412 Insulation保温.docx
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412Insulation保温
4.12MethodStatementsforInsulationWork
保温施工方案
1.DocumentCompliance编制依据
♦DesignSpecificationofInsulationWork(1089A-000-PP-SP-003)
绝热工程规范(1089A-000-PP-SP-003)
2.ConstructionProcedureandTechnicalRequirements
施工程序、技术要求
2.1ConstructionProcedure
施工程序
ØConstructionPreparation
施工准备
ØFixedSupportInstallation
固定支承安装
ØInsulationLayerApplication
绝热层安装
ØVaporBarrier(onlyforcoldinsulation)
防潮层安装(仅冷保温工程)
ØJacketingInstallation
保护层安装
ØInspection
检查
ØRepair
修补
ØInspection&Acceptance
检查合格
ØHandover
交工
2.2TechnicalRequirements
技术要求
a)ConstructionPreparation
施工准备
ØWorkingPlaceonSite
施工场地准备:
Workingshelterof200m2willbesetupasworkshopforfabricationofjacketinglayer.Thisgroundshouldbegraded,leveledandcoveredwithcertainsteelpanelsand4mmsoftrubbersheetshallbelaidonit.Simultaneouslysomesleepersshallbeprovided.Theworkshopshallbesteel–framedstructurewithcladdingwallandshallbeequippedwithfirefightingdevices.Meanwhile,waterandelectricserviceshouldhavebeenapplicable.
在指定的场地准备200M2做为保护层制作车间场地,场地要平整,地面上要铺设一定数量的钢板。
并在上面敷设了4MM厚软胶板。
制作车间为钢架结构,墙为彩光板结构。
并要配备消防灭火设施。
场地要配备一定数量的道木。
水、电已经准备就位。
ØConstructionEquipment
施工机具:
Allnecessaryconstructionequipmentshavebeenmobilizedandinstalledintoplaceandinsoundstatus.Therequiredequipmentislistedbelow:
所需施工机具已准备齐全,安装就位并试运转良好。
需要配备下列主要机具:
SheetShearingMachine(6.3*2000MM):
1sets
剪板机(6.3*2000MM):
1台
CombinedJoiningMachine(1.5MM):
1set
联合咬口机(1.5MM):
1台
SingleFlatJoiningMachine(1.5MM):
1set
单边咬口机(1.5MM):
1台
FlangeMakingMachine(L40*4MM):
1set
煨法兰机(L40*4MM):
1台
SquareFolder(4*2000MM):
1set
折方机(4*2000MM):
1台
ElectricWeldingMachine(21KV.A):
1set
电焊机(21KV•A):
1台
ElectricPlateRollingMachine(2*1600MM):
2sets
电动卷板机(2*1600MM):
2台
ManualEdgingMachine(1.5MM):
5sets
手动压边机(1.5MM):
5台
Winch(2T):
2sets
卷扬机(2T):
2台
ØConstructionMaterial
施工材料:
Partialapprovedconstructionmaterialsuchasinsulationmaterialandjacketingmaterialshouldhavebeenstockedintowarehouse.
部分合格的施工用料,如保温材料、保护层材料已入库。
ØInsulationprocedurehasbeenpreparedaccordingtodesigndocumentationandprojectspecification.Technicalandsafetyclarificationhasbeenissuedtoconstructionstaffs.
根据设计文件及本工程规范的要求,编制了施工方案。
并对施工人员进行了技术和安全交底。
ØTechnicalandsafetytraininghasbeenexecutedforconstructionstaffs.
对施工人员进行了技术和安全培训。
2)FixedSupportInstallation
固定支承安装
ØDuringthermalinsulationapplication,theintervalofadjacentsupportsshallbe1.5~2mforflatwall,2.5~3.5mforcylindertypeequipment,4~6mforverticalpipe.Duringcoldinsulation,theintervalofadjacentsupportsshallbelessthan5mforflatwallorcylinder.
相邻隔热支承的间距:
平壁保温时为1.5~2M;圆筒设备保温时为2.5~3.5M;垂直管道保温为4~6M;平壁或圆筒保冷时为小于5M。
ØWhenequipmentandpipearereadyforwelding,supportring(anglesteelorflatsteel)shallbefabricatedaccordingtoequipment’ssizeandinsulationthickness,thenbeweldedonequipmentorpipe.Forstainlesssteelequipmentorpipe,stainlesssteelsupportringshallbeadopted;ifcarbonsteelsupportringisused,stainlesssteelpadshallbeweldedadditionally.
