鋁皮安裝toinstalltheprotectlayeraluminumplate＞保護層的預(yù)制要符合設(shè)計要求。Topre-fabricateprotectionlayerfollowthedesignofdrawing.＞保護層安裝時，要根據(jù)設(shè)備現(xiàn)場管口情況開除障礙，不能妨礙設(shè)備運行。Tocuttheobstaclepointfollowthenozzlesofequipmentwheninstallationprotectlayer.＞保護層安裝時，搭接應(yīng)順水，接口向下，防止雨水流入保溫層。按順序逐一安裝，固定螺絲要均勻分。Thejointpointmustdownandprotectwaterentryinsulationlayerwheninstalltheprotectlayer.Tofixtheboltsmustequality.保護層施工完畢后應(yīng)馬上進行防潮處理，用密封膠封口。Afterinstalltheprotectlayer,todothewaterproofbyusesealglueatjointpoint.五、PIR/PUR或者玻璃纖維的保溫施工程序PIR/PURorcellularglassconstructionprocedure1、施工工序：Constructionprocedurea.材料準備topreparematerialandtoolsb．管線及設(shè)備涂涮粘結(jié)劑一道tobrushthefeltglueatfaceofpipingandequipment安裝模塊及管殼toinstallthemoduleforfaceofpipingandequipment抹瑪蹄脂一層toputonalayerbyuseMATIgrease纏玻璃纖維布一層totwineonelayerbyusefiberglass抹瑪蹄脂一層toputonalayerbyuseMATIgrease保護層（鋁皮）安裝。Toinstalltheprotectlayer2、施工工藝:Constructiontechniques材料準備topreparematerial按工程任務(wù)單準備材料preparematerialbaseonworkcontents核對購買材料的品種、規(guī)格、數(shù)量、有效期、確認無誤，分類存放、并做好防潮措施。Checkthepurchasedmaterialcategory,standard,quantity,expirydate.Differentcategorymaterialshallstoreseparately,meanwhiletakemeasurekeepitfrommoisture.3、保冷層安裝coldinsulationinstall在管道及設(shè)備表面涂TN-1粘結(jié)劑一道，并及時安裝模塊及管殼，同時模塊及管殼的接縫涂上粘結(jié)劑，以保證良好的粘結(jié)。SpreadTN-1feltglueonthesurfaceofpipeorequipment,theninstallmodule&pipecasetimely.Theapertureofmoduleorpipecaseshellsealedbyfeltgluetomakesuresmoothlyconnectionwasdone.模塊及管殼應(yīng)錯縫安裝。Makesuretheapertureofmodulewillnotmeettheapertureofpipecase.在安裝好的模塊及管殼上涂上一道瑪蹄脂，涂抹時要薄厚均勻一致oEquallyspreadonelayerMATIgreaseonmodule&pipecase.在瑪蹄脂涂抹完以后要及時纏玻璃纖維布一層以達到瑪蹄脂能滲入玻璃纖維布中。AfterMATIgreasesmeared,onelayeroffiberglassshallbetwinedonitintime.SotheMATIgreasecangainenoughtimetopenetrateintofiberglass.涂抹第二道瑪蹄脂，薄厚要均勻一致。WhenspreadthesecondlayerofMATIgreasetheuniformityisstillrequired.4、保護層安裝：installprotectionlayer?根據(jù)設(shè)備的外圓周長加長30?50mm下料，環(huán)向搭接端及縱向搭接應(yīng)壓出凸筋，其環(huán)向搭接尺寸不得少于50mm。Baseonoutsideperimeteroftheobjectaddmore30-50mmtocutmaterial.Whateveratverticalorrounddirectiontheconnectionareashallhaveoverlap.Thereisatleast50mmsuperpositioninrounddirection.設(shè)備及大型貯罐金屬保護層的接縫和凸筋，應(yīng)呈棋盤形錯列布置，其環(huán)向接縫與縱向接縫互相垂直，并成整齊的直線。Forequipment&largecontainerapertureprotectionlayerinrounddirectionshallneverinthesamelinetoadjacentaperture&alwaysperpendiculartoverticalaperture.設(shè)備封頭應(yīng)按封頭的形狀大小進行西瓜形狀分瓣下料，并應(yīng)一邊壓出凸筋，另一邊為直邊搭接。Forblindcoverofequipmentcuttingthematerialshallbaseitsoutsideshapejustlikepiecesofwatermelon.保冷層外安裝金屬護殼時，應(yīng)緊貼防潮層，并采取有效措施以防止損壞里面的保冷層和防潮層.Theprotectionshellforcoldinsulationthecoldinsulationshallclosetothedampprooflayer.Workersshallpayhighlyattentiontokeepthecoldinsulation&dampprooflayerfromanybreak.