1、热控专业管路敷设施工作业指导书（中英文）目录Content1、编制依据1Basicofcompilation2、工程概况及工作量1Engineeringgeneralsituationandconstructionquantity3、作业前条件和准备2Conditionsandpreparationsbeforeoperation4、作业程序、方法6Operationprocedureandmethod5、质量控制点的设置和质量通病预防12Arrangementofqualitycontrolpoint&preventionofcommonproblems6、作业的安全要求和环境条件13Ope
2、rationsafetyrequirementsandenvironmentcondition7、附录17Appendixo1 编制依据BasicofcompilationLl印尼Adipala66万千瓦超临界燃煤电站项目建筑、安装、调试工程分包合同EPCcontract1. 233-F6161S-K0101施工图总说明及图纸目录l&Cpartdescriptionandlistofdetaileddrawing2. 333-F6161S-K0302热控气源系统配置图Workingdrawingofl&Cairsupplysystem3. 333-F6161S-K0408锅炉热控导管阀门清册L
3、istofboilerl&Cconduitandvalves4. 433-F6161S-K0514汽机热控导管阀门清册Listofturbinel&Cconduitandvalves5. 5辅助厂房及其他附属系统热控导管阀门清册Listofauxiliaryplantandothersubsystemconduitandvalves2 工程概况及工作量Projectgeneralandmainquantities1 .1工程概况Engineeringgeneralsituation本工程包括锅炉、汽机主厂房及辅助厂房的热控取源管路敷设及仪用气源管路敷设。热控设计仪用气源不锈钢表管DN50、DN
4、32、DN20、14x2、e12x1.5、8x1及紫铜管6x1,仪表取样管路设计不锈钢316e16x3、e16x3.5、28x4、14x2及合金钢管12CrlMoV16x3.5、25x7。l&Csamplingconduitlayingandl&Cairpipelinelayingwillbeinstalledatboilerandturbinemainpowerhouseandauxiliaryplantinthisengineering.l&Cairpipelinewillbeusedstainlesssteelpipe(DN50sDN32、DN20、e14x2、12x1.5、8x1)an
5、dcopperpipe(06x1).|&Csamplingconduitwillbeadoptedstainlesssteelpipe(316e16x3、16x3.5、28x4、14x2)and12Cr1MoValloy-steelpipe(16x3.5,25x7)asl&Cdesign.2 .2工作量及工期Constructionquantityandconstructionperiod气源管路DN50约900米，DN32约600米，DN20约350米，414x2约800米，012x1.5约2600米，8x1约5400米，6x1紫铜管约120米。l&Cairpipeline:DN50isab
6、out900m;DN32600m;DN20350m;e14x2800m;12x1.52600m;8x15400m;and06x1copperpipe120m.仪表管路12CrlMoV合金管16x3.5约2300米，25x7约100米，不锈钢管16x3约1300米，16x3,5约900米，28x4约200米，14x2约13000米。I&Csamplingconduit:12Cr1MoValloy-steelpipee16x3.5isabout2300m,25x7100m;stainlesssteelpipe16x3isabout1300m,e16x3.5900m,428x4200m,14x213
7、000m.热控管路敷设的施工工期，根据现场施工人员和施工工器具情况，预计施工工期为8个月。Theconstructionperiodofl&Cpipelinelayingisexpectedtofinishwithin8monthsbecauseofsituationofsiteoperationandconstructionfacilities.3 作业前条件和准备Conditionsandpreparationbeforeoperation3.1 技术准备Technicalpreparation1. 1.1设计院和厂家的相关图纸审核完毕，会审中存在的问题已有明确的处理意见。Designin