当设备和管道能够施焊时,根据设备的大小和保温厚度作好的支承圈(角钢或扁钢),焊到设备或管道上。
当是不锈钢设备或管道时,要采用不锈钢制作;当采用碳钢制作时要加焊不锈钢垫板。
ØIfweldingprocessisnotavailableforequipmentandpipe,steelstripclampedaroundvesselstripshallbeadopted.Whenequipmentisconnectedwithvibratedequipment,thenutsshallbefixedbytackwelding.Whenthematerialofequipmentorpipeisnon-ferrite,non-metallicheat-resistantwasherwillbeused.
当设备和管道不能够施焊时,应采用包箍的方法安装,当其设备在机泵、压缩机等有振动的管道上时,用点焊将螺母固定。
当设备或管道系非铁素体钢时,垫非金属隔热垫。
ØMulti-rowstudsorpinsshallbeweldedonthebodyofhorizontalequipmentalongshaftdirection.Forequipmentwhichnominaldiameter<2800mm,3rowsstudsorpinswillbeneeded.Forequipmentwhichnominaldiameter>2800mm,4rowsstudsorpinsshallbeneeded.Whenweldingprocessisnotavailableforequipmentbody,stubsorpinsshallbeweldedonsteelstrip,thensecuredthesteelstripontoequipmentbybolts.
卧式设备应在筒体上轴向焊接数排保温钩钉或销钉,设备公称直径小于或等于2800MM时,设3排;设备公称直径大于2800MM时,设4排。
当设备筒体不能焊接时,应将钩钉或销钉焊接钢带上,然后用螺栓将钢带固定在设备上。
3)InsulationLayerInstallation
绝热层安装
ØThematerialusedforthermalorcoldinsulationshallconformtotherequirementsstatedindesignandspecification.Duringinsulationapplication,glasswool,cellularglass,aluminumsilicateandaluminumplatewillbeused.
所需保冷和保温材料必须符合设计及规范的要求。
玻璃棉、泡沫玻璃、硅酸铝和铝板被使用。
ØPriortoinstallationofinsulationlayer,allsupports,hangersandfixedsupportsforequipmentandpipeaswellastracingpipeandinstrumenttubingshallbemountedcompletely.Hydrostatictest,pipeblowingandoutersurfacepaintinghavebeenfinishedandinspected.
绝热层在安装之前,设备和管道的支吊架、固定架及伴热、仪表接管已安装完毕,压力实验、管道吹扫及外表面防腐等工作已全部完成并经检查合格。
ØWhenonelayerofinsulationwillbeadoptedforthermalinsulationwhichthickness>100mmandcoldinsulationwhichthickness>80mm,itshouldbeappliedasperduallayerormulti-layerwithsimilarthicknessforeachlayer.
保温层厚度大于100MM,保冷层厚度大于80MM时,采用一层隔热材料时,分两层或多层施工,并且各层的厚度应接近。
ØDuringinsulationconstruction,thejointssetonsamelayerandonadjacentlayersshallbestaggeredandcoveredrespectivelywiththeoverlapofnotlessthan50mmThelongitudinaljointsofinsulationlayerforhorizontalpipecan’tbelocatedwithin45°oftwosidesofpipeverticalcenterline.Fortheinsulationlayerforlargesizepipeandhorizontalequipment,thelongitudinaljointsshallbedeviatedfromtheverticalcenterlineasfaraspossible.
隔热层施工时,同层的应错缝,内外层应压逢,其搭接长度不小于50MM。
水平管道的隔热层的纵向接缝,不要在管道垂直中心线两侧的45°范围内。
对于大管道和卧式设备的隔热层纵向接缝位置应尽量偏离垂直中心线位置。
ØWheninsulationmaterialsuchasCELLULARGLASSshallbeused,adherenceapplicationwillbeadopted.Theappliedtemperatureofadhesiveshouldbesuitableforinsulationlayer.Duringapplication,onceadhesiveistookout,thecontainershouldbecoveredwellimmediatelytoavoidfreezing.Oneachinsulationcover,thejointsshallbeappliedwithadhesivefullyandtheadhesiveextrudedformjointsshallberemovedatonce.Forlargerjoints,itshouldbefilledwithglasswool.
隔热材料采用CELLULARGLASS时,使用粘贴法进行施工。
粘结剂使用温度要和隔热层相匹配。
施工中,粘结剂取出后,应及时盖好,不要受冻。
每块制品的缝隙应涂满粘接剂,挤出缝隙的粘结剂应立即挤出去,缝隙大的部位应使用玻璃棉填塞。
ØFortheaccessoriesofequipmentandpipeincoldinsulation,suchasskirt,bracket,liftinglug,instrumentstanchion,support,hanger,etc,theirinsulationlengthshallnotbelessthan4timesofinsulationthickness.
保冷设备和管道的裙座、支座、吊耳、仪表管托、支架、吊架等附件,其保冷长度不小于保冷厚度的4倍。
ØExpansionjointwillbelocatedduringcoldinsulation.Theexpansionjointshallbefilledwithsoftfoamplasticstripandsealedwith50mmadhesivetape,thencoldinsulationshallbeappliedonit.
