有关油漆和保温工作的质量控制程序

PEC-Tech Quality Assurance Department Doc: PL12-UAPRIL-R018 Revision No.: 0 QUALITY CONTROL PROCEDURE FOR PAINTING AND INSULATION 有关油漆和保温工作的质量控制程序 Page 1 of 16 0 2009-10-02 Original原版 PW JH IH JJ Rev. 版本 Date日期 Description内容 Prepared 起草人 Checked 审核人 Checked 审核人 Approved 审批人 PEC-Tech Quality Assurance Department Doc: PL12-UAPRIL-R018 Revision No.: 0 QUALITY CONTROL PROCEDURE FOR PAINTING AND INSULATION 有关油漆和保温工作的质量控制程序 Page 2 of 16 PURPOSE目的 To ensure that Painting and Insulation work, is conducted in accordance with the project specifications and applicable codes and standards governing these activities. 确保油漆和保温工作的执行遵循规定活动的项目规则，规范和。 This procedure also describes how Painting and Insulation related activities will be controlled, the inspection procedure, reporting structure, resources allocated, personnel responsibilities and authority defined for key project team members and their interfaces between PEC-Tech China (PTC) Contractors and Subcontractors. 该程序还陈述与油漆和保温工作相关活动是如何控制的，包括检验程序，报告內容， 资源分配，关键工程队员以及他们与百达承包商和分包商交流的工作介面。 SCOPE范围 This procedure describes the activities carried out to ensure that all Painting, Insulation and related activities performed are accomplished in accordance with approved procedures, quality plans and applicable technical specifications. The procedure defines how Painting, Insulation and related activities are controlled, monitored, inspected and recorded by PTC, Contractor and Subcontractor. 本程序描述已执行的工作以确保所有的油漆工作，保温工作以及相关工作执行遵循批 准的程序，质量和适用的技术规则。本程序解释百达的承包商和分包商是如何控 制，监视，检查和油漆，保温和相关的工作。 This procedure applies to all Engineering, Procurement, Construction Management (EPCM) projects, undertaken by PTC in China 本程序适用于中国百达所承担执行的所有设计，采购，施工，管理项目。 Paint specifications for various environments and service will be developed separately as required. These documents shall be specific for the task. 适用于各种环境的喷漆规则和服务将按要求分别制定。这些文件特别适用与这项工 作。 The following items are specifically covered by this QCP: QCP特别包括下列事项： • invitation to tender or rate negotiation 投标或商务谈判要求 • placing the PR (Purchase Requisition) 提交请购单 • supervision of the Contractor and Subcontractor 承包商和分包商和监督职责 PEC-Tech Quality Assurance Department Doc: PL12-UAPRIL-R018 Revision No.: 0 QUALITY CONTROL PROCEDURE FOR PAINTING AND INSULATION 有关油漆和保温工作的质量控制程序 Page 3 of 16 • inspection and acceptance of the completed work 完工项目的检查与验收 • safety 安全 REFERENCES参考文件 Reference Document Document Number 参考文件 文件编号 Summary Approved Painting System and Manufacturer for PL12 Appendix 1 审批的 PL12工程的油漆工作系统和制造商概要 附录 1 PTC Quality Manual : Pl12-UAPRIL-R001 百达质量手册 PTC Project Quality Plan : PL12-UAPRIL-R002 百达项目质量计划 PTC Inspection & Test Planning : PL12-UAPRIL-R004 百达检验和测试计划 Technical stipulation for surface treatment and Painting –metallic surfaces PL12-LAPRIL-C004 表面处理和金属面上漆工作的技术规定 Technical Specification for Colour Code : PL12-LAPRIL-C007 色码技术细则 Technical Specification for Thermal Insulation : PL12-LAPRIL-C006 热绝缘技术规则 Indicating Oil or Water in Compressed Air : ASTM D4285 压缩空气里含有的油和水 Test for Relative Humidity by Wet-and-Dry-Bulb Psychrometer : ASTM E 337 应用干湿计的相对湿度测试 Measurement of Dry Paint Thickness with Magnetic