不锈钢管道(卡压)施工技术交底

一、施工准备

1.  熟悉本专业及其他相关专业图纸，做好技术、环境、安全交底。

2.  所使用材料已经有关方面认可，报验合格。

二、材料要求

材料进场后首先应检查其有无出厂合格证，再检查其材质是否符合本工程的要求。管壁应薄厚均匀，内外光滑整洁，不得有砂眼、裂纹、疙瘩，管件无偏扣、乱扣、等现象。材料不合格者不得使用。管材、管件在装卸、运输、储存等过程中应该小心轻放，排列整齐，不得手尖锐物品碰撞，不得抛、摔、拖、压，施工现场应防止与腐蚀的介质和污染物相接触，管材、管件内外污垢应清理干净才可供工程使用。

三、主要机械设备

1.  机具：液压卡压机、冲击钻、电锤、砂轮锯、电气焊等。

2.  工具：专用扳手、扳手、手锤、凿子、水平尺、钢卷尺、线坠等。

四、施工工艺及要求

1、管道预制：

（1）预制应在非碳钢材质的平台上制作，预制段尺寸按修正后的管段图进行，保证运输、吊装条件及有可调整的余地。

（2）管子切割：直径DN≤150的采用砂轮切割机切割，DN＞200的采用等离子切割，等离子切割后应彻底修磨其表面。端面倾斜偏差为管子外径的1%且不大于2mm。

（3）坡口加工采用坡口机、手握砂轮机等方式进行，管壁厚度≤3mm的开“I”形坡口（不开坡口），管壁厚度大于3~12mm的开单面60°~70°“V”形坡口，钝边厚度1~1.5mm，加工后的坡口斜面及钝边端面的不平度不应大于0.5mm，角度应符合要求。                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                 

2、管道切割：

薄壁不锈钢管材用专用割刀手工断料，或用专用机械割机断料；精确好配管的长度后，方可用旋转砂轮切割机来断管下料。切割时，保证配管的切口垂直，切割后要仔细修平，断管后要断口的铁膜、毛刺清除干净。

3、画线

在切割好的不锈钢管两端画线，标注出管子插入配件的长度，避免造成托管。

4、插入管件

4.1 在管道插入管件前，应将管道、管件的连接口擦拭干净。

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4.2 检查配件内密封圈是否完好无损，确认后将管子笔直的插入管件内，注意不要碰伤橡胶圈，且橡胶圈不得扭曲、移位，同时应保证管子两端的画线标注到管件承插口端面的净距离在3mm以内。

5、卡压连接

5.1 将薄壁不锈钢管道插入带有“O”型密封圈的管件中后，用能够保证卡压统一性的带有限位锁压、自动卸压的专用双挤压管道手动液压工具对管道、管件连接口进行卡压连接。

5.2 卡压前应检查钳口与管材口径是否一致，检查钳口耳架挂板与钳座复位情况，插销、钳口是否吻合，不允许脱落。

5.3 在选择好相应口径的钳口，并插好插销后，将卡压钳凹槽安置在管子与管件的接头本体圆弧凸出部位，要保证钳口与管道垂直，方可进行卡压连接。

    5.4 将动力泵按顺时针方向关住回油阀，然后反复按加力手柄，使活塞开始工作，观察上、下侧钳口合拢情况，钳口闭合无间隙，使管件和管材的外形微变形，压接成六角形，达到所需连接强度，同时使“O”型密封圈产生压缩变形，使管件和“O”型密封圈紧贴管道表面，达到管道和管件连接口的密封和紧固的效果。

5.5 油泵压力表指针到规定压力值时，安全阀自动打开，停止挤压工作。

5.6 薄壁不锈钢管道与其它材质管道或管道附件连接时，应以相对应的螺纹转换接头相匹配；如果其他管道违法兰连接，应以相应的法兰相匹配。

    5.7 薄壁不锈钢管件与卫生洁具或设备相连接时，按照连接件是内螺纹还是外螺纹，选择相承接的外螺纹或内螺纹连接管件。

    5.8 不同材质内外螺纹的公差可能不同，需认真复核。连接时，在螺纹副内添加适量的密封膏，借助工具将螺纹接口旋入，至手感接近紧密后再旋入1/4圈，达紧密密封，停止旋合。

    5.9 在施工安装间歇或完成后，管子敞口处、管件甩口处均应临时封堵。安装完毕的干管不得有明显的起伏、弯曲等现象，管外壁应无损伤。

6、卡压检查

完成卡压连接后，用六角量规确认是否正确，卡压处完全插入六角量规即封压正确，避免卡压工具出现不良。

7、管道试压

    7.1 冷水管道试验压力为管道系统工作压力的1.5倍，但不小于0.6MPa。热水管道试验压力为管道系统顶点的工作压力加0.1MPa，但系统定点试验压力不得小于0.3MPa。本工程热水系统的工作压力为1.0MPa，试验压力为1.5MPa。