保冷层施工时要流出伸缩缝。
伸缩缝用软质泡沫塑料条填塞,外用50MM宽的不干胶带粘贴密封,缝的外面再进行保冷。
ØThematerialandtypeofinsulationlayerforPP(PersonProtection)shallbesameastheonesofthermalinsulation.
人身保护的隔热层采用和热保温一样的材料和形式。
ØFortiringofinsulationlayer,0.4*13mmstainlesssteelbandwillbeusedforDN<500mmpipe;0.5*19mmstainlesssteelwillbeadoptedforDN>500mmpipeandequipment.Theintervaloftheabovestainlesssteelbandshallbe400mm.
隔热层的绑扎,直径小于500MM的管道,使用0.4*13MM不锈钢带进行绑扎;直径大于500MM的管道和设备,使用0.5*19MM不锈钢带进行绑扎。
钢带的距离不于400MM。
4)VaporBarrierConstruction
防潮层施工
ØForcoldinsulationlayerofequipment&pipingandprotectionlayerofpipinglayingintoditch,theexternalfaceshouldbegivenvaporbarrier.Itshouldbedividedinto3layers:
设备和管道的保冷层和敷设在地沟内的管道的保护层,外表均要设置防潮层,防潮层的结构为:
1stlayer:
vaporproofcoldmasticmateriallayerorinflammationpreventpitchlayer,3mmthick
第一层为防水冷胶料层或阻燃型石油沥青胶层,厚度为3MM;
2ndlayer:
non-waxneutralalkalescencecoursegrilleflatveinsglasscloth,0.1~0.2mmthick
第二层无蜡中碱粗格平纹玻璃布,厚度为0.1~0.2MM;
3rdlayer:
vaporproofcoldmasticmateriallayerorinflammationpreventpitchlayer,3mmthick
第三层为防水冷胶料层或阻燃型石油沥青胶层,厚度为3MM;
ØForheatpreventlayerwithvaporbarrier,theexternalfaceshouldbeclean,dry,flatandeven,withoutsalientandconcavepit.
设置防潮层的隔热层外表面要清洁、干燥、平整、均匀,不得有突角、凹坑现象。
ØWhendirectlydaubingonheatpreventlayerwithvaporproofcoldmasticmateriallayerorinflammationpreventpitchlayer,andmeetingdesignrequirement,strickleitevenlywithspatula,andwrapnon-waxneutralalkalescencecoursegrilleflatveinsglassclothimmediately.
防水冷胶料层或阻燃型石油沥青胶层直接涂抹到隔热层时,达到设计厚度时,要用抹子均匀刮平。
并立即缠绕无蜡中碱粗格平纹玻璃布。
ØGlassclothshouldbewrappedinspiral.Laplengthshouldbenolessthan50mm.Theclothshouldbetightened,flatandwithoutcorrugation.
玻璃布应采用螺旋形缠绕,搭接尺寸不小于50MM,应拉紧、铺平、贴实,不出现皱折现象。
5)JacketingLayerConstruction保护层施工
ØJacketinglayershouldbealuminumplate,with0.5~1.0mmthickness.Alloftherivets,self-tappingscrewsandsteelbindingsshouldbestainlesssteelmaterial.
保护层采用铝板,厚度为0.5~1.0MM之间。
铆钉和自攻螺钉及钢绑带匀为不锈钢材料。
ØForthejacketinglayerofequipment&straightsectionofpiping,thecuttingsizeshouldbemeasuredatsite.Whenmeasureit,thetapeshouldnotbetootightened,andtheperimetershouldremain30~50mmaftermeasurement.Forthethinplateaftercutting,eitherhorizontalorverticalsideshouldbepressedtogetdentaccordingtorequirement.
设备和管道直管段的保护层下料要实际测量,测量时不宜拉的过紧,测量后的周长要有30~50MM的余量。
下料后的薄板,横向、竖向要有一边按需要方向压出凸筋。
ØForthejacketinglayerofequipment&piping,thehorizontaljointshouldbelapped,andtheverticaljointshouldbelappedorbutted.Ifadoptlapping,therequirementasfollowing:
设备、管道的保护层环向接缝采用搭接,纵向接缝要采用搭接或咬口连接。
如果为搭接应符合下列要求:
Thehorizontalandverticaljointofequipmentshouldbelapped50mm;
设备的环向接缝和纵向接缝要搭接50MM;
Thehorizontaljointofpipingshouldbelapped50mm,theverticaljointshouldbelapped30~50mm;
管道的环向接缝的搭接50MM,纵向接缝的搭接30~50MM;
Thelappingsizeofpipingandstraightpipesectionasfollowing:
high-temperaturepipes