TSG07-2019鍋爐安裝工藝+焊接專用工藝卡+施工記錄表

文件編號(hào)：NTADMK/GY-2021

版本狀態(tài)：B/0

受控狀態(tài)：|受控

發(fā)放編號(hào)：ADMK-005

工業(yè)鍋爐安裝通用工藝（含焊接

工藝卡）+施工記錄表

編制：__________________

審核：__________________

批準(zhǔn)：__________________

南通艾德瑪柯XX鍋爐設(shè)備安裝有限公司

頒布日期：2021-6-3實(shí)施2021-7-3

安裝工藝文件文件編號(hào)NTADMK/GY-00

主題目錄頒布日期2021年?6月3日

總目錄

第一部鍋爐安裝工藝...........................................................17

第一章鍋爐安裝施工組織設(shè)計(jì)通用要求............................................18

1.1工程概況及說明.............................................................18

1.1.1工程名稱.................................................................18

LL2使用單位情況介紹：.......................................................18

1.1.3鍋爐制造單位.............................................................18

1.1.4鍋爐型號(hào)及技術(shù)參數(shù)情況...................................................18

L1.5基本情況.................................................................18

1.1.7施工依據(jù)：..............................................................19

1.1.8施工單位：..............................................................19

1.2鍋爐的技術(shù)資料及施工圖的審查...............................................19

L3施工圖審查.................................................................20

1.4鍋爐安裝施工計(jì)劃的編制....................................................20

1.5施工人員及安裝設(shè)備、器具組織計(jì)劃..........................................21

L6主要施工工藝技術(shù)措施.......................................................24

1.6.1施工準(zhǔn)備到竣工全過程施工工序.............................................24

1.6.2基礎(chǔ)檢查及劃線...........................................................24

1.6.3鍋爐本體安裝.............................................................25

1.6.4鍋筒、集箱及受熱面的安裝.................................................26

L6.5受壓元件的焊接...........................................................28

1.6.6鍋爐砌筑..............................................................................................................................................29

1.6.7爐排及變速箱安裝和冷態(tài)試運(yùn)轉(zhuǎn)...........................................31

1.6.8省煤器、空氣預(yù)熱器的安裝................................................32

L6.9附屬設(shè)備的安裝...........................................................33

1.6.10上煤及除渣系統(tǒng)的安裝....................................................34

1.6.11除塵系統(tǒng)安裝............................................................35

安裝工藝文件文件編號(hào)NTADMK/GY-00

主題目錄頒布日期2021年?6月3日

1.6.12水處理設(shè)備安裝..........................................................36

1.6.13安全附件的安裝..........................................................36

1.6.14電氣設(shè)備安裝............................................................38

1.6.15線路敷設(shè)................................................................38

1.6.16熱力管道安裝............................................................38

1.6.17儀表安裝及調(diào)試..........................................................40

1.6.18水壓試驗(yàn)................................................................40

1.6.19烘爐、煮爐..............................................................41

1.6.20嚴(yán)密性試壓和試運(yùn)行.....................................................42

第二章鍋爐安裝質(zhì)量計(jì)劃及安裝質(zhì)量控制環(huán)境、控制點(diǎn)..............................44

2.1鍋爐安裝質(zhì)量計(jì)劃...........................................................44

2.1.1質(zhì)量計(jì)劃的內(nèi)容..........................................................44

2.1.2質(zhì)量目標(biāo)................................................................44

2.1.3質(zhì)量管理機(jī)構(gòu)............................................................44

2.1.4過程控制................................................................45

2.1.5檢驗(yàn)試驗(yàn)計(jì)劃............................................................45

2.2鍋爐安裝質(zhì)量控制環(huán)節(jié)、控制點(diǎn)..............................................46

第三章焊接工藝.............................................................50

3.1焊接準(zhǔn)備工作..............................................................50

3.1.1坡口制備................................................................50

3.1.2焊接設(shè)備機(jī)具準(zhǔn)備........................................................50

