1、热控专业取源部件及敏感元件安装作业指导书（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2Conditionandpreparationbeforeconstruction4、作业程序、方法5Operationmethodandprocedure5、质量控制点的设置和质量通病预防17Arrangementofqualitycontrol&preventionofcommonproblems6、作业的安全要求和环境条件20Op
2、erationsafetyrequirementandenvironmentcondition7、附录25Appendixo1编制依据Basicofcompilation1.1EPC合同EPCcontract1.233-F6161S-K0101施工图总说明及图纸目录l&Cpartdescriptionandlistofdetaileddrawing1.333-F6161S-K0102锅炉侧热控系统图l&CPaIDofboiler1.433-F6161S-K0103汽机侧热控系统图l&CPaIDofturbine1 .533-F6161S-K0104锅炉侧热控设备清册Listofboilerl&
3、Cequipment2 .633-F6161S-K0105汽机侧热控设备清册Listofturbinel&Cequipment3 .733-F6161S-K0408锅炉热控导管阀门清册Listofboilerl&Cconduitandvalves4 .833-F6161S-K0514汽机热控导管阀门清册Listofturbinel&Cconduitandvalves5 .9辅助厂房系统图、设备清册及导管阀门清册AuxiliaryplantP&ID,listofequipmentandconduitandvalves6 .10安装设备厂家图纸Factorydrawingofinstallatio
4、nequipment2 工程概况及工作量Projectgeneralandmainquantities2. 1工程范围Scopeofengineering取源部件及敏感元件安装工程包括机、炉主厂房各系统，辅助厂房各系统测点及分析监测元件开孔和取源部件的安装。Engineeringofsamplingpartsandsensitiveelementsinstallationcontainelementtapping&samplingpartinstallationofmeasurepoint&analysismonitoringofeveryturbineandboilermainpowerho
5、useandauxiliaryplantsystem.3. 2工作量及工期Constructionquantityandconstructionperiod本工程机、炉系统及辅助系统设计温度插座及元件安装561支，其中热电阻251支，热电偶268支，双金属温度计27支；壁温块安装488个；压力插座安装724个，差压压力插座安装292对，一次门安装1095只；防堵取样装置安装58个；氧化错氧量分析取样安装8套;汽水分析取样装置安装1套；炉膛火焰电视安装2套；火焰检测监视探头安装72只。Turbineandboilersystemandaccessorysystemwillbeinstalledt
6、emperaturesamplingtubeandelementsoverall561piecesasdesigned,hereintothermalresistance251pieces,thermalcouple268pieces,bimetalthermometer27pieces.Walltemperatureblockwillbeinstalled488pieces;pressuretube724pieces;differentialpressuresamplingtube292;primaryvalve1095;samplingunitofblocking58piece;analy
7、sisandsamplingdeviceofzirconiaoxygen8unit;analysisandsamplingdeviceofsteamandwater1unit;flameTV2unit;flamemonitoringprobe72pieces.取源部件及敏感元件安装的施工工期，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。Accordingtositeconstructorsandtoolscondition,thisproject(samplingpartandsensitiveelementsinstallation)constructionperiodis8mo
8、nthsbyuspredicted.3 作业前条件和准备Conditionandpreparationbeforeoperation3.1技术准备Technicalpreparation3.1.1 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。Designinginstituteandmanufacturesdrawingsareexaminedcompletely.Cleartreatmentideashadgaveduringexaminationofdrawings.3.1.2作业指导书编制完、并审批合格。Operationinstitutionhasbeenfin
9、ishedandapproved.3.1.3施工用工机具及计量器具准备完成并经检验合格。Constructionfacilitiesandmeteringarepreparedandqualified.3.1.4各工种作业人员进场，满足施工要求。Eachworksoperatorsmayenterthesiteandmeettheconstructionrequirement.3.1.5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,taskofconstructionandwearcom
10、pleteprotectiveequipment.3.1.6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,weestablishrelatedtechnicalandsecuritymeasure.Operatorswhowilljointthisconstructionwillexecutetechnicaldisclosureandsecuritydisclosure.Doubleassignmentshadbeenfinished.3.1.7开工报
11、告审批完成。Examinationofconstructionstartingreporthascompleted.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Qualification能够审清图纸，领会设计思想，掌握取源安装的工艺流程，熟悉施工质量和安环要求。Technicianshouldexaminethedrawing,understanddesignidea,mastercraftofsamplinginstallation,familiarwithconstructionquali
12、tyandsafetyenvironmentrequires.职责Duty1 .全面负责该取源安装的技术工作，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。Technicianisinchargeoftechnicalworkofsamplinginstallation.Suchas:joinrelateddrawingjointhearing,dealwithdesignchangefile,establishoperationinstruction&technicalandsecuritydisclosure,andhostdisclosurework.