8、ginstituteandmanufacturesdrawingsareexaminedcompletely.Cleartreatmentideashadgaveduringexaminationofdrawings.3. 1.2作业指导书编制完、并审批合格。Operationinstitutionhasbeenfinishedandapproved.4. 1.3施工用工机具及计量器具准备完成并经检验合格。Constructionfacilitiesandmeteringarepreparedandqualified.5. 1.4各工种作业人员进场，满足施工要求。Eachworksoperat
9、orsmayenterthesiteandmeettheconstructionrequirements.6. 1.5施工人员清楚施工界限，明确施工任务，劳动防护用品佩带齐全。Constructorsshouldclearaboutscopeofconstruction,taskofconstructionandwearcompleteprotectiveequipment.7. 1.6根据作业环境制定相应的技术和安全措施，作业前已对参加该项作业的相关人员进行安全、技术交底，交底与被交底人员双签字完毕。Accordingtoconstructionenvironment,weestablish
10、relatedtechnicalandsecuritymeasure.Operatorswhowilljointthisconstructionwillexecutetechnicaldisclosureandsecuritydisclosure.Doubleassignmentshadbeenfinished.7.1. 7开工报告审批完成Examinationofconstructionstartingreporthasbeenfinished.3.2作业人员配置Collocationofoperationpersonnel1作业人员工种Type技术员Technician数量Qty.2资格能
11、够审清图纸，领会设计思想，掌握管路敷设的工艺流Qualification程，熟悉施工质量和安环要求。Technicianshouldexaminethedrawing,understanddesignidea,mastercraftofpipelinelaying,familiarwithconstructionqualityandsafetyenvironmentrequires.职责Duty1 .全面负责管路敷设的技术工作，参加相关图纸会审，处理设计变更，编制施工作业指导书、技术、安全交底并主持交底工作。Technicianisinchargeoftechnicalworkofcondui
12、tlaying.Suchas:joinrelateddrawingjointhearing,dealwithdesignchangefile,establishoperationinstruction&technicalandsecuritydisclosure,andhostdisclosurework.2 .深入现场指导施工，及时发现和解决施工中的技术安全隐患，按照指导书的要求指导施工。Technicianshoulddeepenterintoconstructionsiteandguideconstruction;discoverandsolvethetechnicalsafetyhaz
13、ardduringtheconstructionintime;guideconstructioninaccordancewithoperationinstruction.Technicianshouldcooperatewithmonitorandteamleadertoproceedtoself-checkingworkofpipelinelaying.3 .配合班组长进行管路敷设自检工作。发现人员违章操作，有权制止，严重者可令其停工，并及时向有关领导汇报。Techniciandiscoverspersonnelunprofessionaloperationandhaspowertostop
14、thisbehavior,haspowertostoppersonnelwork,reporttorelatedleaderintime.2作业人员工种Type班组长Foreman数量Qty4资格Qualification熟悉管路敷设的工艺流程，能有效组织好施工人员按照作业指导书的要求施工，熟悉施工质量及安全环境要求。Familiarwithtechnologicalprocessofpipelinelaying,effectivelyorganizeconstructorstodoconstructioninaccordingwithoperationinstruction职责Duty1 .