3.1.3焊接材料的準(zhǔn)備..........................................................50

3.2焊工培訓(xùn)與考核.............................................................51

3.3焊接工藝評(píng)定...............................................................51

3.4管子的對(duì)口焊接.............................................................51

3.4.1鍋爐受熱面管子焊接.......................................................51

焊接工藝卡（管-管對(duì)接、垂直固定）..............................................54

焊接工藝卡（管-板角接、水平固定）..............................................55

安裝工藝文件文件編號(hào)NTADMK/GY-00

主題目錄頒布日期2021年?6月3日

焊接工藝卡（管-管對(duì)接、垂直固定）................................................56

焊接工藝卡（管-板角接、垂直仰位）..............................................57

焊接工藝卡（管-板角接、垂直俯位）..............................................58

焊接工藝卡（管子對(duì)接、水平固定673~e159）........................................59

焊接工藝卡（管子對(duì)接、水平固定632~巾57）.........................................60

焊接工藝卡（管-板、垂直俯位SMAW+GTAW）...........................................61

3.5焊接檢驗(yàn)與質(zhì)量要求........................................................63

3.5.1原材料檢驗(yàn)..............................................................63

3.5.2焊接設(shè)備的檢查..........................................................63

3.5.3對(duì)口質(zhì)量的檢查..........................................................63

3.5.4焊接工藝的檢驗(yàn)..........................................................63

3.5.5焊接接頭的質(zhì)量檢驗(yàn).....................................................63

3.6焊縫返修..................................................................65

第四章脹接工藝................................................................66

4.1脹前準(zhǔn)備..................................................................66

4.2脹管操作..................................................................69

4.3脹接質(zhì)量的檢查............................................................70

第五章熱處理工藝..............................................................72

5.1總則......................................................................72

5.2編制依據(jù)..................................................................72

5.3施工準(zhǔn)備..................................................................72

5.4熱處理....................................................................73

5.4.1熱處理范圍...............................................................73

5.4.3熱處理工藝...............................................................74

5.5質(zhì)量標(biāo)準(zhǔn)..................................................................75

5.6質(zhì)量文件...................................................................76

第六章無損檢測(cè)工藝............................................................77

6.1總則......................................................................77

安裝工藝文件文件編號(hào)NTADMK/GY-00

主題目錄頒布日期2021年?6月3日

6.2射線檢測(cè)...................................................................77

6.2.1適用范圍.................................................................77

6.2.2對(duì)探傷人員的要求.........................................................77

6.2.3對(duì)透照工件表面的要求.....................................................77

6.2.4探傷比例的要求及合格級(jí)別.................................................78

6.2.5器材的選擇...............................................................78

6.2.6透照工藝.................................................................78

6.2.7膠片的暗室處理...........................................................79

6.2.8底片質(zhì)量.................................................................79

6.2.9底片的觀察...............................................................79

6.2.10記錄報(bào)告................................................................79

6.2.11安全防護(hù)................................................................80

6.3超聲波檢測(cè).................................................................80

6.3.1適應(yīng)范圍.................................................................80

6.3.2對(duì)探傷人員的要求.........................................................80

6.3.3對(duì)超聲波探傷表面的要求...................................................80

6.3.4儀器、探頭、試塊與耦合劑.................................................80

6.3.5探傷工藝.................................................................81

6.3.6缺陷的評(píng)定...............................................................82

6.3.7小徑管焊接接頭的超聲波探傷...............................................82

6.3.8探傷報(bào)告.................................................................82

6.4磁粉探傷工藝...............................................................83

6.4.1探傷人員.................................................................83

6.4.2設(shè)備、磁粉及靈敏度試片的選用.............................................83

6.4.3工作表面要求.............................................................83

6.4.5檢驗(yàn)步驟.................................................................83

6.4.6當(dāng)出現(xiàn)下列情況之一時(shí)需復(fù)檢：.............................................83

6.4.7缺陷顯示痕跡等級(jí)評(píng)定.....................................................83

安裝工藝文件文件編號(hào)NTADMK/GY-00

主題目錄頒布日期2021年?6月3日

6.5滲透檢測(cè)工藝...............................................................84

6.5.1一般事項(xiàng).................................................................84

6.5.2探傷的方法...............................................................84

6.5.3滲透處理.................................................................85

6.5.4清洗處理.................................................................85

6.5.5干燥處理.................................................................85

6.5.6觀察.....................................................................85

6.5.7復(fù)驗(yàn).....................................................................85