13、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;discoverandsolvethetechnicalsafetyhazardduringtheconstructionintime;guideconstructioninaccordancewithoperationinstruction.3.配合班组长进行取源安装自检工作。Technicianshouldcooperatewithmonitorandteamleaderto
14、proceedtoself-checkingworkofsamplinginstallation.4 .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。Techniciandiscoverspersonnelunprofessionaloperationandhaspowertostopthisbehavior,haspowertostoppersonnelwork,reporttorelatedleaderintime.2作业人员工种Type班组长Monitorandteamleader数量Qty.3资格Qualification熟悉取源安装的工艺流程，能有效组织好施工人
15、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。Familiarwithtechnologicalprocessofsamplinginstallation,effectivelyorganizeconstructorstodoconstructioninaccordingwithoperationinstruction职责Duty1.负责组织安排取源安装人力，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。Theyareinchargeoforganizingandarranginglaborpowerandmaterialresour
16、cesofsamplinginstallation.Duringperformingconstruction,operatorsshouldstrictlyfollowconstructiontechnologyrequirements,qualityrequirementsandsafetyenvironments.2 .做好测点取源的质量自检和工序交接工作。Theyarefullyinchargeofqualityandsecuritywork.Theyshoulddowellwithqualityself-checkingandprogresshandoverworkofsampling
17、installation.3 .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。Iffollowingsituationhappenedduringconstruction,constructioncannotproceed.Suchasuncleardrawing,unqualifiedmaterials,non-disclosureoftechnologyandsafety,unqualifiedacceptanceofupperprocess.4 .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。Ifqual
18、ityorsafetyaccidentshappen,monitorshouldreporttohighleveldepartment.Atthesametime,monitorshouldorganizeteamworkerstocarefullyanalysisas“threeno”principle.3作业人员工种Type施工人员Construction数量Qty.15资格Qualification熟练掌握取源安装的技术、工艺要求，知道施工的质量安环要求。knowwellaboutrequirementsoftechnologyandcraftofpipelinelayingandreq
19、uirementsofsafetyenvironment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。Theyshouldexecuteconstructioninaccordingwithconstructiontechnologyrequirements,qualityrequirementsandsecurityenvironmentrequirementsinoperationinstrument.2 .爱护施工所用工器具，严格按照操作规程作业。Takecareofallconstructiontoolsandstrictlyconstructfo
20、llowoperationrules.3 .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。Ifqualityorsafetyaccidentshappen,operatorsshouldprotectthesiteandreportrelatedleaderanddealwiththesituation.4 .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.Operatorsa
21、reinchargeoftheirownconstructionquality.Constructorscannotexecutesomeorderswhichareunclearorincorrect.3.3作业工器具Constructionfacilities序号No.名称Name型号规格Modelandspecification数量Qty.1电焊机Electricwelder直流DC22直角尺L-square标准Standard53角向砂轮机Anglegrinder100mm24扳手Wrench插口45手枪电钻Electricpistoldrill13mm86绕线器Bobbinwinde
