MethodStatementFORHVACDuctInstallation暖通风管安装施工方案中

XXXXXProject xxxxXXXXMethodStatementFORHVACDuctInstallation暖通风管安装施工方案MS-OOO-M-0017-REV-1105/04/2015IFA009/03/2015IFAREV#DATEISSUEDFORORIGINATORCHECKEDAPPROVED目录Content26953（1）施工工序332301（1）ConstructionProcedures 3256901.工程概况 3137501.Overview 378512.参考 3211532.References 362543.施工准备 5223803.ConstructionPreparation 54.风管安装 84.HVACDuctInstallation82292（2）风险评估 202497（2）RiskAssessment 2025689（3）安全管理方案 229731（3）SafetyPlan 22施工工序ConstructionProcedures1.工程概况1.Overview此工程为XXXX暖通风管项目。特此编制全厂区风管工程施工方案。TheprojectisHAVCductinstallationprojectofXXXXProject-XXX.ThismethodofstatementisdevelopedforDuctworkinthewholeplant.2.参考2.References适用标准，规范和规格（哈萨克斯坦）ApplicableCodes,StandardsandSpecifications(Kazakhstan)SNiPRK4.02-42-2006Heating,VentilationandAirConditioningSNiPRK4.02-42-2006暖通空调系统SNiPRK2.04-01-2001BuildingClimatologySNiPRK2.04-01-2001建筑气候学SNiPRK2.02-05-2009FireSafetyforBuildingsSNiPRK2.02-05-2009厂房火险安全SNiPRKThermalEngineeringForConstructionSNiPRK施工热力工程GOST12.1-005-88GeneralSanitaryRequirementsforWorkingZoneAirGOST12.1-005-88工作区域气体一般卫生要求。GOST14918-80ContinuousGalvanizedsheetmetalspecificationsGOST14918-80连续镀锌钢板规范。GOST24751-81Airhandlingequipment.Nominaldimensionsofconnection'scrosssectionsGOST24751-81空气处理设备。连接处截面标称尺寸。GOST19903-74Hot-rolledsteelsheetsdimensionsGOST19903-74热轧钢板尺寸。GOST25751Cuttingtools.GeneraltermsanddefinitionsGOST25751切割工具。一般条款和定义。MSN4.02-03-2004Equipment&PipelinesThermalInsulationMSN4.02-03-2004设备和管道热力绝缘。当本地规范不可用或不可行时，用澳大利亚和国际标准和顺序来取代，优先顺序如下：Wherelocalstandardsandcodesaresilent,thenAustralianandinternationalcodesandstandards,willbesubstitutedinorderofprecedenceasfollows:适用规范，标准和规格（澳大利亚）ApplicableCodes,StandardsandSpecifications(Australian)AS4254Ductworkforair-handlingsystemsinbuildingsAS4254建筑物内部空气处理系统风管工程。AS1668Theuseofventilationandair-conditioninginbuildingsAS1668建筑物内通风和空调的应用。AS1554SAAStructuralSteelWeldingCodeAS1554SAA钢结构焊接规范适用规范，标准和规格（国际）ApplicableCodes,StandardsandSpecifications(international)ASHRAE2011ASHRAEHandbookHVACApplicationsASHRAE2011ASHRAE暖通指南应用。SMACNA2005HVACDuctConstructionStandards-MetalandFlexibleSMACNA2005暖通施工标准-金属和灵活部件。SMACNA2004HVACSystems-DuctDesignSMACNA2004暖通系统-风管设计AHRI880-2008PerformanceRatingofAirTerminalsAHRI880-2008空气终端性能功率NFPA90AStandardfortheInstallationofAir-ConditioningandVentilatingSystems3.施工准备3.ConstructionPreparation3.1技术准备3.1Techniquepreparation3.1.1根据设计图纸及设备厂家安装手册（以厂家安装手册为主），进行设计图纸自审和会审，明确施工范围。3.1.1Accordingtodesigndrawings,designdrawingswillbeself-studyandjointly-studytocleartheconstructionscope.3.1.2熟悉图纸，了解相关项目要求施工范围，熟悉相关制度和规格。