電伴熱施工技術(shù)方案（中英文版）
Technical Scheme for Construction of Electric Heat Trace Project
一、工程概況 ⅠProject Overview
本工程為船舶涂料公司5000萬升/年船舶涂料機(jī)電安裝工程，工程位于青島高新技術(shù)產(chǎn)業(yè)新城區(qū)內(nèi)新材料團(tuán)地。
The project is an electrical and mechanical installation project of Jotun COSCO Marine Coatings (Qingdao) Co., Ltd, for ship coatings of 50 million liters per year. The project is situated within the new material section of Qingdao Hi-tech Industry development zone.
工程環(huán)境為防爆區(qū)域，需嚴(yán)格按照設(shè)計、規(guī)范要求施工，本方案為施工技術(shù)、質(zhì)量、安全做出指導(dǎo)。
The project locates within explosion-proof region, thus the construction should be in strict accordance with the requirements of design and specification. The scheme will provide guidance for the project in the aspect of construction technology, quality and safety.
電伴熱是利用伴熱電纜輸出的熱量來補(bǔ)償管道、容器、罐體等儲運(yùn)系統(tǒng)所耗散的熱量，以維持系統(tǒng)操作介質(zhì)始終處在工藝要求的適宜溫區(qū)。所以，熱工設(shè)計首先要確定工藝裝置的熱損失即散熱量，然后根據(jù)散熱量確定所需伴熱電纜的功率和長度。本工程伴熱電纜約為5000米；
The electrical heat trace is to use the heat output from heating cable to make up for the heat consumed by storage and transportation system, such as pipes, containers and tanks, in order to keep the system-operating medium at a proper temperature required by the techniques. Therefore, the foremost thing of thermal performance design is to determine the heat loss of process unit, namely, heat dissipating capacity. Then the power and length of needed wires have to be fixed on the basis of heat dissipating capacity. The heating cable for the project is about 5000meters long.
二、編制依據(jù)ⅡCompilation Basis
施工圖紙及相關(guān)技術(shù)文件Construction drawings and relevant technological documents
GB50254-96《電氣裝置安裝工程低壓電器施工及驗收規(guī)范》
GB50254-96 Code for Construction and Acceptance of Low-Voltage Apparatus Electric Equipment Installation Engineering
GB50258-96《電氣裝置安裝工程 1kV 及以下配線工程施工及驗收規(guī)范》
GB50258-96 Code for Construction and Acceptance of 1KV and Lower voltage Wiring Project Electric Equipment Installation Engineering
GB50150-91《電氣裝置安裝工程電氣設(shè)備交接試驗標(biāo)準(zhǔn)》
GB50150-91 Acceptance Trial Norm for Electric Apparatus Installation Project Electrical Device
GB50168-92《電氣裝置安裝工程電纜線路施工及驗收規(guī)范》
GB50168-92 Code for Acceptance and Construction of Electric Apparatus Installation Engineering Cable Line
GB50171-92《電氣裝置安裝工程盤柜及二次回路接線施工及驗收規(guī)范》
GB50171-92 Code for Acceptance and Construction of Electric Apparatus Installation Engineering Cabinet Secondary Circuit
三、施工技術(shù) Ⅲ Construction Technique
1、安裝前的準(zhǔn)備The preparations before installation
1) 安裝前首先要查看設(shè)計圖紙，確認(rèn)發(fā)熱電纜及配件配備齊全，并與設(shè)計相一致。
Before installation, you have to check the drawings to make sure that heating cable and accessories are complete and consistent with the design.
2) 安裝管道系統(tǒng)并驗收完畢。管道及閥門等附配件均已安裝完畢，并且按相關(guān)安裝規(guī)范試壓驗收完畢。
Install piping system and complete acceptance check. Pipes and accessories, such as valves, have already been installed and accepted through pressure test.
3) 管道外刷防銹層、防腐層完畢并徹底干透。檢查管道外表面確認(rèn)無毛刺、銳角，以免在安裝時對電纜造成損壞。
The pipes, painted with antirust coating and anticorrosive coating, are thoroughly dried. Check the surface of pipes to avoid burrs and sharp angle, which could spare all damages to wires in the process of installation.
