散 装 胀 接 锅 炉 安 装 阳工 法.doc

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1、videoconference, Secretary of the provincial Committee of Xia Baolong stressed: this year is the five water treatment 357 timetables for three years to resolve outstanding issues, obviously worked, victory of the year. The Countys departments at all levels must firmly establish the guanghui is gold

2、and silver green development concept, convinced that Castle is not relaxed, always maintaining strategic ability and strong determination to improve the environment, consistently playing well five water treatment of winning the war, ever-higher levels of comprehensive well-off society was built. (A)

3、 lay the sewage uphill battle. This year we will river water quality improved at the county level, up to five this basic objective grasp of pollution control that focus, with the focus on three things: a good job, clear rivers reaching the County created. Organization look back special inspection, t

4、he County garbage River, black and odorous River is Dragnet investigation, timely rectification of problems found in place firmly to prevent river pollution rebound. In accordance with the one-stop strategy, improving the inferior five water quality monitoring stations work this year to ensure the E

5、limination of 1 provincial control, five water quality section 3 municipalities controlled deterioration, ensure the creation this year of clear rivers standards. Second, pay special attention to pollution-cutting construction of nanotubes. Intercepting nanotubes are the basis of pollution of water

6、source engineering, engineering, matter of success or failure of water management. Urban sewage treatment, to improve effluent from sewage treatment rate, running accuracy, compliance requirement, speed up the towns support network construction, is focusing on nanotubes home last meters question. Do

7、mestic sewage treatment in rural areas, this year is the final year of the three-year action, determination to fight and the momentum around, ending the battle on which fully to ensure the realization of all County 648 formed village coverage. Also, be sure to attach importance to focus on rural dom

8、estic wastewater treatment facility operation and management, ensure that wastewater treatment facility up and running, role play, avoid the Sun problem. Third, pay special attention to the River Lake pond desilting operation. Provinces now have focused on pollution control of water go to dig up mud

9、, as the deepening water of this years plays. Next, to jump-start an investigation line touches work, implementation plan according to the priorities and the programme of work, in accordance with the one river one policy requires detailed cleaning, dredging plan, planning ahead of time cleaning out

10、mud way out, according to local conditions to do sludge, promote scientific resource utilization of silt and mud. (B) the heavy regulation of heavily polluting industries. Pollution of water must grab the source, wastewater is primarily the source of backward production capacity, increase the intens

11、ity of散 装 胀 接 锅 炉 安 装 工 法1、前言在化工安装和工业设备安装工程中，经常遇到蒸发量不超过二十吨的散装胀接锅炉。这类锅炉一般体积庞大，零部件多，施工程序繁琐，安装周期较长，劳动生产率相对较低。我们通过工种实践，对该类锅炉的安装从施工组织，技术管理，质量控制以及施工程序、机具配备等方面作了一些探索，取得了一些经验。本工法适用于现场组装的、蒸发量在420t/h的散装胀锅炉。本工法的特点是：在锅炉安装全过程中，推行先进的施工工艺，采取科学的管理办法，对安装质量预控，提高工程质量；尽量提高机械化施工程度，减轻劳动强度，提高生产率和经济效益。二、工艺原理及特点（一）工艺原理散装胀接锅

12、炉安装主要有以下几个步骤：1.锅炉钢架的安装；2.锅炉受热面安装；3.炉管的胀接；4.其它部件和辅机的安装。在以上步骤中，炉管胀接是最重要的，也是较容易出问题的工序，它对整台炉的安装质量起决定性作用。因此，安装过程中，在兼顾全面的同时，将炉管胀接作为质量控制的重点，给予充分重视。胀管的原理是；利用金属塑性变形和弹性变形的性质，在胀接管头插入汽包管孔中后，利用胀管器从管内壁施加径向力向外扩张，使管头产生塑性变形。当管外径与管孔壁完全接合，径向力开始传到管孔壁上，使管孔产生一定的弹性变形。当胀管达到要求退出胀管器以后，被胀大的管子外径（已产生塑性变形）基本保持不变，而管孔由于只产生了弹性变形，当外