根据施工顺序和施工进度计划来安排动员材料。现场施工人员须熟悉施工工艺和相应的技术要求，以QA/QC以及进度要求为准则。施工前编制施工方案，并提交业主进行审批。制定合理的施工方案以及施工程序，确保工程能够满足进度以及顺序要求。3.1.2Studythedesigndrawingstocleartheconstructionscopeofprojectrequirements,andfamiliarizewiththerelevantnationalregulationsandspecifications;mobilizetheconstructionmaterialsaccordingtoscheduleandconstructionsequence;on-siteconstructionpersonnelshallbefamiliarwiththeconstructionprocessandtherelatedtechnicalrequirements,andworktotheQA/QCandschedulerequirements.Amethodstatementshallbepreparedandsubmittedforapprovalbeforeconstruction.Determinereasonableconstructionsequenceandconstructionmethods,toensurethatworkisdoneinsequence.3.2人力资源配置3.2Laborresources根据安装任务和施工工期安排配置人员以满足施工计划。操作人员初步配置如下表：Installationpersonnelrequirementshouldbewellarrangedaccordingtoinstallationtasksandconstructionperiod,andpersonnelrequirementshouldbeadjustedimmediatelyinaccordancewiththeactualsituation.PreliminaryarrangementofoperatingpersonnelareasThefollowingtable:Profession职位Numberofpeople人数Profession职位Numberofperson人数Decisionlayer决策层Administrativestaff管理人员2persons2人Workerlayerliftingworker吊装工人2person2人Executivelayer执行层Technician技工4person4人Crane,cardrivers吊车和卡车司机2persons2人Ventilationworkers通风负责工人4persons2人Thequalityengineer质量工程师1person1人Plumbers管工4persons4人Electrician电工1persons1人Safetyofficer安全员1person1人Welder焊工2persons2人Commissioningengineer调试工程师2persons2人Labor劳工11persons10人Total总数36persons36人3.3Constructiontool,equipmentpreparation施工机具准备ThetypeofConstructiontoolsandequipmentareasperthefollowingtable.Beforeapproachingandcomingintouse,Machineryandequipmentshallbecheckedbysafetydepartmentandcertified.施工机具类型如下表所示。在使用前以及使用时须经过相关安全部门检查并认证。No.序号EquipmentName设备名称Size/Model大小和型号Unit单位Qty数量1Truck-mountedcrane卡车吊25tea.12Flattruck平板车20tea.13Nylonsling尼龙吊带2tset24Snapring卡环2tea45Lifttrucks吊车18mea.16Sectionsteelcutter钢板切割器ea27Chainblock链条葫芦2tea48ACarcwelderAC弧焊机BX1-315ea29Anglegrinder角磨机GWS6-100100Eea.410Spiralduct

machine螺旋风管机SBTF-1500ea.111Flanging

machine矩形风管折边机ea.112Ductbitemachine矩形风管咬口机SA-12Bea.1HVACDuctInstallation暖通风管安装4.1材料选择4.1ThechoiceofmaterialsTheoutdoor&indoorductworkshallbeconstructedfromprimequalitygalvanizedsteeltoATSMAG53A,Theminimumzinccoatingrequirementonstandard1000×2000mmgalvanizedsheetsshallbeinaccordancewiththefollowingschedule:镀锌板材须及以下计划一致：0.26kg/m2(0.85ouncepersqft)for0.5mmthicksheets0.26kg/m2(0.85ouncepersqft)0.5mm厚钢板0.315kg/m2(1.05ouncepersqft)forsheets0.6mmto1mmthick0.315kg/m2(1.05ouncepersqft)0.6到1mm厚钢板0.375kg/m2(1.25ouncepersqft)forsheets1.20to1.25mmthick0.375kg/m2(1.25ouncepersqft)1.20到1.25mm厚钢板Accordingtotheaboverequirements,andcombinedwiththeactualsituation,thefollowingfabricationscheduleforgalvanizedsheetmetalductingwillbeused:根据以上要求，结合实际情况，镀锌金属板的制作计划如下：Platethickness(SNiP4.02-42-2006)板厚（SNiP4.02-42-2006）CircularductsMinimumductdiameter(mm)UptoMaximumductdiameter(mm)Sheetthickness(mm)0to200inclusive0.5250to450inclusive0.6500to800inclusive0.7900to1250inclusive1.01400to1600inclusive1.2RectangularductsMinimumgreaterside(mm)UptoMinimumgreaterside(mm)Sheetthickness(mm)0to250inclusive0.5300to1000inclusive0.71250to2000inclusive1.02000to2300inclusive1.2notono34.2风管制作4.2Ductpipefabrication4.2.1圆形风管制作卷管：圆形风管我们将用螺旋风管机自动卷管、机械内部自动咬口自动成型；Rollingpipe:Forfabricationofroundductpipe,weshallautomaticallyrolltubebyspiraltubemachine,occlusionandformingautomaticallyinsidemachine.螺旋风管机卷管成型图SPIRALDUCTPIPEROLLINGANDMOLDINGFIGURE连接：圆形风管连接方式根据直径不同而不同，直径0＜Ф≤800的我们将采用“插座连接”方式；800＜Ф≤1500我们将采用“平环法兰连接”方式。Connection:Roundductconnectionwayshallbevariousasperdifferentdiameter,weshalluse“socketconnection”forpipeofdiameter0＜Ф≤800;use“flatringflangedconnection”forpipeofdiameter800＜Ф≤1500.CIRCULARDUCTPIPECONNECTIONSHOWNASBELLOWi:插座连接法（0＜Ф≤800）Socketconnection（0＜Ф≤800）：ROUNDSPIRALDUCTJOINTS圆形螺旋风管接头连接Flatringflangedconnection（800＜Ф≤1500）：圆形风管加固：风管将用镀锌螺栓和铆钉加固。所用法兰边沿以及其他的缝口将用风管密封剂进行密封。镀锌铁皮风管所有角度的铆钉,除了在管道系统的实例部分镀锌生产后,在这种情况下,成角部分可以焊接。Roundductpipereinforcement:Itwilluserivetsandgalvanizedboltsinductwork.Allslipflangesandotherjointswillbesealedbyductsealant.Rivetallanglestogalvanizedsheetmetalduct,exceptininstanceswhereductworksectionsaregalvanizedaftermanufacture,inwhichcaseanglesmaybewelded.4.2.2矩形风管制作4.2.2Rectangularductfabrication矩形风管成形及咬口：矩形风管制作我们将采用矩形风管折边机及咬口机进行制作成型，风管的咬口采用“两片成型法”，具体如下图所示：Rectangularductmoldingandocclusion:Forrectangularductfabrication,weuseflangingmachineandnipmachine,occlusionofductuse“two-pieceformingmethod”,anddetailshownasbelow:两片成型法成型示意图Two-pieceformingmethodMoldingfigure图中所示L1=13~16mm，L2=7~10mm，L3=6~8mm（板材厚度δ符合SNiP4.02-42-2006）InthefigureL1=13~16mm，L2=7~10mm，L3=6~8mm(thicknessofplateδcoincideswithSNiP4.02-42-2006)矩形风管采用薄钢板“连体法兰”连接：矩形风管我们采用薄形钢板连体法兰连接Connection:Rectangularductuse“thinsteelplateflangedconnection”.THINSTEELPLATEFLANGEDCONNECTIONTHESPRINGCLIP薄钢板法兰弹簧夹弹簧夹板厚（mm）Springclipthickness(mm)使用范围Usingrange≥1.0Mediumandlowvoltageduct中低压风管风管加固：矩形风管加固采用轧制加强筋的方法加固，加固间距200mm~300mm。Ductreinforcement：Reinforcerectangularductbyrollingstrengtheningrib,reinforcementdistance200mm~300mm.4.3Ductworksupports风管支撑Supportsforducts,dampers,etc.shouldbegalvanized.Ductworksupportsareasfollowingtable:风管，气阀等的支撑需要镀锌。