22、r10m47角磨Straightgrinder标准Standard48游标卡尺Verniercaliper标准Standard29绝缘电阻表Insulationresistancemeter500V110开孔器Tapper28、035等中28、35etc.足量Fulldose3.4主要材料Mainmaterials取源导管、温度压力底座、取源一次门、槽钢、角铁等l&Csamplingconduit,temperaturepressurepedestal,primarysamplingvalve,U-steel,angleironetc.3. 5施工条件Constructioncondition
23、3.5. 1个人工具及劳动防护用品、用具配备齐全。Personaltoolsandprotectiveequipmentareallinreadiness.3.5.2管道及其设备安装完毕。Installationofpipelineandrelevantequipmentarecompleted.3. 5.3插座及阀门材质分析完毕。Analysisofsamplingtubeandvalvesmaterialsiscompleted.4. 5.4元件校验完毕。Verificationofelementiscompleted.5. 5.5现场安全设施准备到位，照明良好、脚手架搭设并验收完毕。Si
24、tesafetyequipmentisinhere;welllighting;scaffolderectionandexaminationarecompleted.4作业程序、方法Operationprocedureandmethod4.1 作业程序Operationprocedure4. 1.1仪表测点的开孔程序Procedureoftappingofinstrumentmeasurepoint核定测点位置H核实插座尺寸H划线开孔卜阱凿测孔卜修诲丽H临时封堵VetifypositionofmeasuringVerifythesizeofsamplingtube|fLineationandta
25、ppingHExcavatesamplingholes|Repairandpolishsamplingholes|Temporaryplugging4. 1.2温度插座(保护套管)安装程序Procedureoftemperaturetube(orprotectivesleeve)installation菽至I，H停|f陵查垂直度1丽H临时封闭Alignmentofit|welding|fRecheckverticality|WeldinfTemporarysealing4. 1.3取源阀门安装程序Procedureofsamplingvalvesinstallation外观检查卜丽f国蜀f丽一
26、陨吊Visualinspection-pressurete刮一|ConnectionHFasten|Hangtag|4. 2测温元件安装Installationofmeasuretemperatureelement4. 2.1测点位置的选择Selectpositionofmeasurepoint测点位置需环境无剧烈震动，测点部位符合设计要求，安装检修方便。测点的测孔躲避焊缝或热影响区，两测孔的间距应大于或等于被测管道外径D,且不少于200nm1。Positionofmeasurepointshavenoacuteshakingandmeetthedesignrequirementandinst
27、allandexamineconveniently.Samplingholeofmeasurepointavoidareawhicheasilyeffectedbyhotorweldedjoint.Distancebetweentwoholesshouldbenotlessthan200mmandD(pipelinediameter).测孔应选择在管道直线段上。测孔应避开阀门、弯头、三通、大小头、挡板、人孔(入口)等对介质流速有影响或会造成泄漏的地方。同一位置压力或温度测孔中，用于自动控制系统的测孔应沿介质流向选择在前面。Samplingholeshouldbeselectedatstraig
28、htsectiononpipeline.Samplingholesshouldstayawayfromtheplacewhicheasilyleakoraffectmediumflowrate.Suchas:valves,elbow,teejoint,concentricreducer,damper,incomingholes.Pressureortemperaturesamplingholesatoneposition,samplingholeofautomaticcontrolsystemshouldbeinfrontsamplingholeoflocalsysteminaccordanc
29、ewiththedirectionofmedium.4.2.2测孔开凿和插座(保护套管)安装Excavatesamplingholeandinstallsamplingtube(orprotectivesleeve)测孔的开凿，应在热力设备和管道正式安装前或封闭前进行，禁止在已冲洗完毕的管道上开孔。测孔开凿后应立即焊上插座并封堵，否则应采取临时封闭措施，以防异物掉入孔内。插座安装前应把插座坡口及测孔周围用锂刀或砂布打磨出金属光泽，并清除掉测孔内边的毛刺。油系统的取样插座安装应在管路酸洗之前进行，并将管道内部铁屑及毛刺处理干净，不能马上安装设备的应将取样孔密封好。参加水压的取源部件安装应在水压之
30、前进行，取源部件参加水压试验。Excavatesamplingholespriortoinstallingorsealingheatingpowerequipmentandpipelines.Itisstrictlyprohibitopeningholesoncleanpipeline.Samplingholesshouldbeimmediatelyweldedsamplingtubeorpluggedoradoptedtemporaryclosingmeasuretoavoidsundriesafterdigit.Samplingtubegrooveandaroundsamplinghole