15、负责组织安排管路敷设人力，物力。严格按照作业指导书的施工工艺要求，质量要求和安全环境要求进行施工。全面负责质量、安全工作。Theyareinchargeoforganizingandarranginglaborpowerandmaterialresourcesofpipelinelaying.Theyareinchargeoforganizationandarrangementofconstructionmanpowerandmaterialsource.Duringperformingconstruction,operatorsshouldstrictlyfollowconstruction
16、technologyrequirements,qualityrequirementsandsafetyenvironments.Theyarefullyinchargeofqualityandsecuritywork.2 .做好管路敷设的质量自检和工序交接工作。施工过程中，图纸不清不施工，材料不合格不施工，技术、安全不交底不施工，上一级工序验收不合格不施工。Theyshoulddowellwithqualityself-checkingandprogresshandoverworkofpipelinelaying.Iffollowingsituationhappenedduringconstr
17、uction,constructioncannotproceed.Suchasuncleardrawing,unqualifiedmaterials,non-disclosureoftechnologyandsafety,unqualifiedacceptanceofupperprocess.3.发生质量、安全事故立即上报，同时组织本班组职工按照“三不放过”的原则认真分析。Ifqualityorsafetyaccidentshappen,monitorshouldreporttohighleveldepartment.Atthesametime,monitorshouldorganizetea
18、mworkerstocarefullyanalysisasthreenoprinciple.3作业人员工种Type施工人员Operator数量Qty20资格Qualification熟练掌握管路敷设的技术、工艺要求，知道施工的质量安环要求。Knowwellaboutrequirementsoftechnologyandcraftofpipelinelayingandrequirementsofsafetyenvironment职责Duty1 .严格按照作业指导书的施工工艺要求、质量要求和安全环境要求进行施工。Theyshouldexecuteconstructioninaccordingwit
19、hconstructiontechnologyrequirements,qualityrequirementsandsecurityenvironmentrequirementsinoperationinstrument.2 .爱护施工所用工器具，严格按照操作规程作业。发生质量、安全事故应保护好现场，并迅速告知有关领导，做好处理工作。Takecareofallconstructiontoolsandstrictlyconstructfollowoperationrules.Ifqualityorsafetyaccidentshappen,operatorsshouldprotectthesit
20、eandreportrelatedleaderanddealwiththesituation.3 .有疑难问题有权向技术人员、班组长请示解决办法，对自己的施工质量全面负责，对不正确、不明确的指挥有权不执行。Constructorscouldgethelpandsolutionformtechnicianormonitororteamleader.Operatorsareinchargeoftheirownconstructionquality.Constructorscannotexecutesomeorderswhichareunclearorincorrect.4 .焊工持证上岗。Weld
21、ershouldhaverelatedlicense.3.3作业工器具constructionfacilities序号No.名称Name型号规格Model&specification数量Qty.备注Remark1电焊机Electricwelder直流DC22角向砂轮机Anglegrinder(p100mm63水平尺Levelruler600mm44手枪电钻Electricpistoldrillq)13mm25绕线器Winder10m46液压弯管器Hydraulicpipe-bender组合多用Combinedtype17钢卷尺Steeltap5m48手动弯管器Manualpipe-bender
22、14、16、859焊线及焊把Weldingwire&holder4氢弧焊Argon-arcwelding10无齿锯Toothlesssaw111锯弓Sawbow212割管刀Pipecutter853.4主要材料Primarymaterials槽钢、角铁、仪表管、气源管及安装附件等。U-steel,angeliron,l&Csamplingconduit,l&Cairpipe,installationaccessoriesandsoon3. 5施工条件Constructioncondition3.5 .1所有施工人员都经过安全技术交底并熟悉了施工现场。Alloperatorsshouldpass