立式設(shè)備、垂直管道金屬護殼，應(yīng)自下而上安裝，接縫上搭下。每道環(huán)縫均應(yīng)設(shè)“S”形夾，“S”形夾間距不大于500mm，且每道環(huán)縫不少于2個，以防金屬護殼滑墜。Theprotectionshellforstandingequipmentorverticalpipeshallinstallfromdownsidetoupside.EveryrounddirectionapertureatleastwindedbytwoStypeclampsincasetheprotectionshellfalldownmeanwhilethedistancebetweenanyStypeclampshallnotexcess500mm.外殼上用于接管、支架等的開口應(yīng)盡量開得合適，達到緊密配合。穿過保護層的開口要作好密封處理。Theopenholefromprotectionshellforconnectpipesupportmustmakesureinpropersizetoachievecloselymatch.Anybranchconnectionfrominsulationshallbesealedproperly.金屬護殼的接縫處應(yīng)嵌填密封劑或包纏密封帶。Thejointedapertureofprotectionshellshallbesealedbysealantorwindedbysealtape.金屬保護殼的平整度用1米長靠尺檢查，偏差不大于4mm。Thelevelofprotectionshellsurfaceshallbeexaminedby1mlevelgauge.Thetoleranceis4mm.金屬保護層不得有松脫、翻邊、豁口、翹縫和明顯的凹坑，環(huán)向接縫應(yīng)與管軸線垂直，縱向接縫應(yīng)與管道軸線保持平行。Theprotectionshellnotappearanyloose,turnover,damagejoint,uprisingaperture&obviousconcave.Therounddirectionjointshallverticaltoaxesofthepipe.Theverticaldirectionjointshallparalleltoaxesofpipe.六、保冷發(fā)泡類施工方案Foamupcoldinsulationmethodstatement1、施工工序Constructionprocedure材料準備preparematerial設(shè)備及管道外殼制作makemoduleforEquipment&pipeprotectionshell安裝外殼采用澆注式灌裝硬質(zhì)聚氨酯（PUR）發(fā)泡泡沫installprotectionmoduleshell,irrigatehorninessPURtofoamup修復(fù)接縫做密閉性檢查repairjuncture保護層（外殼）封閉。Protectionshellclosure2、施工工藝；Constructiontechniques材料準備preparematerial＞按工程任務(wù)單準備材料preparematerial＞核對購買材料的品種、規(guī)格、數(shù)量、有效期、確認無誤，分類存放、并做好防潮措施。Tocheckthevarietystandard,quantity,periodofvalidityofthematerial.Andconfirmallarecorrect,thenkeepthemanddampproofforthem.保護層（外殼）安裝installtheprotectlayer＞外殼的安裝即為澆注模具的安裝，根據(jù)設(shè)備的大小及管道的具體形狀，可采用分段安裝。Toinstalltheprotectlayer,itismodelinstallation.Themodelfollowthesizeandfigureofequipmentandpiping.,itiscaninstallationofsubsection

＞澆注完成，做完密閉檢查后，便可恢復(fù)保護層的完整狀態(tài)。Aftermoulding,checktheobturation,thenreplacetheprotectlayer＞保護層形成模具的寬度要和保冷層的厚度一致。Thesizeofprotectmodelissameasthecoldinsulation.保冷層安裝toinstallthecoldinsulation＞模具安裝前保證設(shè)備及管道無銹、無粉塵、無污染、無潮氣。若有露水或霜，應(yīng)予以去除和干燥。Becarefulnorust.nodirt,nopollution,nowater,Beforetoinstallthemodel.Iftherearedewandpolluteonthefaceofequipment,piping,mustcleananddry.采用現(xiàn)場發(fā)泡，將原料按比例混合均勻后，注入模具中即可。ToPourthematerialtothemodelfollowtherataandmixeduniformity.七、施工質(zhì)量及安全措施Constructionqualityandsafetymeasures1、質(zhì)量保證體系QualityOrganizationSystem材料工ilii師en,王彥晶gi管道ipia材料工ilii師en,王彥晶gi管道ipia程師Yaneieg保溫工Rmgniengine黃仁剛王雨略er設(shè)備n工YmiUeengineerMengQingli孟慶利施工隊質(zhì)檢員TeamQC2、質(zhì)量檢查QualityInspection建立健全質(zhì)保體系，充分發(fā)揮質(zhì)保體系的作用。定期進行檢查，督促工序自檢，及時糾正影響質(zhì)量、違反操作工藝要求的低、老、壞習慣。