Gauges : SSPC PA – 2 应用磁力测厚仪测量干漆厚度 Methods of Test for Paints : EN BS 3900 漆料测试 Preparation of steel substrates before application of paints and related products : BS EN ISO 8501-1:2001 PEC-Tech Quality Assurance Department Doc: PL12-UAPRIL-R018 Revision No.: 0 QUALITY CONTROL PROCEDURE FOR PAINTING AND INSULATION 有关油漆和保温工作的质量控制程序 Page 4 of 16 钢材表面涂料前的准备程序 RESPONSIBILITY AND AUTHORITY责任和权力 4.1 GENERAL概要 4.1.1 PTC QA Manager 百达 QA经理 Reporting to the Project Director, the QA Manager is responsible for: QA经理负责向项目董事报告下列事项： • preparation and maintenance of this procedure 准备和维护这个程序 • allocation & supervision of QC personnel for specialist inspection and QC support activities 监督所分配人员的专业检查活动和QC支持活动 • review and approval of Contractor and Subcontractor QMS 审核并审批承包商和分包商的 QMS • review and approval of Contractor and Subcontractor painting procedures 审核并审批承包商和分包商的上漆程序 • management of NCR Database 管理 NCR数据库 4.1.2 PTC QC Inspectors 百达 QC检验员 Reporting to the QA Manager, the QC Inspectors are responsible for: QC检验员负责向 QA经理报告下列事项： • patrol inspection of painting and insulation works conducted by Contractor and Subcontractor 巡检承包商和分包商的油漆和保温工作 • liaison with PTC Discipline Engineers & Construction Supervisors 联络百达部门工程师和施工监督员 • review and approval of Contractor and Subcontractor painting and insulation inspection reports 审核并审批承包商和分包商的油漆和保温工作报告 • preparation of NCR for non conforming product or work 准备不合格记录或产品的不合格记录 4.1.3 PTC Construction Supervisors百达施工监督员 Reporting to the PTC Discipline Engineers, the Construction Supervisors are responsible for: PEC-Tech Quality Assurance Department Doc: PL12-UAPRIL-R018 Revision No.: 0 QUALITY CONTROL PROCEDURE FOR PAINTING AND INSULATION 有关油漆和保温工作的质量控制程序 Page 5 of 16 施工监督员负责向百达部门工程师报告下列事项： • supervision of all Contractor and Subcontractor Painting and\Insulation activities at site 监督所有承包商和分包商的现场油漆和保温工作 • expediting Contractor and Subcontractor submission of QMS for PTC approval 敦促承包商和分包商向百达提交 QMS以审批 • review of submitted QC records prior to submission to PTC QC Inspector for approval 在提交百达 QC检验员以审批之前，审核所提交的 QC记录 • liaison with PTC QC Inspectors 联络百达 QC检验员 • follow-up / closure of NCR for non conforming product or work 跟踪并完成不合格产品或工作的不合格记录 4.1.7 Contractor / Subcontractor承包商/分包商 Reporting to the Site Manager the Contractors and Subcontractors, shall be responsible for: 承包商和分包商负责向工地经理报告下列事项： • liaison with PTC QC Inspectors, Discipline Engineers and Construction Supervisors 联络百达 QC检验员，部门工程师和施工监督员 • follow-up / closure of NCR for non conforming product or work 跟踪并完成不合格产品或工作的不合格记录 • preparation of QC Documentation & submission to PTC QC Inspectors for review & approval 准备 QC文件并提交给百达 QC检验员以审核并审批 QUALITY CONTROL质量控制 5.1 PAINTINGC 油漆工作 5.1.1 Inputs材料输入 The painting dept. receives inputs from design and specification via area coordinator. 负责漆料工作的部门通过区域协调员接收设计图和工作细则。 5.1.3 Specification 工作细则 The specifications for surface treatment (sandblasting or power wire brushing) and painting are stated in Section 3 above 有关表面处理和油漆工作的细则在上面的第三部分已作说明。 PEC-Tech Quality Assurance Department Doc: PL12-UAPRIL-R018 Revision No.: 0 QUALITY CONTROL PROCEDURE FOR PAINTING AND INSULATION 有关油漆和保温工作的质量控制程序 Page 6 of 16 5.1.4 Coordination协调 PTC coordinates information and data required for painting. 