31、sweregrindedoutmetalliclusterandeliminatedinnerburrsbeforesamplingtubeinstallation.Installsamplingtubeofoilsystempriortocarryingoutpipeacidpicklingandcleaningirondustandburrsinsidepipeline.Ifequipmentcannotinstallimmediately,samplingholesshouldbesealedwell.Samplingpartswhichattendhydraulictestshould
32、beinstalledbeforecarryouthydraulictest.测孔的开凿均采用标准规格的电动钻头及开孔器开孔，风压管道上开孔可采用氧气乙烘焰切割，但孔口应磨圆挫光。测孔直径误差不大于1mm,开孔垂直偏差不大于3nUn。Samplingholesexcavationwilladoptstandardelectricdrillandtapper.Tappingofairpressurepipelinemayadoptoxy-acetylenetocutandorificesshouldbepolished.Diametererrorsforsamplingholemm,vertic
33、alerrorsforsamplinghoeW3mm.温度插座(保护套管)安装前需对插座进行光谱分析，按设计要求检查材质及尺寸。汽、水及油管道插座(保护套管)安装时作业人员配合进行，掌握垂直度后用氢弧打底，由专业焊工施焊。插座(保护套管)安装垂直偏差不超过1mm,部分合金插座(保护套管)焊接后进行热处理。插座焊接完后，检查其内部，不应有焊瘤存在；测温元件插座焊接时可用石棉布覆盖，防止焊渣落入丝扣。Samplingtubeshouldcarryoutspectralanalysistocheckmaterialandsizeaccordingtodesignrequirementbeforein
34、stallationoftemperaturesamplingtube(orprotectivesleeve).Wheninstallingsteamandwaterandoilpipelinessamplingtubes(orprotectivesleeve),operatorscoordinatewitheachother:masterverticality,renderwithargonarc,weldingbywelder.Verticalerrorsforsamplingtube(orprotectivesleeve)mm.Partialalloysamplingtubes(orpr
35、otectivesleeve)shouldbeproceededtoheattreatmentafterweld.Operatorscheckinnersamplingtubetoavoidoverlapafterweld.Whenweldingsamplingtubeoftemperatureelement,itmaycoverwithasbestoslinentoavoidweldingslagdroppingintoscrewthread.4. 2.3测温元件安装Measuretemperatureelementinstallation测温元件安装前需进行外观检查及校验，安装时检查密封垫
36、片材质符合安装要求，放置垫片需平整，不偏斜。Temperatureelementshouldbeproceedingtovisualinspectionandverificationbeforeinstallation.Materialsofsealgasketmeettheinstallationrequirement.Wheninstallationsealgasket,itshouldbesmoothandstraight.热电偶或热电阻插入深度符合设备清册安装规范，未具体要求的，遵守以下原则：对高温高压蒸汽管管道外径D大于250mm的，其插入深度为100mm；对管道外径D不大于250m
37、m的，其插入深度为70mm；对一般流体管管道外径D大于500mm的，其插入深度为300mm；对管道外径D不大于500mm的，其插入深度1/2D；风、粉、煤管道插入深度为1/3DT/2D。TheinsertiondepthofThermalcoupleorthermalresistanceaccordwithequipmentinstallationspecificationandobeyregulationasfollows:HVandHPsteampipe:D(pipelinediameter)250mm,itsinsertiondepthis100mm;Dw250mm,insertiond
38、epth70mm.Fluidpipe:D500mm,insertiondepth300mm;Dw500mm,insertiondepth1/2D.Wind,power,coalpipe:insertiondepth1/3D-1/2D.双金属温度计感温元件插入深度应全部浸入被测介质。在介质流速较大的低压管道或气固混合物管道上安装测温元件时，应有防止测温元件被冲击和磨损的措施。水平安装的测温元件，若插入深度大于1m,应加有保护套管防止弯曲。Temperature-sensingelementforbimetalthermometershouldbefullydippedintomediumwhic
39、hismeasured.WheninstalltemperatureelementonLVorair-solidmixturepipelineswhichhavebiggermediumflowrate,measureswhichavoidtemperatureelementdamagingorimpactingshouldbeprepared.Ifinsertiondepthofhorizontaltemperatureelementismorethan1m,itshouldbeaddedprotectivesleevetoavoidbending.元件装配用扳手紧固，无渗漏。Tempera