Establishasoundqualityassurancesystem,andgivefullplaytotheroleofqualityassurancesystem.Conductregularinspectionsonself-testprocessandpromptlycorrecttheimpactofthequalityprocessrequirementsviolatethelow,old,badhabits保溫質(zhì)量檢查和竣工驗收執(zhí)行GBJ126-89《工業(yè)設(shè)備及管道絕熱工程施工及驗收規(guī)范》和GB50185-93《工業(yè)設(shè)備及管道絕熱工程質(zhì)量檢驗評定標準》中的相應(yīng)條款。InsulationqualityinspectionandcompletionoftheacceptanceoftheimplementationofGBJ126-89"industrialequipmentandpipinginsulationconstructionandacceptancenorms"andGB50185-93"industrialequipmentandpipinginsulationEngineeringQualityInspectionandEvaluationStandards"inthecorrespondingprovisionsof作好原材料的復(fù)驗和檢查驗收工作，落實每批材料的使用部位，做到有帳可查并有追蹤性。Preparetherawmaterialre-inspectionandinspectionandacceptanceofworktoimplementtheuseofeachbatchofmaterials,parts,andensurethataccounttobeinvestigatedandafollow-upof保溫材料固定件布局應(yīng)符合規(guī)范要求，其焊接應(yīng)牢固。Thelayoutofthefixedpiecesofthermalinsulationmaterialshouldmeetthespecificationrequirements,weldingshouldbefirmlye.保溫材料容重允許偏差為+5%，保溫厚度允許偏差+10%(-5%)。Thermalinsulationmaterialbulkdensitytoallowdeviationof+5%,insulationthicknessTolerance+10%(-5%)絕熱層與保護層的伸縮縫和膨脹間隙，應(yīng)符合設(shè)計要求，應(yīng)檢查縫的位置、寬度、間距、膨脹方向等施工應(yīng)正確?？p內(nèi)填充物的使用溫度應(yīng)符合要求。Insulatinglayerandtheprotectivelayeroftheexpansionjointsandexpansiongapshouldbeconsistentwithdesignrequirements,shouldcheckthelocationofjoints,width,spacing,directionoftheconstructionshouldbeproperlyinflated.Theuseofsuturematerialwithinthetemperatureshouldbefilledtomeettherequirements金屬保護層的平整度用1m長靠尺進行檢查，其允許偏差不大于4mm。Metalprotectionlayerflatnesswith1mlongbyfootinspection,whichallowsdeviationislessthan4mm管道金屬保護殼的環(huán)向接縫，應(yīng)與管道軸線保持垂直，縱向接縫應(yīng)與管道軸線保持平行；設(shè)備金屬保護殼的環(huán)縫應(yīng)與縱縫互相垂直，并成整齊直線。ShellPipelinemetalprotectionringtothejointsshouldbeperpendiculartopipeaxis,theverticaljointsshouldbemaintainedinparallelwiththepipeaxis;equipment,metalprotectionshell-girthandlongitudinalseamshouldbeperpendiculartoeachother,andintoaneatstraightline保溫施工時，保溫材料敷設(shè)應(yīng)與表層鋁皮施工同步。保溫層施工完后未及時安裝保護層的，應(yīng)用塑料布進行防護以免受潮、雨淋。Insulationduringtheconstruction,insulationmaterialsshouldbelaidsimultaneouslywiththesurfaceofaluminumskinconstruction.Insulatinglayerofconstructiontoinstallprotectivelayernottimelyexhausted,theapplicationofplasticsheetingforprotection,soastoavoidmoisture,rainvertical,andintoaneatstraightlinej.安裝好的保護層嚴禁踩踏。在不可避免時應(yīng)采取防護措施。Stampedeinstalledprotectivelayerisstrictlyprohibited.Protectivemeasurestobetakenintheinevitableh.腳手架搭設(shè)不得固定于DN50以下的管線上；上料及施工時不得撞擊、踩踏電儀穿線管和接線盒。施工時不得隨意開關(guān)閥門，嚴禁拆卸設(shè)備零配件，對易損件應(yīng)進行保護。ScaffoldingshallnotbefixedinDN50putsupthefollowingpipeline;onthematerialsandconstructionshallnotimpact,stampedeelectricmeterthreadingpipeandjunctionbox.Duringtheconstructionarenotfreetoswitchvalves,non-demolitionequipment,spareparts,wearingpartsshouldbeprotectedagainst3、安全措施SafeBox現(xiàn)場絕熱施工區(qū)域，必須用警戒線拉好，無關(guān)人員嚴禁入內(nèi)ThereshouldbebarricadeonthesiteofInsulationconstruction,unrelatedpersonsprohibitedfromentering所有施工人員應(yīng)熟練掌握本工種的安全操作規(guī)程，牢固樹立“安全第一，預(yù)防為主”的觀念，進入作業(yè)區(qū)一律穿戴好勞動保護用品，佩帶風鏡、防塵帽、手套和口罩，并備有防護藥物和用具。