百达协调油漆工作所需的信息和材料。 PTC prepares a technical specification for the painting work to be part of the contract, which will also include other PEC-Tech and International Standards. 百达起草油漆工作的技术细则并作为的一部分，该技术规则包括其他百达和国际 标准。 5.1.5 Outputs输出材料 1. Technical and specification data sent to procurement department for painting work as part of main contracts. 送给采购部门的油漆工作的技术和规则和材料将作为主合同的一部分 2. Site supervision allocated. 工地监督分配 3. QC Inspection allocated. QC检验分配 5.1.6 Inspection Controls检验控制 Quality and schedule for completion of the work shall be responsibility of the contractor. 承包商将负责工作质量和日程。 • Sandblasting shall be done as per BS EN ISO 8501-1:2001-Sa 2.5/SSPC-SP10 standard 喷砂工作遵循 per BS EN ISO 8501-1:2001-Sa 2.5/SSPC-SP10标准 • Power tool cleaning shall be done as per BS EN ISO 8501-1:2001 St3/SSPC-SP3 standard 动力工具的清理遵循 per BS EN ISO 8501-1:2001 St3/SSPC-SP3标准 • Sand blasting or power tool cleaning and primer painting shall be done before fabrication. 喷砂或动力工具的清理和初级油漆工作将在装配之前完成 • Roller application of primer coat is not permitted. 不能手刷涂底漆 • Generally, primer paint shall be applied by airless spray only (brush application maybe used only on minor areas or those difficult to reach by airless spray). 通常，涂底漆只适合用液压喷漆方式（次要区域或液压喷漆不方便的地方刷子 可用涂漆） • Mid-coats shall be applied only after fabrication work is complete and shall be done in painting yard, after primer coat complete. PEC-Tech Quality Assurance Department Doc: PL12-UAPRIL-R018 Revision No.: 0 QUALITY CONTROL PROCEDURE FOR PAINTING AND INSULATION 有关油漆和保温工作的质量控制程序 Page 7 of 16 只有装配工作完成后才进行二道底漆工作，该工作在涂完底漆之后将在涂漆场 地上完成。 • Touch-up painting of areas where paint has been damaged during transportation, installation, welding etc. shall be conducted by the painting contractor, except in specific cases agreed with the responsible PTC Area Engineer. 除了在百达区域工程师同意的特殊情况下，油漆工作承包商负责运送，安装和 焊接过程中损坏油漆的修补工作。 • Finish coat paint shall be applied only after completion of fabrication and under coat paint and shall be conducted in the painting yard. 装配工作完成之后进行面漆工作，底漆工作要在涂漆场地进行。 5.1.7 Coating thickness镀层厚度 The maximum allowable variation of Dry Film Thickness (DFT) for paint or other protective coating is ± 5% from the value stated in the applicable specification. 根据所适用的规则，漆料的干膜厚度和其他保护镀层的最大允许变化范围是±5% The following measuring instruments shall be used to control and verify paint film thickness. 下列测量工具将用来控制和验证漆膜厚度 • Wet film thickness gauges. • 湿膜厚度计 • Dry Film Thickness (DFT) measuring instruments (Elcometer model 345 or similar) 干膜厚度测量工具（英国易高模型 345或类似的） 5.1.8 Handling of Painted Goods已上漆物品处理 • nylon or similar non-metallic slings are to be used for the lifting of painted structures, equipment, pipes etc. 提升已上漆结构，装配，管道要用尼龙或非金属吊索。 • adequate care shall be exercised at all times to prevent damage to painted surface. All damage shall be repaired at the expense of the contractor that caused the damage. 要充分注意以防止漆面遭到破坏。所有损坏漆面的修补费用应有造成破坏的承 包商承担。 5.1.12 Use of Thinners冲淡剂的应用 Thinners, or solvent may be mixed with paint only when used in strict compliance with the recommendations of paint manufacturer. This information is clearly shown in the Manufacturer’s Technical Data Sheet. 