23、securitytechnicaldisclosureandfamiliaraboutconstructionsite.3.6 .2个人工具及劳动防护用品、用具配备齐全。Personaltoolsandsafetyequipandproductsarecomplete.1.1.1 5.3管道及其设备基本安装完。Installationofpipelineandotherfacilitieshadbasicallycompleted.1.5.4 平台、梯子、走台基本齐全。Platform,laddersandwalkingboardarebasicallycomplete.1.5.5 阀门及导管
24、材质分析完。Materialsqualityofvalvesandconduitwereanalyzed.3. 5.6具备施工及照明用电。Electricforconstructionandlightingarecomplete.4作业程序、方法Operationprocedureandmethod4.1 作业程序operationprocedure外观检查b府庙获用导管吹扫用管路支吊架制作安装H导管弯第t|导路敷设I-丽一|导管连接用骨路刷漆H管路（阀门）挂牌Visualinspectionj忖entificationofmaterialqualityHPurgeofconduihFabri
25、cationandinstallationofpipelinesupportsandhangers|T|Conduitbending|一Guidepassagelayind7Fasten|T|Conduitconnecti痴ijpipelinemoppingl-pipeline（vake）hangtag4. 2施工方法及要求Constructionmethodsandrequirements4. 2.1导管使用前的准备Preparationbeforeusingconduit导管使用前应对其进行外观检查，导管外表无裂纹、伤痕和严重腐蚀等缺陷；检查导管平直度；管件无机械损伤及铸造缺陷，检验椭圆度
26、；仪表管表面无锈斑。Carryoutvisualinspectionpriortousingconduit,andmakesurethatoutsideofconduitwithoutflawless,scar,seriouscorrosionetc.defects;inspectconduitstraightness;pipefittingwithoutmechanicalinjuryandfoundrydefectandinspectovality;surfaceofl&Cconduitwithoutrust.不锈钢管和合金管通过金属实验室专业人员对其进行100%光谱复查，鉴定导管材质，按
27、照设计院导管阀门清册选择相应规格和材质的导管。Stainlesssteeltubeandalloy-steelpipeshouldbepassed100%spectrumreexaminationbymetallaboratoryprofessional.Wewillchooserelevantstandardandmaterialconduitinaccordingwithlistofl&Cconduitandvalve.用干净布浸以洗料，用钢丝带着穿过导管来回拉擦，除净管内积垢。清洗后导管两端用胶布封好，防止污物进入管内。Cleanclothwhichisdippedtowashingwa
28、susedtocleanconduitinsidescalewithsteelwire.Conduitbothendsshouldbesealwithtapetoavoiddirtenterintoconduit.4. 2.2管路支吊架制作安装Fabricationandinstallationofpipelinesupportsandhangers技术员根据实际位置，管道敷设数目，确定支吊架形式，通常使用L40x4（或L50x5）角钢（或花边角钢）；施工人员根据施工图下料，在敷设管子的角钢上等距离钻孔，孔距为管径2（4）倍，孔径为6mm；焊接组合，角钢边缘处理光滑，焊缝饱满；清除焊皮，并用钢
29、刷除锈；先刷一遍防锈漆，等干后再刷一遍银粉漆。管路支架间距均匀。Accordingtopracticalpositionandnumbersofpipelinelaying,techniciansconfirmformofsupportandhanger,weadoptL40x4(orL50x5)angleiron(angleironwithlace)ingeneralsituation.Constructorsdomaterialspreparationasconstructiondrawing.Angleironwhichisusedtolaypipelinesshouldbedrille
30、dholeswithequidistance.Distancebetweenofholesshallbetwiceorfourtimeslargerthanpipediameter,borediameteris6mm.Combinationbywelding,smoothanglesteeledge,plumpweldjoint.Clearawayweldingcoverandremoverustwithsteelbrush.Brushrustresistantcoatingandthenbrushsilverpaint.Pipelinesupportsspacingshouldbeunifo
31、rm根据不同支撑面确定安装形式，钢构件采用焊接，混凝土墙采用膨胀螺栓固定；将支吊架牢固地安装于支撑面上，坡度符合规程要求，横平竖直，水平段间距41.5m,竖直段42m均匀布置；焊接时，烧坏的油漆表面要补刷油漆。Accordingtodifferentbearingsurfaces,weconfirminstallationform.Steelmemberisadoptedweldingconnectionandconcretewallsarefasteningwithexpansionbolts.Supportsandhangersshouldbefastenedatbearingsurfac