40、tureelementshouldbefixedwithspecialwrenchandwithoutleakage.4. 2.4金属壁温安装Installationofmetalwalltemperature测量金属壁温的铠装热电偶安装前需检查型号规格、外观及绝缘电阻，所使用的元件需经过校验并合格。壁温块安装位置符合设计，壁温块与被测金属表面光滑无毛刺，焊接由专业焊工完成，焊接严密牢固。热电偶插入壁温块，并用螺丝咬紧。测量端至接线端依次绑扎固定牢固并用槽盒或制作保护罩保护。热偶剩余部分留在保温层内。Sheathedthermalcouplewhichmeasuremetalwalltempe
41、raturetype,specification,appearance,andinsulationresistanceshouldbecheckedandpassedexaminationbeforeinstallation.Installationpositionofwalltemperatureblockmeetsthedesignrequirement.Walltemperatureblockandmeasuredmetalsurfaceshouldbesmoothandwithoutburrsandweldingshouldbefinishedbyspecialwelder.Therm
42、alcouplewillbeputintowalltemperatureblockandfastenedscrewthread.Measuringterminaltoconnectionshouldbefastenbylashingandprotectedbycabletrayorprotectivesleeveinturn.Remainderpartsofthermalcouplewillstayinsidethermallayer.测量金属壁温的专用热电阻安装前检查元件规格型号及外观，箱电阻绝缘符合安装要求。推力瓦测温元件安装测孔直径偏差大于0.2d,测孔边缘靠乌金面距离0.5mm,测孔深
43、度预制25-30mmo热电阻引出线选用耐油耐高温导线，焊接固定。轴承测温元件与轴承座螺纹核对吻合后进行安装。推力瓦测温元件安装时要注意引线不受机械损伤和摩擦，从瓦座到瓦块段的引线应留有适当伸缩量，以免瓦块活动时引线受力而折断，但同时不宜过长，否则应因受油的冲击而折断。在汽轮机前箱扣盖时应复核热电阻及引线的完好情况。Beforeinstallthermalresistanceformetalwalltemperaturemeasurement,itsspecificationandappearanceshouldbecheckedandplatinumresistorinsulationmeet
44、stheinstallationrequirement.Installationoftemperatureelementforthrustpad:diametererrorforsamplingholesismorethan0.2d;distancebetweenofholeedgeandblacksurface0.5mm,prefabricatedepthforsamplinghole25-30mm.thermalresistanceleadshouldbeadoptedoilandHTresistancewireandweldingfixed.Bearingtemperatureeleme
45、ntandbearingpedestalscrewthreadshouldbematchedwitheachotherbeforeinstallation.Wheninstallingthreadpad,operatorsshouldpaymoreattentiontopreventleadformmechanicalinjuryorfriction.Leadfromtiltingfillertopadsectionshouldberemainedproperstretchtensortoavoidleadfromdamaged.Ifleadistooshort,itmaybreakoffbe
46、causeofpressure;ifleadistoolong,itmaybreakoffbecauseofoilimpact.Whenlidfrontbearingboxofturbine,reexaminethermalresistanceandleadintactsituation.电机绕组测温元件检查包括绝缘电阻测量和电阻值测量，保证元件测量准确进行接线。Examinationoftemperatureelementformachinewindingcontainsinsulationmeasurementandresistancevalvemeasurementandmakesure
47、thatelementmeasurementsareaccurate.Thendowiring.4. 3压力取源装置安装Installationofpressuresamplingdevice.6. 3.1测点位置的选择Selectionofmeasurepointposition1）测点部位符合设计要求。Partsofmeasurepointshouldmeetthedesignrequirement.2）测点测孔与焊缝间的距离，应在焊缝的热影响区域外。Distancebetweensamplingholesandweldinglineshouldbelargerthanheateffect
48、iveareaofweldingline.103）测点的压力与温度测孔距离，压力测孔按介质流向在温度测孔前。压力测孔与温度测孔间距应大于D（D为被测管道外径），且大于200mmoDistancebetweenofpressureandtemperaturesamplingholesofmeasurepoint:pressuresamplingholestaysinfronttemperatureaccordingtodirectionofmediumflow;distancebetweenpressureandtemperaturesamplingholemustbemorethanD（Dmeansmeasuredpipelinediameter）and200mm.4）在倾斜或水平管道