风管支撑如下表：SPIRALDUCTSUPPORTSSPIRALDUCTDIAMETER(mm)螺旋风管直径（mm）MAX.HANGERSPACING最大挂钩间距RODANDSTETBOLTmmФ杆和膨胀螺栓FLATBARSUPPORT(wxt)平条支撑HORIZONTAL水平VERTICAL垂直UPTO200到2005003000625x3m201TO800201到80025003000625x3m801TO1000801到1000200025001032x3mm1001TO15001001到1500200025001240x3mmRectangularDuctHangers–MinimumRequirements矩形管吊架Maximumhalfofductperimeter(p/2)MaximumSpacingRodDiameterStrapSizeUpto750mm3000mm6mm25x0.8(mm)751mmto1800mm3000mm10mm25x1.2(mm)1801mmto2400mm3000mm10mm25x1.6(mm)4.3.1SpiralductsupportsHorizontalroundduct垂直圆管支撑4.3.2Rectangularductssupports注：图中C型钢吊架可及同类型角钢互换Note:The

figure

ofCtype

steel

hanger

isinterchangeable

withthesametypeofanglesteel水平矩形管SUPPORTFORHORIZONTALRECTANGULARDUCT垂直矩形管支撑SUPPORTFORVERTICALRECTANGULARDUCT4.4DuctworkInsulation风管保温绝缘Ductworkshallbeinsulatedtopreventcondensationandunnecessaryheatexchangeandmaintainthefireintegrityofbulkheads.风管需要进行保温绝缘保护，以防凝结以及不必要的热量交换，维持隔板热量一致Allinsulatingmaterialsshallhavethefollowingproperties:所有保温绝缘材料需要具有以下性能：Benon-combustible非易燃物Notemittoxicfumesorsmokewhenheated加热时不会排除毒性气体或烟雾Beinorganicandnon-hygroscopic无机材料，Bechloridefree不含氯化物Beasbestosfree不含石棉Theinsulationshallbecutonsitetosuitthesizeoftheductwork.Onrectangularductworkthetopandbottomsectionsofinsulationshalloverlapthesidesections.Theinsulationshallbebondedtotheductworkbymeansofasuitableadhesive,whichshouldbeappliedinfullaccordancewiththemanufacture'srecommendations.绝缘材料需要根据风管的现场尺寸来进行切割，使之及风管的尺寸一致。方管顶端和底端的绝缘需要及侧面的进行搭接。绝缘材料需要使用适合的粘合剂量粘合在风管上，在应用时要安全按照厂家的推荐进行使用。Allductworkinsulationshallbeadditionallysecuredtotheductwork,bymeansof25mmwidebandsat600mmcenters.Furthermore,theinsulationontheundersideoftherectangularductworkshallbeadditionallysecured,bymeansofsuitableinsulationhangers,at300mmcenters.Cornerreinforcementangles,topreventthecrushingofinsulation,shallbeprovidedonrectangularductwork.所有的风管绝缘层都需要用25mm宽的带状物（间距600mm中心到中心）进行加固到风管上。并且，方管底端的绝缘保护层需要用合适的绝缘挂件（挂钩）进行加固到方管上，间距300mm中心到中心。方管的四个角上的位置需要用加固角钢进行加固，防止绝缘层破环。Whereinstruments,tapings,controldampers,accessdoorsorsimilaritemsareprovidedontheductwork,theinsulationshallbecutawayandtheedgesneatlyfinishedandsealed,tocreateadjacentfinishes,allowingclearaccesstoeachitem.当仪表，龙头，控制气阀，进入门，或类似的部件需要安装在风管上时，绝缘层需要根据相关部件的尺寸进行切割，切割后的边沿要进行处理密封.为每个部件留出通道。Insulationshallbeeasilyremovableandreplaceableatpointsrequiringinspectionsandmaintenance.在接头处需要进行检测和维修的地方的绝缘层须能随便进行移动和替换。