13、力撤去后，就力图恢复原状，其弹性力将管子牢牢箍紧，达到胀接目的。（二）工艺特点1.采用多工种平行流水线作业，尽量缩短施工期。2.炉管校对采用校管平台，按实际尺寸放样，提高校管精确程度，保证锅炉安装质量。3.炉管退火采用“铅浴法”，用热电偶控制温升，加热均匀，温控准确，退火质量高。4.管头处理采用电动磨管机，磨削均匀，质量好，效率高。5.胀接采用电动胀管机，由2011二级建筑工程备考试题自动控制仪自动控制。按经过试胀预选的胀管率进行炉管胀接。机械化程度高，胀紧程度易于掌握。三、施工工艺(一)锅炉安装施工工艺流程图见图一。(二)锅炉施工网络图见图二。(三)施工工艺要点1.锅炉钢架安装（1）锅炉钢架

14、采用现场分散组对的方法进行安装。安装前依据基础图和钢架图精确定位放线。（2）钢架应安装一件，找正一件。严禁在未找正的构件上进行下一工序的安装工作，以免造成难以消除的积累误差。2011二级建筑工程备考试题图一：锅炉安装施工工艺流程图施工准备设备清点检查校对 炉管退火 管头磨光基础验收定位放线钢架组装 汽泡安装 胀 管水冷壁安装 预热器安装省煤器安装本体管安装水压试验燃烧系统安装筑 炉烘 炉 煮 炉 试运行 辅机安装烟风道安装电仪安装辅机试运竣工验收图二：锅炉施工网络计划2011二级建筑工程备考试题基础验收（2）定位放线（2）刚架组装（3）胀管（3）汽包安装（3）施工准备（1）设备清点（2）检查校

15、对（2）炉管退火（2）管头磨光（2）水冷壁安装（3）预热器安装（3）省煤器安装（3）辅机安装（6）水压试验（4）燃烧系统（3）筑炉（5）烘炉（5）本体管安装（3）风道安装（6）电仪安装（6）辅机试运（6）煮炉（5）试运行（7）总体验收（17）竣工 （3）为了防止焊接变形，可视具体部位采用对称焊接或在焊口附近予加拉撑等措施。2.汽泡安装（1）先安装有支座的一个汽泡（一般为上汽泡），该汽泡找正后加临时固定，防止在以后的安装过程中移位。（2）另一个汽泡（无支座的汽泡）放置在可调节的临时支架上，以上汽泡为基准对其进行找正。（3）汽泡纵横方向的水平以其上的水平中分线（一般制造厂应在汽泡两端作出标记，现场

16、复查）为基准，用玻璃管水平仪进行找平。下汽泡的纵横中心位置从上汽泡中心往下吊垂线进行检查。3.受热面管子的安装(1)管子的检查和校正管子在校管平台上进行检查 和校正。校管平台上应放出弯管大样，将炉管逐根进行检查。如有超差现象应予以校正。（2）管子检查完毕，应进行编号。编号应醒目且具有方向性。即在安装过程中，不至于搞错方向。（3）管端退火。用铅浴法对胀接管管端进行退火，退火长度不小于100，退火温度为600650C，保持1215分钟，然后放入石棉灰中缓冷至常温。硬度抽检HB170。（4）管头磨光。用电动磨管机对管头进行磨光处理。（5）试胀。用和正式胀接相同规格，同材质，同硬度的管和板（由锅炉厂供

17、）进行试胀，通过试胀，确定合理的胀管率。（6）胀管。先胀基准排，然后采用反阶梯式顺序（见图三）依次完成胀管作业。胀管时应坚持经常检查，防止出现较多不合格胀口。图3 胀管顺序（7）炉管的焊接。对接口采用氩弧焊，角焊缝采用手工电弧焊。5、施工环境条件(1)胀管时环境温度不应低于0C；(2)焊接时环境温度不应低于0C，相对湿度在90以下；(3)施工区域应不受风、雨、雪以及较多灰尘的侵袭。四、 机具设备锅炉安装主要机具设备见表一。表一 要施工机具一览表编号名称规格型号单位数量备注1汽车吊16t台12汽车吊18t台13电焊机直流AX-320台44氩弧焊机NSA4-300台25气焊工具套26电动胀管机P3

18、Z1-51台2带自控仪7电动磨管机5170台28电动试压泵SY-600台19手动试压泵6.4MPa台210手提式硬度计HB0 5台111卷扬机5t慢速台312钢管式抱杆10t根113砂轮切轮机400台114手把砂轮机150台415角向砂轮机100台416行灯变压器220/12v台117力光探伤仪RFZ505台118通风机轴流式台419空压机2V-6/8台120砂浆搅拌机375L台121液压弯管机G 3台2五、 质量标准和质量控制（一）质量标准1、符合蒸气锅炉安全技术监察规程（原劳人部1987版）中有关要求；2、达到机械设备安装工程施工及验收规范 TJ231-78各项技术指标；3、符合锅炉制造厂