6.5.8后處理...................................................................85

6.5.9探傷劑...................................................................85

6.5,10對(duì)比試塊................................................................85

6.5.11缺陷顯示痕跡............................................................85

6.5.12缺陷顯示痕跡的等級(jí)分類..................................................86

6.5.13探傷結(jié)果的標(biāo)識(shí)與記錄....................................................86

6.6相關(guān)/支持性文件............................................................86

第七章吊裝、就位工藝.........................................................88

7.1總則.......................................................................88

7.2工作職責(zé)...................................................................88

7.3起重與吊裝方案.............................................................88

7.4起重與吊裝施工.............................................................89

7.4.1吊裝前的檢查。...........................................................89

7.4.2試吊.....................................................................90

7.4.3起吊就位.................................................................90

7.5整裝鍋爐和組裝鍋爐的吊裝...................................................90

7.5.1整裝鍋爐吊裝工藝.........................................................90

7.5.2組裝鍋爐吊裝工藝.........................................................90

7.6索具采購、保養(yǎng)和維護(hù).......................................................93

7.7就位.......................................................................93

安裝工藝文件文件編號(hào)NTADMK/GY-00

主題目錄頒布日期2021年?6月3日

7.7.1鍋爐基礎(chǔ)的檢查..........................................................93

7.7.2整裝鍋爐本體就位。......................................................94

7.7.3組裝鍋爐鋼架及本體就位。................................................94

第八章鋼結(jié)構(gòu)（包括平臺(tái)扶梯）制作安裝工藝.....................................97

8.1基礎(chǔ)驗(yàn)收、劃線和處理.......................................................97

8.1.1基礎(chǔ)外觀檢查............................................................97

8.1.2基礎(chǔ)劃線步驟............................................................97

8.1.3基礎(chǔ)處理................................................................97

8.2平臺(tái)扶梯施工順序..........................................................98

8.3一般規(guī)定..................................................................99

8.4鋼架組合架.................................................................99

第九章校正、組合工藝.........................................................106

9.1受熱面管子的檢查校正和組合...............................................106

9.1.1放樣平臺(tái)的搭設(shè).........................................................106

9.1.2放樣...................................................................106

9.1.3受熱面管子的檢查與校驗(yàn)................................................107

9.2管束與鍋簡(jiǎn)、集箱的焊接...................................................110

9.2.1管束與鍋筒的焊接.......................................................110

9.2.2管束與集箱的焊接.......................................................111

9.3焊接變形的矯正與防止措施.................................................111

9.3.1施工中防止焊接變形的措施...............................................111

9.3.2焊接變形的矯正.........................................................112

第十章鍋爐修理工藝...........................................................113

10.1爐管拆換和組裝工藝......................................................113

10.2鍋筒挖補(bǔ)和受壓部件焊接工藝..............................................113

10.3無損探傷：見無損檢測(cè)工藝................................................115

10.4水壓試驗(yàn)................................................................115

第十一章受熱面管子安裝工藝...................................................116

安裝工藝文件文件編號(hào)NTADMK/GY-00

主題目錄頒布日期2021年?6月3日

11.1水冷壁組合安裝.........................................................116

11.2省煤器組合安裝..........................................................117

11.3過熱器組合安裝..........................................................120

11.4調(diào)溫器安裝..............................................................121

11.5鍋筒安裝.................................................................122

第十二章鑄鐵省煤器及空氣預(yù)熱器的安裝工藝.....................................124

12.1鑄鐵省煤器水壓試驗(yàn)要求...................................................124

12.2冀片檢查.................................................................124

12.3煙道密封施工要求.........................................................124

12.4鑄鐵省煤器安裝偏差.......................................................124

12.2空氣預(yù)熱器的安裝工藝.....................................................124

12.1空氣預(yù)熱器安裝前的檢查...................................................124

12.2管箱式預(yù)熱器的安裝.......................................................124

12.2.1準(zhǔn)備..................................................................124

12.2.2設(shè)置吊裝機(jī)具..........................................................125