32、esandgradientshouldmeettheregulationrequirements:horizontalseparationdistance1.5m,verticalsection2m.Appearanceshouldbeperfect.Burnedoutpaintsurfaceshouldberepairedwithpaint.管路固定支架不允许焊接在承压容器、管道及需要拆卸的设备上，必须在主设备或管道上固定时采用U形螺栓或抱箍固定。管路支架禁止压在设备上，以免影响主设备的机械强度。Pipelinepermanentsupporthasnotbeenweldedatpressu
33、re-bearingcontainer,pipelineandneedknocked-downequipment.ItwilladoptUboltorclampboltwhenitmustbefastenatmainequipmentorpipeline.Pipelinesupportprohibittoweighonequipmentinordertoavoidinfluencingmechanicalstrengthofmainequipment4. 2.3管路弯制Pipelinebending导管的弯制均采用冷弯法弯制。采用相应的弯制工具，液压弯管器或是手动弯管器。弯制后，管壁上应无裂痕
34、、凹坑、皱褶等现象。Duringfabrication,coldbendingmethodwillbeadopted.Adoptrelevantbendtoolssuchashydraulicpipebenderormotorpipebender.Afterfabrication,tubewallshouldbewithoutcrack,pit,rugaetc.phenomenon.导管的弯曲弧度不宜太小，否则会使导管的椭圆度增大，易造成导管损伤。管子的弯曲半径，对于金属仪表导管应不小于其外径的3倍，椭圆度小于10%。Conduitbendradianshouldnotsosmalltoavo
35、idenlargingconduitovalityanddamagingconduit.Bendradianofmetall&Cconduitshouldisnotlessthan3timesoutdiameterandovalityshouldbelessthan10%.4. 2,4管路敷设Pipelinelaying管路的敷设应根据取样点和压力仪表的位置进行合理布置，并尽可能减少交叉；管路尽量以最短距离进行敷设，以便增加测量的准确性；管路避免敷设在易受机械损伤、潮湿、腐蚀、震动附近，并敷设在便于检修的地方；油管路敷设时，应远离热表面，严禁将管路平行敷设在热表面上部，油管路与热表面交叉布置时
36、，应留出2150mm的安全距离；管路应尽量集中敷设，其路径一般与主体设备平行，禁止在地面敷设，如必须敷设时，应设有专门沟道。当管路须穿墙敷设时，应加装保护管。Accordingtosamplingpointandpressureinstrumentposition,pipelinelayingshouldbearrangedproperlyandreducedcrossover.Pipelinelayingshouldbeasshortaspossibleaswecaninordertoincreasemeasureveracity.Pipelineshouldavoidlayingbehin
37、dthesepositionasfollows:easilyattachedbymachine,moist,corrode,andshake.Pipelineshouldbelaidateasilyexamineposition.Whenlayingoilpipe,itshouldfarfromhotsurfaceandstrictlyparallellayabovehotsurface.Whenarrangingoilpipelineandhotsurfacecrossing,safetyspaceshouldbenotlessthan150mm.Pipelinelayingarecentr
38、alizedanditslineparallellargeequipmentingeneralsituation.Strictlyprohibitlayingontheground.Ifpipelinehavetolayontheground,specialtrenchshouldbeset.Ifpipelinelayinghavetopassthroughwall,protectivepipeshouldbeadded.测量管路长度，压力测量管路长度S150m,微压真空测量管路4100m,水位流量等差压测量管路450m；气体包括炉风压管路及汽轮机真空、氢气等测量管路管路向上敷设，测量仪表(变
39、送器)的安装位置一般应高于测点。无论是向上还是向下敷设，由取源装置引出时，先向上引出高度不小于6mm。液体测量管路向下敷设，测量仪表一般低于测点位置，如果测量管路向上敷设，就应在最高点加装排气门。油系统及酸碱测量管路敷设时应向下倾斜，不允许加装气门。流量、液位测量的管路必须向下敷设，并加装排污门。蒸汽测量管路的敷设与液体测量管路基本相同，一次门前和后的管路总长应不小于3m。Measurepipelinelength:pressuresurveypipelinelength150m;micropressurevacuummeasurepipelinelength100m;waterlevelan