只有严格按照油漆制造商的建议时，冲淡剂或溶剂才可以与油漆混合。这些信息已在 制造商的技术数据表里清楚说明。 PEC-Tech Quality Assurance Department Doc: PL12-UAPRIL-R018 Revision No.: 0 QUALITY CONTROL PROCEDURE FOR PAINTING AND INSULATION 有关油漆和保温工作的质量控制程序 Page 8 of 16 5.1.13 Paint Mixing涂料混合 Correct mechanical paint mixers shall be used when mixing paints so as to provide a homogeneous mixture of all components and to avoid wastage. Wooden sticks, iron rods or the like, shall not to be used for mixing paint. 混合涂料时需调节涂料混合机以使混合的涂料均匀，避免浪费。混合涂料时，不能用 木棍，铁棍或类似的东西。 5.1.14 Grit-blasting Aggregate喷砂骨材 For abrasive-blasting, Copper Slag, Garnet, or similar industrial abrasives shall be used. 铜矿渣，石榴石或相似的工业磨料可用于磨料喷砂。 5.1.15 Paint Storage涂料储存 Paint shall be correctly stored in accordance with the manufacturer’s recommendations. Particular attention should be paid to avoiding exposure to heat, fire risk and the ingress of dirt, water or other contaminants. 涂料将按照制造商的建议妥善储存。应特别注意以避免受热，火灾以及灰尘水或其他 污染物的入侵。 5.1.16 Contractors Equipment承包商的设备 The painting Contractor’s equipment shall include the following: 油漆商的设备包括下列事项： • Air compressor having a minimum capacity 250 cfm 最小容量为 250立方英尺的空气压缩机 • Pressure at the grit-blasting nozzle shall be at least 7kg/cm² (100 psi) 喷砂机喷嘴的压力至少每平方厘米 7公斤（100psi） • Airless spray pump ratio shall be minimum of 30 : 1 无气喷涂泵的最小比率应为 30：1 • Airless spray gun shall be used 应用无气喷涂枪 • A conventional spray gun may also be used in certain circumstances 在某些情况下可能会用到传统的喷涂枪 • A mechanical paddle-mixer shall be used for paint mixing 用机械桨式混合机混合涂料 • Power-tool cleaning shall be by wire brush 用钢丝刷清理动力工具 • An air / oil separator filter shall be installed in-line with the grit-blasting pot 应安装内嵌于喷砂壶的空气/油分离器 PEC-Tech Quality Assurance Department Doc: PL12-UAPRIL-R018 Revision No.: 0 QUALITY CONTROL PROCEDURE FOR PAINTING AND INSULATION 有关油漆和保温工作的质量控制程序 Page 9 of 16 • An air / oil separator filter shall be installed in-line shall be used with airless spray pump 无气喷射泵应安装内嵌的空气/油分离器 • A means of containing grit blast dust to the immediate grit-blasting area shall be provided. 应在直接喷砂的区域内提供收集喷砂尘的方法。 The Contractor or Subcontractor responsible for painting of piping and equipment on the project shall provide qualified painting inspectors to monitor and inspect the work in progress. The PTC Construction Supervisor assigned to supervise painting activities, shall be responsible for releasing piping and / or equipment for painting. 负责项目管道和设备油漆工作的承包商和分包商将分派合格的油漆检验员监督和检验 油漆工作。被分派监督油漆工作的百达施工监督员将负责发放需上漆的管道和/或装 备。 The Painting Contractor or Subcontractor shall be responsible for preparing and maintaining QC records of inspections which shall be available for review by the PTC Construction and QC personnel at all times. The information recorded shall include, but not be limited to: 油漆承包商和分包商将负责准备并保持检验的 QC记录以方便百达施工和 QC人员的 随时审查。