4) 管道穿墻處預(yù)留好電纜穿墻套管，套管位置與數(shù)量根據(jù)該處穿越電纜位置數(shù)量確定。
Reserve wire wall bushing at the wall entrance of pipes. The location and quantity of pipes should be fixed according to the location and quantity of penetrating wires.
5) 檢查控制箱安裝位置是否符合設(shè)計要求。與其它專業(yè)協(xié)調(diào)，確保安裝過程中與其它專業(yè)無沖突。
Check whether the mounting location of panel box is line with design requirements and avoid the conflict of all fixtures in the process of installation.
2、進(jìn)場材料檢查與保管 The inspection and management of newly-arrived Materials
1) 檢查收到的電纜型號和功率輸出是否正確。所有電纜外套都標(biāo)有部件號、電壓等級和功率輸出。
Check whether the model and power output of purchased wire are correct. Outer coat of all cables bear the part number, voltage class and power output.
2) 視察貨物在運(yùn)輸中是否有破損。
Check whether the goods are damaged in transit
3) 電伴熱電纜和附件應(yīng)儲藏在干凈和干燥的環(huán)境中。
Electric heating cable and accessories should be stored in clean and dry place.
3、電伴熱電纜施工 The Construction of electric heating cable
1）單根電熱帶施工方法 The Method of Construction of Single Ribbon Heater
a.在電伴熱電路的送電點開始安裝，玻璃纖維壓敏膠帶或鋁膠帶每隔約300mm處綁扎一次。在閥門、 泵、過濾器等部位做可以使設(shè)備移動的安裝。
It should be installed from the power transmission point of electric heating circuit. Pressure-sensitive tape of Fiber glass or aluminum tape should be used every 300mm. In the parts of valve, pump and filter, installation could be made such as to enable the equipment to move.
Make the wiring according to the design layout(winding index).
e.所有散熱體（如支架、閥門、法蘭等）應(yīng)按設(shè)計圖要求預(yù)留所需電熱帶長度，將此段電熱帶纏繞于散熱主體上并固定。
All the heating bodies, such as framework, valve and flange, should reserve needed ribbon heater in accordance with the requirements of design layout. The ribbon heater will be wound around the heating body and fixed.
下列各點應(yīng)注意：The following points should be noticed
*散熱體應(yīng)有設(shè)計所需電熱帶的長度。The heating body should have a ribbon heater of the length required by the design.
*電熱帶可互相重疊或交叉。Ribbon heaters could overlap or intersect.
*纏繞方法應(yīng)盡可能使散熱體必要時隨時可拆除進(jìn)行維修 或更換而不損壞電熱帶或影響其它線路。
A proper winding method should be adopted so that heating body could be dismantled for reparation or change anytime if necessary, while it will not damage ribbon heater or affect other circuits.
*在使用二通或三通配件處，電熱帶各端應(yīng)預(yù)留40cm長度。
At the points using two-way or three-way accessory, 40cm should be reserved at the ends of ribbon heater.
2）螺旋纏繞 Spiral winding
如纏繞系數(shù)為1.4，即5m管道需要布7m的電熱帶，施工時先將7m長的電熱帶兩端固定于一段長度為5m的管道上，然后將松馳的電熱帶纏繞在管道上，并加以固定。
If the winding index is 1.4, it simply means that 5cm pipe needs 7cm ribbon heater. In construction, the two ends of 7cm ribbon heater should be first fastened to a 5cm pipe, after which the loose ribbon heater will be wound around the pipe and fixed.
4、安裝注意事項 Notes on installation
1) 電熱帶安裝時，不要在地面上拖拉，以免被鋒銳物損壞。不要與高溫物體接觸，防止電焊熔渣濺落到電熱帶上。
When installing ribbon heater, don’t drag it on the floor to avoid being damaged by sharp objects. Don’t expose it to hot objects to prevent wielding slag from spilling on ribbon heater.
2) 電熱帶有良好的柔性，但不允許硬折，需要彎曲時，彎曲半徑不得小于伴熱電纜厚度的6倍。
Despite good flexibility, ribbon heater couldn’t be folded freely. Its bending radius shouldn’t be less than sixth of thickness of the heating cable.