19、各项设计要求。（二）质量控制措施1、严格按照公司锅炉质量保证体系控制图表的要示进行管理。2、切实抓好质量保证的基础。从设备制造质量直至竣工验收，每个施工环节均有检验，有记录，做到“上道工序不合格决不交下道工序施工”。3、实行质量预控制，将锅炉安装全过程分解为若干工序，对每一工序根据有关规范，技术要求制定出质量标准，施工人员严格照此标准执行，不得超标。对炉管胀接质量的预控尤为重要，通常采用以下两种方法：（1）电动胀管，自动控制仪控制胀管率。该方法的特点是：使用带自控仪的电动胀管机，通过试胀，确定一合理的胀管率H，对应该H值，就有一定的胀紧扭矩和一定的电流，控制该电流，即可达到控制胀管率的目的。具

20、体作法是：将试胀时选定的电流，作为电动胀管机自控仪设定值，胀管时，当达到该电流，即达到了预选的胀紧值，胀管机自动退出。（2）百分表控制管外径胀管法。该法的特点是：胀管时用带百分表的专用量具测量炉管外径，当达到预定的胀管值时，即停止胀管。使用该方法操作技术简单，胀接质量稳定，能可靠的实行予控制。4、推行“工程质量责任制”，将施工任务与施工质量挂钩。层层分解，落实到人，使每个施工者对自已所承担的施工项目技术要求，质量标准清楚，并对此承担责任。5、按工艺程序进行“三检”与“停点共检”的全过程的质量控制。六、劳动组织以两台SHL-10-1.27A型锅炉安装为例，施工工期为90天，施工人员及数量见表二。

21、表二 锅炉安装人员及岗位序号工种人数岗位1钳工8本体及辅机安装、胀管2铆工4钢架、烟风道、煤斗安装3起重8运输、吊装、配台安装4电焊4本体内焊接5气焊2配台安装6电工6电气安装7仪表工4自控安装8管工4校管及本体管安装9油工2除锈、防腐10筑炉工12筑炉11保温工4保温12技术员5各专业技术管理合计63锅炉安装人员由现场指挥统一调配，根据施工进度需要，对各作业组进行调整，做到灵活调配，不拘一格。各施工人员认真执行岗位责任制，达到其工作标准。劳动力旬平衡计划见附件一。七、安全措施锅炉安装除遵守一般安全规章制度(如炼油化工施工安全规程、建筑安装工人安全操作规程)外,还应从以下几个方面采取措施:1.

22、 进入汽包内施工，行灯电压为12V，且应加通风装置。汽包外应有人监护。2. 电气设备应加保安装置，防止触电事故。3. 用四氯化碳清洗管头和管孔时，应通风良好，防止中毒。4. 管头用铅液退火时，操作人员应穿戴整齐劳保护具，防止铅液溅出伤人。5. 锅炉试压以及烘炉、煮炉和试运行期间，严禁带压作修理工作。八、经济分析（一）施工手段用料见表三；（以安装两台10吨链条炉为例，下同）。表三 施工手段用料一览表编号名称材质规格单位数量备注1钢板A3F=12t18平台周转2工字钢A3F16t4.1平台周转3槽钢A3F12t0.48临时支架4角钢A3FL505t0.188临时支架5水煤气管A3F1t2.28脚手

23、架周转6无缝钢管202377t0.46抱杆7无缝钢管20383t0.05试压8钢管黄铜101.5m20试压（二）消耗材料见表四；表四 材料消耗一览表 序号名 称材 质规 格单位数量 备 注1电焊条T422 3.2kg1852电焊条T4222.5kg253焊丝H08A2.0kg104镀锌铁丝A38-12#kg1605花篮螺栓M16250套186煤油70#kg307机油10#kg408黄油钙基脂kg109四氯化碳kg5010石棉橡胶板=2-3kg1011锉刀12把1012铁砂布0#张4013钢锯条细牙根5014砂轮片400片2015砂轮片150片5016砂轮片100片5017破布kg3018白布m