40、ddischargeetc.differentialpressuremeasurementpipeline50m.I&Cairpipelinecontainboilerairpressurepipelineandturbinevacuumandhydrogenetc.measuringpipeline.Measuringpipelineshouldbeuplaid.Installationpositionofmeasuringinstrument(transmitter)ishigherthanmeasuringpointingeneralsituation.Wheninstallingsam
41、plingdevices,elicitationofpipesshouldbehigherthan6mmandbeuplaidnomatterwhatkindofmeasuringpipelinelaying.Liquidmeasuringpipelineshouldbedownlaid.Installationpositionofmeasuringinstrumentislowerthanmeasuringpoint.Ifliquidmeasuringpipelineisuplaid,exhaustvalveshouldbeaddedatthepeak.Oilsystemandacid-ba
42、semeasuringpipelineshouldbedownlaidandshouldhavenotaddexhaustvalve.Flowandliquidlevelmeasuringpipelineshouldbedownlaidandhaveexhaustvalve.Layingofsteammeasuringpipelineisthesamethatofliquid.Overallpipelinelengthoffrontandbackprimaryvalveshouldnotbelessthan3m.管路沿水平敷设应有一定的坡度。差压管路的坡度应大于1：12,其他管路应大于1：10
43、0；当其他管路与差压管路同排敷设时，应按差压管路的要求坡度敷设。管路敷设时应考虑主设备的热膨胀，其引出管应加“Q”形膨胀弯加以补偿，以保证取源装置及管路不因热膨胀而损伤。管路敷设完毕后，应用水或空气进行冲洗，确保无漏焊、堵塞及错焊等现象，管路严密无泄漏。气源管路需进行严密性试验，并对所有管路进行吹扫。Itshouldhaveaparticulargradienttohorizontallayingpipeline.Gradientofdifferentialpressurepipelineshouldbemorethan1：12;otherpipelineshouldbemorethan1：1
44、00;iflayingotherpipelineanddifferentialpressurepipelineatthesametime,layingpipelinesshouldbelayingasdifferentialpressurepipelinegradient.Whenlayingpipeline,thermalexpansionofmainequipmentshouldbeconsidered.ItselicitationpipeshouldbeaddedQexpansionbendtokeepsamplingpositionandpipesareintact.Afterlayi
45、ngpipelines,waterorairshouldbeusedtoflushtokeepwithoutlackofweld,stoppageorwrongweldetc.phenomenon.Pipelineshouldbesealed.I&Cairpipelineneedtoproceedtosealtestandallthepipelinesshouldbeconductedwithflushing.4. 2.5导管的固定Conduitfastening导管固定应采用能拆卸的卡子，常用M5x20镀锌螺丝将导管固定在支架上。若成排敷设,两管的间距就应均匀且保证两管中心距离为2D(D为导
46、管外径)。有膨胀弯及膨胀弯以前的导管(取源装置引出管)应处于自由状态，固定点应放在膨胀弯之后。Conduitfasteningwillbeadoptedknocked-downclip.ConduitwillbefasteningatsupportwithM5x20galvanizedscrewsingeneralsituation.Ifpipelayinginrows,distancebetweentwoconduitshouldbeuniformityandkeepcentraldistanceis2D(Disconduitexternaldiameter).Conduits(sampli
47、ngdeviceselicitationpipe)whichhaveexpansionbendsorneedtobendshouldbefreestateandfixedpointsshouldbesetafterexpansionbends.4. 2.6导管连接Conduitconnection导管连接形式有两种，即焊接连接和接头连接。Therearetwotypesofconduitconnection:weldingconnectionandjointsconnection原则上所有仪表导管的对口连接部位均须采用焊接连接，即采用火焊、电焊和氢弧焊等进行的导管连接。无论哪种焊接形式，均须由
48、专业焊工进行焊接，并使用合适型号和规格的焊丝或焊条。Inprinciple,buttweldingpartsofalll&Csamplingconduitshavetoadoptweldingconnection:suchasfirewelding,electricweldingandargonarcweldingetc.professionalweldersconductallweldingandadoptsuitablestandardandcertificationweldingwireandweldingrod.焊接连接导管时，可按下列工艺要求步骤进行：Whenweldingconne