3) 電熱帶嚴(yán)禁用重物硬砸，如被砸 伴熱電纜應(yīng)重新進(jìn)行電氣測試，合格后才能使用。
It is prohibited to hit ribbon heater with heavy objects. Once hit, heating cable should undertake an electrical testing again and shouldn’t be used until it is up to standard.
4) 電熱帶應(yīng)與被伴熱管道(或設(shè)備)貼緊并固定，以提高伴熱效率。固定電伴熱帶時應(yīng)用專用尼龍扎帶，嚴(yán)禁用金屬絲綁扎。
Ribbon heater should be attached closely to heated pipes and then fixed in order to improve heating efficiency. A special ribbon should be used to fix electric heating cable, while wire should be avoided.
5）非金屬管道應(yīng)在管外壁與伴熱電纜之間貼一層鋁膠帶，用來增大接觸傳熱面積。
In the case of Non-metallic pipe, a coat of aluminum tape should be used between external wall of pipes and heating cable to expand heat transfer area.
6) 電熱帶的安裝要充分考慮管道附件(或設(shè)備)的拆卸可能性，且電伴熱帶又不需要被切斷。電熱帶被剪斷或接頭時要注意接頭的密封。
During the installation of ribbon heater, a serious consideration has to be given to the possibility of detachment of pipe accessory (or equipment), while electric heating cable needn’t to be cut off. When ribbon heater was cut off or connected with other equipments, the sealing of connector should be given close attention.
7) 每米管道熱損失大于每米伴熱電纜輸出功率時，采用纏繞方式，以利維修時拆卸。
When the heat loss of pipe exceeds power output of heating cable per meter, winding method should be adopted in order to contribute to detachment for maintenance.
8）法蘭處易產(chǎn)生泄漏，纏繞電伴熱帶時，應(yīng)避開其正下方。
Leakage is common around flange. Therefore, ribbon heater shouldn’t be wound right under it.
9) 電熱帶在管道上的安裝方法與固定，扎帶材料應(yīng)根據(jù)管道的溫度選用。
The installation method and fixation of ribbon heater on pipe, and ribbon should be chosen according to the temperature of pipe.
10) 電熱帶安裝完畢后，必須逐個回路進(jìn)行電氣測試合格后，再進(jìn)行通電試驗，檢查電熱帶發(fā)熱情況。確認(rèn)正常后，才允許保溫。
After the installation of ribbon heater, every circuit has to receive electrical testing. Only then could power test be conducted to check the heating condition of ribbon heater. It is not subject to insulation unless it is confirmed to be normal.
11) 保溫材料應(yīng)干燥。潮濕的保溫材料不但影響伴熱效果，還會導(dǎo)至對電熱帶的腐蝕，縮短使用壽命，未包外保護(hù)層的保溫管道，被雨雪澆濕后，應(yīng)風(fēng)干后再施工外保護(hù)層。
Insulation material should be dry. The moist insulation material not only affects the heating efficiency, it can also cause corrosion to ribbon heater, which will shorten its service life. Pipe of insulation, without external protection, shouldn’t be given protective coating unless it is dried after getting wet with rain and snow.
12) 伴熱系統(tǒng)施工完畢，應(yīng)在管道的外保護(hù)層做出明顯的電伴熱標(biāo)記，以提醒人們注意。
After the construction of heating system, an obvious sign of electric heating should be made on outer protective coating of pipe as a reminder to people.
13) 電熱帶安裝時，當(dāng)電纜一端接入電源前應(yīng)將母線另一端用配套的封頭套封好，兩條母線不得短路。
During the installation of ribbon heater, when one end of cable was connected to power, another end of bus bar should be sealed with matching head so that two bus bars will not have a short circuit.
14) 多回路電熱帶從同一接線盒接出時，各母線都要有絕緣套隔離以防短路。
When multi-loop ribbon heaters extend from the same junction box, every bus bar needs an insulation bush to avoid short circuit.
15) 接線盒應(yīng)密封，防止雨水進(jìn)入。
The junction box should be sealed to keep it from rainwater.