24、419钢板3#=2-16t0.420焦炭t0.821木材kg30022青铅kg120只计损耗23石棉带440kg1224石棉绳10kg2025电石kg320（三）实际成本与预算成本分析比较见表五。表五 实际成本与预算成本分析表项目预算成本实际成本 成本降低额（元）降低率%锅炉本体辅机锅炉本体辅机机械费2904.14105.362350.5069.00590.0019.60材料费7617.67643.286262.82546.551451.5817.57人工费2423.03649.882156.00552.40364.5111.86合计12944.841398.5310769.321167.95

25、2406.0916.77注：1 本表以安装SHL-10-13锅炉一台为单位进行分析比较。2 本表套用定额：全国统一安装工程预算定额。表中只计了定额直接费，未计其他费用。（四）材料管理措施1.单位工程编制施工预算，施工预算中对各种材料用量作了详细规定，用以指导内部各种物料的消耗以及库存。施工预算原则上不得突破施工图预算，如有突破，应找出原因，予以纠正。2.单项工程实行限额领料制度。向施工作业组下达施工任务的同时，下发限额领料单，作业组以此为依据，领用材料，不得超额。3.搞好现场文明施工，作好材料回收工作。九、应用实例该工法由于提高了机械化施工程度，降低劳动强度，并且有一定的社会效益和经济效益，自

26、开发以来，被有关安装队承认并采用。例如在国营二三九厂供热工程施工中，由于采用了该工法，二台10吨/时散装胀接锅炉的安装被评为优质工程，工期提前20天，经济效益和社会效益较为显著，事故发生率为零。受到了上级和当地劳动监察部门的好评。同时，我们也认识到该工法还存在许多不足之处，如炉管胀接工艺的改进和提高，以期胀管质量得到有效控制；对不同型式的锅炉应根据具体情况采取更为合理的安装工艺；以及安装现场多专业，多工种施工时，更加科学地作好劳动力的调配和协调，真正做到“人尽其力，物尽其用”。使工程质量，经济效益，安全生产等方面取得进一步的提高。treatment of heavily polluting i

27、ndustries. According to municipal, and municipal government deployment of seven big heavy pollution industry regulation three years action plans, requirements to December 2016 end of Qian, all included shut stopped eliminated of enterprise all shut stopped eliminated in place; June 30, 2017 Qian, al

28、l included place regulation upgrade and agglomeration restructuring of enterprise by unified standard regulation in place, late not standard of enterprise are implementation discontinued; June 30, 2018 Qian, all intends Park production of enterprise relocation Park in place, late not Park of are dis

29、continued. In the process of renovation, will focus on four aspects: to firmly close the high energy consumption and heavy pollution, hopeless enterprise governance and production lines, eliminated a number of yearly emission intensity, low value-added products of backward production capacity. Secon

30、d, we must strictly enforce the space, total project Trinity environment access system, promoting industry access and environmental conditions of access of enterprises to the Park, industrial park, in principle, no longer the class on the new project. Thirdly, promoting replacement and reconstructio

31、n of heavily polluting industries, mergers and reorganizations, guide enterprises to energy conservation, recycling and low-carbon and clean production, and improve the level of green development. Four to establish a long-term supervision mechanism, increase the intensity of special inspections, inv

32、estigate and punish the rectification is not in place, normal business of running anti-pollution installations do not. (Iii) linkage to promote flood control water, drainage, water supply, improving water saving. Speed up cross Yang support river dike reinforcement, and along Pu seawall except insur

33、ance reinforcement, and Lake Qian sluice, and BA Cao sluice, and cloud cover reservoir, focus flood control drainage engineering construction, vigorously implementation strong library solid di spread row engineering, increased geological disaster hidden points governance efforts, solid advance small

34、 basin torrent disaster governance, efforts from essentially solution basin sex, and regional flood control drainage capacity insufficient of problem. Vigorously implement the piers, algae and other water sources protection and, promoting rural drinking water safety projects, setting up water pricin

35、g reform and environmental protection mechanism, guiding water depth. Further soil pollution and repair, strengthen agricultural non-point source pollution prevention, mountain, water, forests, fields, lakes, various elements mutual long. Four, manage to tighten control, to play three to split battl

36、e. Xia Baolong, Secretary of provincial party Committee stressed that while the three to split operation time is over three years, but three to split must continue to catch on, and resolve a split cannot be changed. All localities and departments to the village and no unauthorised created附件一 劳动力旬平衡计划12345678910人数65605040302010 时间12345678910