Allconstructionpersonnelshouldbefamiliarwiththetypesofworksafetyrulestofirmlyestablishthe"safetyfirst,preventionfirst".AllthepersonalswhoisintotheareashouldwearPPE,wearinggoggles,dustcaps,glovesandmasks,andthereshouldbedrugsandequipment,protectiveC.高處作業(yè)必須戴安全帶，并搭腳手架，搭設(shè)的腳手架應(yīng)符合安全要求，并請專人檢查后方可使用；吊裝保溫材料時應(yīng)用筐或箱裝運材料，不得直接用繩索捆綁材料，吊裝下方嚴禁站人。Heightoperationmustwearsafetybelts,thesCaffoldingshouldConformtosafetyrequirements,andrequestedhandinspeCtionbeforeuse;usingbasketsorboxestohoistthethermalinsulationmaterials,thematerialsCanbedireCtlytiedwithropes,thereshouldbenonestandingunderthelifting在施工當中，每天施工結(jié)束后，要求專人對現(xiàn)場的余料、碎料進行清掃整理，使施工現(xiàn)象保持清潔衛(wèi)生，做到“工完料盡場地清”。AttheendofConstruCtionofeaChdayduringtheConstruCtion,assignsomeoneonthesCenetoCleanthedebrissothattokeepthesiteCleanandtidy.未盡事宜詳見《石油化工安全技術(shù)規(guī)程》(SH3505-1999)Unaccomplishedmatterrefersto"oil-ChemiCalSafetyTeChniCalRegulation"4、安全保證體系Safetyassurancesystem精品文檔精品文檔精品文檔精品文檔精品文檔八、施工機具計劃PlanofConstructionequipment序號SN名稱NAME數(shù)量NO.備注REMARKS1滾圓機rounder1臺set2聯(lián)合咬口機nipmachine1臺set3配電箱distributionboard5臺set4電剪刀electricshears8把pc5手槍鉆breastborer10把pc6鉗子pliers10把pc7螺絲刀Screwdriver10把pc精品文檔精品文檔精品文檔精品文檔精品文檔精品文檔有專人維護用電設(shè)備;臨時用電設(shè)備應(yīng)有良好接地正確使用電動工具，雨天施工做好防雨措施there有專人維護用電設(shè)備;臨時用電設(shè)備應(yīng)有良好接地正確使用電動工具，雨天施工做好防雨措施therespecialstafftomaintainelectricalequipment;tenelectricalequipmentshouldbewellgrounded;stiinspectionsandtheproperuseofpowertools,ratheconstructionofmeasures精品文檔附件一工作危害分析（JHA）JHARECORDFORMSWorkTaskstep工作步驟PotentialHazard潛在風險Consequences后果RiskAssessment風險評估HazardControl危害控制Sev.Prob.RiskLeveloperationhandovertopreparationstartwork工藝的工作移交和工作開始前準備。leak\liberatedpoweraccident泄漏\能量的意外釋放事故pollution\personnelinjure污染\人員傷害1CLbyCC、SC、JSAcontrol,wearcorrectPPacquaintancetheemergencycontactandsafeusemethod.通過CC、SC、JSA文件中的安全和工作，并佩戴正確的PPE,每個工作的員工都計劃和受到化學品傷害的處理。InsulationMaterialConveyance保溫材料運輸trafficaccident交通事故damageequipment'personnelcasualty設(shè)備損壞\人員傷亡4BMonlyqualifieddriveanthorizedtooperaterespvehicle有資質(zhì)的司機上崗；followspeedlirCSPCdriversafetyabsolutes遵守限速規(guī)定和禁令；materialloadandunloadfallfrom材料在裝卸過程中跌落materialdamage\personnelcasualty材料損壞\人員傷亡3BLDefemineweightofloadensurecorrecttigginisusedtaglinerestrictswingingofload.確定起載、保證正確使用索具、可限制負荷擺動弧度standclearofloadingrangechoosetheapprcstytlerotactthefitting無關(guān)人員不準進入裝卸合適的方式保護配件vehiclemalfunction車輛故障damageequipment\personnelinjure設(shè)備損壞\人員傷亡2BLinspectionofvehicleregularly車