记录的信息应包括但不受限定： • surface preparation 表面处理 • temperature, Relative Humidity (RH %) and dew point readings 温度，相对湿度和露点湿度记录 • paint system used, including Manufacturer and batch numbers 应用的油漆做法，包括制造商和批号 • Dry Film Thickness (DFT) recorded 干膜厚度记录 Contractor or Subcontractor Painting Inspector shall randomly check surfaces to be painted for preparation in accordance with applicable specifications. Surfaces that are not prepared in accordance with the approved procedure shall be rejected and re-prepared. 承包商或分包商的油漆工作检验员将按照所适用规则随意抽查待上漆表面的准备。没 有按审批程序准备的表面将被拒绝并重新处理。 He shall also randomly check paint prior to application for specification, service and application procedures. No deviations will be accepted without written approval from the PTC Discipline Engineer. 检验员也会在规则，服务和实施程序实施之前随意抽查油漆。除非百达部门工程师书 面批准，否则不接受任何变动。 PEC-Tech Quality Assurance Department Doc: PL12-UAPRIL-R018 Revision No.: 0 QUALITY CONTROL PROCEDURE FOR PAINTING AND INSULATION 有关油漆和保温工作的质量控制程序 Page 10 of 16 Upon completion of painting, the Contractor or Subcontractor Paint Inspector shall randomly check surfaces for complete coverage and DFT as specified in the paint system specification. An approved, calibrated DFT gauge shall be used for the DFT Check. 在油漆工作完成之际，承包商或分包商的检验员将按照指定的油漆系统规则随意抽样 检查完工的表面及干膜厚度。用审批的校准好的干膜厚度计干膜厚度。 6. INSULATION 保温 6.1.1 Inputs输入 Insulation inputs originate from design and equipment suppliers via area coordinator or piping/tanks discipline managers. 设计和设备厂商通过区域协调员或管道/槽罐部门经理提供保温材料。 6.1.2 Inquiry and Order查询和订购 Insulation is usually carried out by area main contractors. It may be necessary to issue the contractor with marked-up drawings showing lengths, fittings and areas to be insulated. 保温工作通常由区域主承包商执行。可能有必要发送给承包商表明长度，装备和需保 温区域的标明图。 6.1.3 Coordination协调 The area main contractor shall prepare a technical specification for the erection work to be part of the contract, which shall also include other PTC and international standards. 区域主承包商应准备一份安装工作的技术规则并包括其他百达和国际标准。该规则将 成为合同的部分。 6.1.4 Inspection Controls检验控制 Quality and schedule for completion of the work shall be responsibility of the contractor. The procedures and checks listed below will be followed when preparing erection. 承包商将负责完成工作的质量和进度。安装工作的准备工作应遵循下列程序和检查。 • All flanges and valves for high pressure and high temperature pipe shall be insulated unless otherwise specified. When a flange joint, valve, etc is not specified to be insulated, the adjoining pipe insulation shall be closed with end sleeves at such a distance from the flanges that the removal of the flange bolts does not damage the insulation. 所有法兰和高压高温管件的阀门都应保温，除非另有规定。当法兰接头，阀门 等没有规定保温，那么相邻的管道保温将闭合到套管末端，并且要与法兰相隔 一定距离以致拆除法兰螺栓时不会破坏保温材料。 • The covers for flanges, valves, blank flanges and manholes etc shall be removable types. These removable covers shall be made of metal sheets, l PEC-Tech Quality Assurance Department Doc: PL12-UAPRIL-R018 Revision No.: 0 QUALITY CONTROL PROCEDURE FOR PAINTING AND INSULATION 有关油漆和保温工作的质量控制程序 Page 11 of 16 • ined with rigid insulation slabs or matting with wire netting facing fastened to the inside of the metal cover. Covers for instrument parts shall be furnished with quick release toggle grips, all other covers can be secured with self tapping screws. 法兰，阀门，盲法兰和检修孔的盖子应可移除。器具部分的盖子将配备速开肘 节柄。所有其他的保温层可用自攻螺丝固定。 • The insulation of covers shall extend over the adjoining pipe insulation for distance of at least the pipe insulation thickness, but never less than 50 mm. 