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   7.2 检验方法：各系统的升压时间不应小于10min，升至试验压力后，观察各接点部位，不应出现渗、漏水现象，并且10min内压力将不得超过0.02MPa。然后压力降至工作压力后，压力应不下降，更不应该出现渗、漏水现象。

8、管道冲洗

     饮用水管道在试压合格后用生活饮用水以流速不小于1m/s对管道进行连续冲洗，直至出口处浊度、色度与入口处相同为止。

9、干管、立管、支管的安装

1、干管安装：

1.1 干管安装一般从总进入口开始操作,管道预制后、安装前应做好防腐。将预制好管道运至安装部位按编号依次排开。安装前清扫管膛，安装后找直找正，清除接头污物，所有管口加好临时丝堵。管道应合理配置伸缩补偿装置与固定支架和活动支架,以控制管道的伸缩方向或补偿。

1.2  横管以0.002～0.003的坡度，坡向泄水装置。

2、立管安装：

2.1立管与导管连接要采用2个弯头，立管直线长度大于15m时，宜采用3个弯头，立管如有补偿器其安装同干管。

2.2 管道穿越墙壁、楼板时，须配合土建留洞、预埋套管，嵌墙暗敷时，须配合土建先留槽或开凿墙槽。

2.3 预留孔洞尺寸宜较管外径大2个型号。

2.4预埋套管宜伸出楼板面50mm。套管下端应与饰面齐平。套管管径应大1～2号。

3、支架安装：

3.1 支管明装。将预制好的支管从立管甩口处依次逐段进行安装，有阀门时应将阀门盖卸下再安装，根据管道长度适当加好临时固定卡，核定不同卫生器具的冷热预留口高度、位置是否正确，找平找正后栽支管卡件，去掉临时固定卡，上好临时丝堵。支管如装有水表应先装上连接管，试压后在交工前拆下连接管，安装水表。

3.2支管暗装。确定支管高度后画线定位，剔出管槽，将预制好支管敷在槽内，找平找正定位后用勾钉固定。卫生器具冷热水预留口要做在明处，加好丝堵。

4、管道伸缩补偿，支、吊架及保温

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4.2管道固定支架间距应根据直线管段伸缩量、设置波形膨胀节的允许伸缩量和管段走向的布置等因素确定，一般不宜大于15m。固定支架宜在变径、分支、接口及穿越承重墙、楼板的两侧等处设置。

4.3 管道配水点处、设备接管处、水箱雨水池出口处，要采取固定支架措施。

4.4热水薄壁不锈钢管应保温，绝热材料不可使用含可溶性卤族离子材料。在有雨水浸入处或湿度高的场所还要作防水层，应采用不腐蚀的不会使氯化物渗透到管壁上的材质。绝热厚度由图纸设计说明确定，本工程热水管采用密度40kg/m3厚度为30mm的泡沫橡塑制品保温（嵌墙支管可不作保温）。

4.5公称直径不大于25mm的管道安装时，可采用塑料管卡或不锈钢管卡。采用其他金属管卡或吊架时，与管道之间应用木质或橡胶隔垫。

    4.6 室内管道支架及吊架参见国标图集03S402。

五、安全文明施工

在施工中要正确贯彻“安全为了生产，生产必须安全 ” 及 “ 预防为主”的方针，施工中除必须遵守国家有关安全生产的法规及我公司安全管理制度外，还应针对管道安装的特点制定相应安全管理制度： 

（1）电工、焊工必须持证上岗，并且在进入现场前应进行现场考试，合格后才予进入现场实际操作。 

（2）专业工长应对工人进行安全技术书面交底，每天班前会强调总结前一天安全情况，提醒注意当天工作可能发生的安全问题，专职安全员负责现场跟踪检查，及时消除安全隐患。 

（3）水平管基本上都敷设在板下，均需登高作业；垂直管大部分在管井或沿柱子下行，也需要登高作业。在管中心距地面 4 米以下时， 可以采用“人”字梯作脚手架。在管中心距地面超过 4 米时，必须用龙门架搭设操作平台，平台必须坚固耐用，经安全员验收合格后方可使用。另外平台作业人员必须戴安全带、安全帽等保护用品。 

（4）立管施工自下而上安装，管道在楼板上的预留孔洞应临时用木板层层封堵，以防石子等物体掉下，砸伤下部操作的人员。每个立管接口完成后应立即用管支架固定牢固，防止滑脱，尤其是受力集中的部位更应加强固定。

（5）严禁酒后上岗作业。

（6）禁止随地大小便。

（7）禁止随意改动、破坏安全防护设施。

（8）工作完毕后严禁将材料或废料遗留在施工现场。

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