12.2.3找正支承梁............................................................125

12.2.4起吊就位..............................................................125

12.2.5預(yù)熱器附件安裝........................................................125

12.2.6空氣試漏...............................................................125

12.3安裝檢查合格標(biāo)準(zhǔn)（表12-2）..............................................................................................125

第十三章整裝鍋爐安裝工藝....................................................127

13.1總則...................................................................127

13.2安裝前的準(zhǔn)備.............................................................127

13.2.1鍋爐房定點(diǎn)手續(xù)，鍋爐設(shè)計(jì)圖紙的檢查.....................................127

13.2.2制造廠家圖紙的清點(diǎn)、檢查...............................................127

13.2.3設(shè)備及零部件的清點(diǎn)檢查.................................................128

13.2.4基礎(chǔ)的測(cè)量與驗(yàn)收.......................................................129

13.3鍋爐安裝工藝.............................................................129

安裝工藝文件文件編號(hào)NTADMK/GY-00

主題目錄頒布日期2021年?6月3日

13.3.1鍋爐本體安裝..........................................................129

13.3.2水位計(jì)的安裝要求：....................................................130

13.3.3壓力表的安裝要求：.....................................................131

13.3.4水位控制器、報(bào)警器的安裝：.............................................131

13.3.5安全閥的安裝：........................................................132

13.3.6鍋爐附屬設(shè)備的安裝....................................................132

13.3.7輔機(jī)安裝..............................................................134

13.3.8水處理設(shè)備的安裝......................................................136

13.3.9管道、閥門安裝.........................................................137

13.3.10電氣儀表、控制設(shè)備及動(dòng)力線路的安裝...................................139

13.3.11焊接的要求...........................................................139

13.3.12水壓試驗(yàn).............................................................140

13.3.13保溫和防腐...........................................................142

13.3.14烘爐、煮爐、調(diào)整安全閥試運(yùn)行........................................142

13.3.15整體驗(yàn)收.............................................................146

第十四章組裝鍋爐安裝工藝.....................................................148

14.1總則....................................................................148

14.2安裝工藝.................................................................148

14.2.1鍋爐房定點(diǎn)手續(xù)，鍋爐設(shè)計(jì)圖紙的檢查.....................................148

14.2.2制造廠家圖紙的清點(diǎn)、檢查...............................................148

14.2.3設(shè)備及零部件的清點(diǎn)檢查.................................................149

14.2.4基礎(chǔ)的測(cè)量與驗(yàn)收.......................................................150

14.2.5鋼架安裝..............................................................151

14.2.6鍋筒、聯(lián)箱的安裝......................................................151

14.2.7受熱面管安裝..........................................................151

14.2.8脹管..................................................................152

14.2.9受壓元件的焊接.........................................................152

14.2.10省煤器及空氣預(yù)熱器安裝................................................153

安裝工藝文件文件編號(hào)NTADMK/GY-00

主題目錄頒布日期2021年?6月3日

14.2.11水壓試驗(yàn).............................................................154

14.2.12爐墻砌筑.............................................................155

14.2.13烘爐、煮爐...........................................................156

14.2.14嚴(yán)密性試驗(yàn)及試運(yùn)行...................................................157

14.2.15總體驗(yàn)收投入使用.....................................................157

第十五章水汽管道系統(tǒng)安裝工藝.................................................159

15.1總則....................................................................159

15.2管子及管件安裝前的檢驗(yàn)..................................................159

15.2.1管子的檢驗(yàn)............................................................159

15.2.2管道附件檢驗(yàn)..........................................................159

15.3鋼管的加工預(yù)制..........................................................159

15.3.1管子的切割............................................................159

15.3.2鋼管彎制..............................................................160

15.3.3管子彎制后的質(zhì)量要求..................................................160

15.3.4TI形補(bǔ)償器制作.........................................................161

15.3.5管道預(yù)制..............................................................161

15.4管道附件配制............................................................161

15.5管道安裝................................................................161

15.5.1施工測(cè)量..............................................................161

15.5.2支吊架安裝............................................................162

15.5.3管道敷設(shè)..............................................................162

15.5.4管道系統(tǒng)試壓和沖洗....................................................163

15.5.5管道涂漆與絕熱........................................................163

15.6相關(guān)標(biāo)準(zhǔn)................................................................163