保温层应延伸到毗邻管道，其距离至少为管道保温层的厚度但不能少于 50mm. • The thickness of insulation for fittings, flanges, valves, etc shall be the same as for the adjacent pipe insulation, unless otherwise specified. 配件，法兰，阀门等的保温层厚度应与毗邻管道的保温层厚度相同，除非另有 规定。 • The upper part of the packing gland of valves shall be kept out side the insulation cover. 阀门压盖的上部应在保温层外面。 • The insulation shall allow free movement of pipes on the supports. 保温层应允许管道在支撑上自由移动。 • The insulation work shall not proceed until pressure and other necessary tests have been carried out and the contractor has obtained written permission from the area coordinator to begin the work. The insulation of flanged joints shall be made after the piping has been tested and flushed. 保温工作不能进行直到压力测试以及其他的必要测试完成并且承包商已从区 域协调员那儿得到开始工作的书面允许。法兰接头的保温工作需在管道测试 和冲刷完成之后。 • Name plates and test marks shall not be covered. 不能覆盖商标和检验标识。 • The surface to be insulated shall be clean and dry before starting the insulation work. 在保温工作开始之前，被保温的表面应清洁干燥。 • Qualified structural welders shall be engaged for all aspects of welding work to be carried out. 合格的结构焊接工将从事各个方面的焊接工作。 • The insulation shall be made in such a way that there are no openings or gaps in the joints and that the smoothest possible insulation is achieved. 保温工作的完成应使接头无开口或缝隙，保温层尽可能达到最光滑的程度。 • Longitudinal joints in horizontal pipe insulation shall be on the underside of the pipe work. When there are several layers of insulation, the joints shall be staggered. 横向管道保温材料的纵向接口管道的下面。当有多层保温材料时，接口要错 开排列。 PEC-Tech Quality Assurance Department Doc: PL12-UAPRIL-R018 Revision No.: 0 QUALITY CONTROL PROCEDURE FOR PAINTING AND INSULATION 有关油漆和保温工作的质量控制程序 Page 12 of 16 • The insulation of pipes and tanks shall be prevented from sagging or shifting by use of distance rings. Vertical insulation shall be fixed to welded studs at a distance of 1.5 to 1.8 m or as per project standard LAPRIL-K6 for all areas. 管道和槽罐的保温材料将用定距环防止松垂或移位。垂直的保温材料将以 1.5m 至 1.8m 的间距固定在焊好的螺栓上或按照适用于所有区域的项目标准 LAPRIL-K6处理。 6.1.5 Tank Insulation槽罐保温 • Required steel spikes are to be welded on the tanks as per standard SFS 3978.E of standard LAPRIL-K6. 要求的铁钉将按照 LAPRIL-K6标准中的 SFS 3978.E标准焊到槽罐上。 • Fixing pins/spikes and welding rods on carbon steel tanks shall be by low hydrogen welding electrode. 用在碳钢槽罐上的固定钉和焊条应为低氢焊极。 • Similar fixing to stainless steel tanks shall be by type 309L welding electrode. 用于不锈钢罐上的类似的固定物应为 309L型的焊极。 • Supply of pins/spikes and welding rods is normally in the scope of the insulation contractor, including supply of the welding machines. 保温材料的承包商应供应钉子和焊条和焊接机器。 6.1.6 Material Identification材料选择 The type of insulation material and thickness selection should be as per appendix I to IV of PTC-LAPRIL-C006. 保温材料和厚度的选择应按照 PTC-LAPRIL-C006的附录 1-4. • Cladding material 包覆材料 • For tanks in corrosive environments SS304 sheet to be used. 处于腐烂环境的槽罐应用 SS304钢板。 • For other tanks and equipment 0.8 mm thick aluminum sheet may be used. 其他槽罐和设备可用 0.8mm厚的铝板。 • For pipes and fitting up to DN 150 mm, 0.5 mm thick aluminum sheets to be used. And for pipes and fitting DN 200 mm and above, 0.8 mm