Thethermalinsulationappliedtotheexternalfacesofductworkshallbemanufacturedfromamaterialwithspecificationssimilartothefollowingasaminimumrequirement:风管外边面的保温绝缘层制作的材料至少要满足以下规范：Density:_50kg/m3密度：-50kg/m3KValue:0.030W/mKat100CK值：0.030W/mK@100WaterVapourTransmission:10ugm/Nhat380C,88070RH水蒸气传送：10ugm/Nh@380C，88070RHFireProperties:Class'O'toBuildingCodeRegulations火性能：建筑物规范条例“O”级ClosedCellContent:90070minimum封闭槽（细胞）含量：90070最小。Theinsulationatsupportpointsshallbeofaheavydensity(80kg/m3minimum).支撑点的绝缘层的密度需要大一些（最小80kg/m3）室外风管我们将采用超细玻璃保温棉作为保温材料保温，具体如下：RequiredDuctworkInsulationThicknessLocationofDuctSupplyAir供风ReturnAir回风ExhaustAir排风InExposedAirarea50mm25mmNotinsulated不保温Innon-heatedarea25mm25mmNotinsulated不保温Inheatedarea25mmNotinsulated不保温Notinsulated不保温风管保温示意图Allexposedinsulatedductworkshallbecoveredwith0.6mmthickaluminiumjacketsheetingtopreventwatervapourtransmissionandkeeptheinsulationdrytopreventstructuraldamage.Theinstalledjacketsheetingshallhavealljointslappedandarrangedtoensurethesheddingofwater.4.5AftertheHVACductinstallation风管安装完成后的后续工作Supervisortoensurethatallcompletedinstallationslookneatandtidy,andthatthereisadequatespacingbetweenductworkandinlineequipmentallowingaccessforoperationandeaseofmaintenance,toapproveddrawingsandmanufacture'srecommendations.现场主管需要确保以完成的工程表面干净而整洁，并且学要确保风管和管道内设备有足够的间距，以便能够进入进行操作和维修，以厂家的推荐和获批的图纸为根据。Thesupervisorinchargeshallcontinuouslymonitortheactivitiestoensurethatallcomponentsindicatedontheapproveddrawingshavebeeninstalledandthattheinstallationisinaccordancewiththecontractrequirementsandspecifications。现场的负责人要不断监控现场的活动，确保所有获批图纸上的所有部件安装完毕，确保安装合同要求以及规范一致。RiskAssessment风险评估RiskAssessmentofElectricalInstallation电气安装风险评估WorkScope工作范围WorkPhase工作阶段IdentifiedRisk风险鉴别LikelyConsequence风险后果MitigationStrategy修正措施UnitheaterInstallation加热器安装Pre-lifting预吊装Nopermitofliftingwork无吊装许可Operatingagainsttheregulations违规操作Applyforpermitofworkpriortoeveryliftingworkinaccordancewiththeregulations.规矩规定在每次吊装作业前开工作许可Insufficientpersonalprotectiveequipment(PPE)劳保用品佩戴不齐Incidentsandinjuries事故和伤亡EnsuretoequipwithPPE,safetybelt,hamletandlifevest,checkthoroughly彻底检查，保证PPE，安全带，安全帽和马甲佩戴齐全。Operatorsarenottrainedwithsafetyregulations操作员没经过安全培训Injurytopersons人员伤亡Workertrainingpriortoliftingworkandsitetraining员工吊装前培训，现场临时培训。Inadequatemonitoring监管不力Dealingwithincidentsnottimelywhichresultsinseriousincident.未及时处理事故，导致更严重事故发生Constantmonitoringbywelltrainedpersonnelandoverallexaminationbeforestartworking.有经过培训的人员不断监管，开工前大检查Inadequatefireequipmentandimproperemergencyrescuemeasures防火设备不足，紧急撤离措施不可行Injurytopersons人员伤亡Overallexaminationbeforestartandensurefireequipmentandemergencymedicineareallavailable.