5、伴熱控制報警箱的安裝 The Installation of Alarm Box of Heat Tracing Control
根據(jù)相關(guān)規(guī)范，結(jié)合工程實際情況，我公司摸索制定了電伴熱控制報警箱定位原則：① 依據(jù)配電室所在位置；②不影響其它電氣設(shè)備的安裝；③安裝的墻為實墻，陶�；蚩招拇u墻要加裝支架；④高低位置原則以易觀察、易維修為佳。 對于伴熱控制報警箱要嚴(yán)格按設(shè)計要求安裝，箱體安裝高度、垂直誤差等均應(yīng)控制在規(guī)范允許的范圍內(nèi)。箱內(nèi)配線應(yīng)整齊美觀、走向合理、綁扎成束并適當(dāng)固定。導(dǎo)線與電器的連接頭必須符合規(guī)范的規(guī)定即多股導(dǎo)線壓接后應(yīng)鍍錫、單股導(dǎo)線按螺旋方向盤圈。采用螺栓頂按時應(yīng)雙線徑插入，線端絕緣邊裸露導(dǎo)體長度應(yīng)不大于3 mm。25mm2及以上的截面的導(dǎo)線，不宜采用開口式接線端子�？刂齐娖骺蓜佑|點端必須是負(fù)荷端。各配電支路、控制回路應(yīng)在專設(shè)的銘牌框內(nèi)標(biāo)注明確。
According to relevant code and actual conditions of the project, our company manages to formulate the positioning principle of alarm box of electric heating control: (1)based on the location of distribution room: (2) causes no effect to the installation of other electrical equipments.(3)It has to installed on solid walls, and, in the case of ceramic or brick cavity wall, needs to be installed with bracket.(4) It is better to fix the height which helps observation and maintenance. The heating control alarm box has to be installed in strict accordance with the requirements of design. The mounting height of cabinet and vertical error should be limited to an acceptable rate of relevant code. The box wiring should be arranged in orderly, beautiful and rational manner and properly fixed after being bound into bundles. The connector of wire and electrical apparatus should comply with the norms, which means that stranded wire should be coated with tin after being compressed and solid wire should be coiled according to the direction of spiral. When pressing the top of bolt, double wire should plug in. The exposed conductor of insulating side of line end should be less than 3mm. The section of 25mm2 or above should not use open type terminals. The movable tip side of control circuit apparatus must be load side. The branch circuits of distribution and control loop should be clearly marked in the special nameplate.
6、電伴熱系統(tǒng)的現(xiàn)場測試與檢查 The Spot Test and Inspection of Electric Heating System
1) 測試要求 Testing requirements
所有電纜和相關(guān)組件均應(yīng)按下列要求進(jìn)行測試。下面的"檢查單"應(yīng)填寫。
All wires and relevant components should be tested according to the following requirements. The inspection list below should be completed.
a) 最初檢查和絕緣抗阻測試報告, 表格 SH3503J543。
The report of initial inspection and insulation resistance test, form SH3503J543
b) 安裝測試報告，表格 ITR-01.
The report of installation test, form ITR-01
2) 測試工具 Testing equipments
a) 搖表, 500V~1000V DC magneto-ohmmeter, 500V~1000V DC
b) 電壓表 voltmeter
c) 便攜電流表 portable ammeter
3) 測試 test
在進(jìn)行測試前確認(rèn)所有電路連接和接地都已正確完成。在測試后，確認(rèn)所有接線盒、控制器等正確關(guān)閉，潮氣不能進(jìn)入。
Before the test, all circuit connection and ground connection have to be completed correctly. After the test, all junction boxes and controllers have to be closely correctly to prevent any moisture.
絕緣抗阻測試: 用一個500V或1000V的直流搖表,測量電纜導(dǎo)體與外金屬套(金屬屏蔽層)之間的絕緣電阻值,應(yīng)得到最小 20MW 的數(shù)值。
The test of insulation and resistance； use a 500v or 1000v DC magneto-ohmmeter to measure the insulating resistance, and the minimum value should be 20MW.
a) 在電伴熱安裝后,保溫層安裝前,重復(fù)絕緣電阻測試.測試人員應(yīng)完成安裝測 試報告,表格 ITR-01 的記錄,有任何問題應(yīng)立即報告。
Between the installation of electric heating and insulating layer, the test of insulation resistance should be repeated and testers should complete the report of installation test, form ITR-01. Any problems found should be reported immediately.
b) 電伴熱帶長度應(yīng)記錄在安裝測試報告,表格 ITR-01 上。
The length of electric tracing cable should be recorded in the report of installation test, form of ITR-01.