第十六章水壓試驗(yàn)工藝.........................................................164

16.1水壓試驗(yàn)的條件..........................................................164

16.2組織....................................................................164

16.3水壓試驗(yàn)前的準(zhǔn)備工作....................................................164

安裝工藝文件文件編號(hào)NTADMK/GY-00

主題目錄頒布日期2021年?6月3日

16.4水壓試驗(yàn)壓力.............................................................165

16.5水壓試驗(yàn)要求.............................................................165

16.6水壓試驗(yàn)步驟及試壓過程控制..............................................166

16.7水壓試驗(yàn)合格要求.........................................................166

16.8水壓試驗(yàn)后工作...........................................................167

第十七章筑爐工藝.............................................................168

17.1筑爐基本要求.............................................................168

17.2筑爐工作應(yīng)具備下列條件..................................................168

17.3現(xiàn)場(chǎng)配置混凝土及抹面灰要求...............................................168

17.4耐火混凝土爐墻起吊規(guī)定...................................................168

17.5混凝土爐墻、磚砌輕型爐墻的膨脹縫:.........................................168

17.4爐墻施工間隙規(guī)定.........................................................169

17.5混凝土施工要求..........................................................169

17.6框架式耐火混凝土爐墻施工規(guī)定............................................169

17.7敷管爐墻施工應(yīng)符合要求...................................................170

17.8豉砌爐墻施工應(yīng)符合的要求................................................170

第十八章燃燒器及爐排安裝與調(diào)試...............................................174

18.1燃燒器安裝工藝..........................................................174

18.1.1主要施工方法及技術(shù)措施.................................................174

18.1.2質(zhì)量要求...............................................................174

18.1.3燃燒的調(diào)試.............................................................175

18.1.4正常運(yùn)行...............................................................175

18.1.5日常維護(hù)：.............................................................175

18.1.6每月維護(hù)..............................................................176

18.1.7半年維護(hù)..............................................................176

18.1.8一年維護(hù)..............................................................176

18.2爐排安裝................................................................176

18.2.1手燒爐排安裝（多為鑄鐵澆制）..........................................176

安裝工藝文件文件編號(hào)NTADMK/GY-00

主題目錄頒布日期2021年?6月3日

18.2.2鏈條爐排的安裝.........................................................176

18.2.3爐排的安裝.............................................................177

18.2.4加煤斗安裝.............................................................179

18.3爐排的冷態(tài)試運(yùn)轉(zhuǎn)和調(diào)試...................................................179

18.3.1運(yùn)轉(zhuǎn)前的準(zhǔn)備工作.......................................................179

18.3.2冷態(tài)運(yùn)轉(zhuǎn)和調(diào)整.........................................................179

第十九章輔機(jī)及安全附件的安裝.................................................180

19.1總則.....................................................................180

19.2風(fēng)機(jī)的安裝...............................................................180

19.2.1安裝前的準(zhǔn)備工作.......................................................180

19.2.2風(fēng)機(jī)安裝工藝...........................................................180

19.2.3分步試運(yùn)...............................................................182

19.3給水設(shè)備的安裝...........................................................183

19.3.1各種給水泵的安裝.......................................................183

19.3.2給水泵的找正...........................................................183

19.4給水箱的布置和安裝.......................................................183

19.4.1給水箱的布置：.........................................................183

19.4.2給水箱的安裝：.........................................................184

19.5碎煤機(jī)和輸煤設(shè)備的安裝...................................................184

19.5.2碎煤機(jī)（錘擊式和反擊式）的安裝...........................................189

19.5.3輸煤設(shè)備的安裝.........................................................189

19.6除渣設(shè)備的安裝...........................................................191

19.7除塵設(shè)備的安裝...........................................................191

19.8安全閥的安裝.............................................................192

19.9水位表的安裝.............................................................193

19.10壓力表安裝..............................................................193

19.11閥門安裝................................................................193

19.12溫度計(jì)的安裝............................................................193

安裝工藝文件文件編號(hào)NTADMK/GY-00

主題目錄頒布日期2021年?6月3日

第二十章水處理設(shè)備安裝調(diào)試工藝....................