开工前大检查，确保防火设备和紧急药物就为Slingisdamagedseriously,whilethesafetyfactorsarenotuptotherequirements吊带严重破损，安全因素没满足要求Fallfromhighandinjurytoperson高出坠落和人员伤亡Overallexaminationonsteelmaterialsandexecutestrictlyinaccordancewiththeregulations.对钢丝材料进行大检查，并严格按规定来执行操作DefectorDamagedmaterialsandtools工具材料缺陷或破坏Injurytopersons人员伤亡Overallexaminationbeforeusing.使用前大检查Lackofcommunicationwiththesite,unclearsignalandincorrectcommanding.缺乏及现场沟通。标志不清处，指挥不当Injurytopersons人员伤亡Establishcontactwithappointedpersonandcommandusingunifiedsignals.由专人和现场联系沟通，用统一的标志指挥现场。Nosafetycordonsorwarningsigns.无安全警戒线或警告标志Injurytopersons人员伤亡Delineatecordonsandsetwarningsigns.设置警戒线和警告标志RiskAssessmentofElectricalInstallation电气安装风险评估WorkScope工作范围WorkPhase工作阶段IdentifiedRisk风险鉴定LikelyConsequence后果MitigationStrategy修正措施UnitheaterInstallation加热器安装Pre-lifting预吊装Non-constructionpeopleenterintoconstructionsite非施工人员进入施工现场Injurytopersons人员伤亡Designatepersontomonitorandsafeguard,orputupwarningsigns.设专人进行监控和保护，设置警告标志Liftimproperly不正当吊装Injurytopersons人员伤亡Doashortpre-liftwithlowangle.吊装角度底短时不要吊装Electrocution(byuseofelectricmachines)触电事故（使用电气设备）Fatality/injury致命或伤亡Checkthecablesforanydamagetoinsulation.onlyinsulatedtoolstobeused.Electricalcablesshallbelooselycoiledtoavoidanyoverheating.检查电缆绝缘层是否破损。只能用绝缘工具。电缆线疏松打圈放置，避免温度过高DangerofFireandexplosion火灾和爆炸危险Equipmentandpropertydamage设备和物产损坏Allequipmentmustbeproperlyearthed(forstaticelectricity),Ensurefireextinguishersareplacedinappropriatelocation所有设备都必须接地（静电），确保灭火器放到正确位置。Leakageofhazardousmaterialorotherabnormalties危险物品泄漏或其他不正常的连接Injurytopersons人员伤亡Stopworkingandwithdrawthepersonnel.停止工作，撤离人员Aftercompletion完工后Notcleanupthesite现场没有清理Injurytopersons人员伤亡Cleanupthesitetimely及时清理现场XXXKazakhstanCopperProjectHVACDuctInstallationSafetyManagementPlanXXX哈斯克斯坦铜矿项目暖通空调风管安装安全管理规定GeneralRequirements总要求1.1在工作之前，按照作业程序要求，必须申请PTW工作许可，同时附带风险评估及JHA工作安全分析。1.2Compilemethodstatement(MS)forsteelhoistingandmakeallparticipantsinvolvedinthistaskhavefullunderstandingwiththeMSandsafetyplan.编制钢构件吊装方案，确保所有参及人员完全掌握方案意旨和安全规定。1.3Operatingareashouldbeclearlydefinedwithconspicuoussigns(inallcommonlanguagesusedonsite);onlyauthorizedpersonnelareallowedforentrance;forextremelydangeroussite,monitoringpersonneedtobearrangedforsecurity.操作区域要安装明显可见的标志（用现场所有通用语言）；未经授权人员不得进入；特别危险区域要派人进行安全监管。1.4Operatorsmusthavelicensedissuedbyauthorizeddepartment.操作人员必须有法定授权部门签发的证书。1.5Thegroundcommandermustinstructhoistingworkduringthewholeoperationandhecannotholdotherjob,watchliftingvehiclesandensuretheoperatorgettheclearandexactcom