c) 安裝完成后(保溫層已安裝完畢),作為預(yù)運(yùn)行檢查的一部分，重復(fù)絕緣抗住測試。執(zhí)行測試的人員應(yīng)完成安裝測試報告，表格 ITR-01
After installation (insulation layer has already been installed), the test of insulation resistance needs to be repeated as a part of pre-operation check. The working staff performing the test should finish the report of installation testing, form ITR-01
d) 確認(rèn)告示標(biāo)簽已每隔 3 米安裝在氣候防護(hù)層外。
Make sure that notice labels have been installed on the climate protection layer every 3m.
4) 運(yùn)行步驟及系統(tǒng)操作 Operating procedure and system operation
在系統(tǒng)投入使用前，確認(rèn)對每一個伴熱回路已進(jìn)行測試，報告已完成。
操作電伴熱系統(tǒng)包括如下步驟
Before the system goes into service, make sure that every heating loop has been tested and respective report has been completed.
a)在通電前，確認(rèn)所有的接線盒、溫控器、電纜密封是正確安全的。
Before the current is switched on make sue all junction boxes, temperature controllers, and cables are sealed correctly and safely.
b)設(shè)置溫控器的參數(shù)為設(shè)計值。參見溫控器安裝指導(dǎo)手冊。溫控器參數(shù)的設(shè)置值應(yīng)在單管圖或電伴熱安裝圖上找到。
Set the parameter of temperature as design value. Refer to the installation guide of temperature controller. The setting value of temperature of controller should be found in the single-pile drawing or installation drawing of electric heating.
c) 接下來，給伴熱回路送電，記錄電流值。將記錄與電伴熱計算書進(jìn)行比較。測試人員應(yīng)完成安裝測試報告,表格 ITR-01 的記錄,有任何問題應(yīng)立即報告。
Then, connect heating loop to power and record current value. Compare the record with calculation sheet of electric heating. The working staff performing the test should finish the report of installation testing ITR-01 and any problems found should be reported instantly.
四、SHE管理 Ⅳ, SHE Management
一、安全施工 Ⅰ Safety Construction
1)建立以項目經(jīng)理為主的安全生產(chǎn)保證體系，完善安全管理網(wǎng)絡(luò)，強(qiáng)化全員HSE教育培訓(xùn)，增強(qiáng)員工HSE管理意識；開展危害控制和隱患治理，防止事故發(fā)生和環(huán)境污染；創(chuàng)造良好的工作生活環(huán)境，確保安全施工和員工健康。
Establish Safety production and assured systems dominated by project manager, improve network security management, strengthen HSE education and training of all working staff, enhance their HSE management consciousness, and launch damage control and hidden danger treatment to prevent accidents and environmental pollution; create a good living and working environment to ensure safety construction and employee health.
2)進(jìn)入現(xiàn)場工人施工時應(yīng)正確、合理使用工具。安全帽、工作服、防護(hù)眼鏡、安全鞋及必要的安全防護(hù)用品必須帶齊配齊。
The worker should use tools correctly and rationally. Helmet, overalls, safety goggles, safety shoes and needed safety products have to be taken without exception.
3)冬季雨雪天氣不得運(yùn)輸設(shè)備、控制裝置及開展現(xiàn)場施工作業(yè)。設(shè)備到貨開箱后要集中放置設(shè)備庫房,并做好防凍、防潮工作。
When it rains or snows in winter, the transportation of equipments and control units and any construction should be forbidden. All newly-introduced equipments, whose box has been opened, need to be placed in equipment warehouse, and the work of anti-freezing and anti-humidity has to be done.
二、文明施工 Ⅱ Civil Construction
1)現(xiàn)場材料堆放整齊，要做到工完料盡場地清。
Site materials need to be stacked in a tidy manner, and make sure that the site is free from any slag after the project is completed.
2)當(dāng)日工作當(dāng)日清理，保證施工現(xiàn)場清潔。
The work of that day should be finished without delay, and ensure the cleanliness of construction site.
3)施工中所產(chǎn)生得廢料集中堆放，不得隨意亂丟。
The waster material produced during construction should be piled in the same location and couldn’t be thrown away freely.