管道油漆修补方案.docx

Table of Content
目 录

一、 Project General Introduction工程概况
二、 References 编制依据
三、 Preparations 准备工作
四、 Painting Process 涂漆工艺
1、 Confirm the regions that need to repair and repair method
确认油漆损伤部位和修补方法
2、Surface Preparation Method表面处理方法
3、Painting涂漆
五、 Quality control and Inspection 质量控制及检查
六、 Safety 安全
七、 Paint Protection油漆保护

一
二 References 编制依据
三 Preparations 准备工作
1、The design and other technical document is ready; the construction drawing is reviewed.设计及其他技术文件齐全，施工图纸业经会审；
2、 Construction procedure and technical instructions are completed; The safety training and technical training from international company have been provided.完成施工方案和技术交底，进行了安全技术教育和国际公司技术培训；
3、 pipe and fittings shall have qualifications.
管段应具备出厂合格证；
4、 Material, tools, apparatus for test and inspection, construction facility and space are ready.材料，机具，检测仪器，施工设施及场地已齐备；
5、 Inspection must be done during the course of anticorrosion construction, and perform the acceptance immediately after anticorrosion is completed.防腐蚀工程施工过程中，必须进行中间检查；防腐蚀工程完工后，应立即进行验收；
6、 The coating shall have qualification from its manufacturer 油漆应有制造厂的质量证明书；
7、 Painting environmental condition shall be in accordance with the information on the product sheet. The surface temperature to be 30C.above dew point relative humidity shall be less than 85%.
涂装环境条件必须和产品说明书的信息一致。表面温度至少大于露点30C.。相对湿度最大植为85%。
8、 Selection of Paint 油漆选用
DC has provided the painting system suitable for this project. The selection of paint shall strictly follow DC construction painting system. Paint type, finish paint color and paint repair color should be chosen in accordance with the line list. The specific painting systems are as follows.
本项目DC已经给出了适合本项目的油漆系统，油漆选择严格按照DC油漆系统进行选择施工 。油漆种类、面漆和油漆修补的颜色按照line list规定选用，主要有如下种类。详细油漆系统对照表如下：
Painting SystemDC201A
油漆系统DC201A
DC201A：new steelwork，piping and fabricated equipments，shop prepare（-20 to 1200C）
Location 部位
DC201A
Surface reparation
表面处理
Abrasive blast cleaning to ISO8501-1 Sa2.5, (Roughness 40-75
microns)喷砂处理至 ISO8501-1 Sa2.5，粗糙度达到Rz=40-75 微米
Coating System 涂层配套
Coat Name
涂层名称
Product Name
产品名称
DFT: microns干膜
厚度：微米
Prime Coat
底漆
Inorganic zinc-rich, Interzinc 22 Greenish grey, Matt
无机富锌底漆 Interzinc 22 绿灰色，平光
60-75
Mid-Coat
中间涂层
MIO Epoxy Intergard475HS Gray
环氧MIO 中间漆 Intergard 475HS, 灰色
100-150
Top Coat
面漆
Polyurethane color：meet Spec’s requirements
聚氨酯面漆 颜色：符合规范要求
60-75
Typical Minimum/Maximum DFT Range
典型最小/最大干膜厚度范围
220-300
Pipe supports sand blasting, painting requirement should be the same as piping,.
管道支架的喷砂、涂漆与管道要求相同。
DC201B：Site work and repairs of steelworks,piping and fabricated equipments (-20 to 1200C)
Location 部位
DC201B
Surface preparation
表面处理
Abrasive blast cleaning to ISO8501-1 Sa2.5, (Roughness 40-75
microns)
喷砂处理至 ISO8501-1 Sa2.5，粗糙度达到Rz=40-75 微米
Coating System 涂层配套
Coat Name
涂层名称
Product Name
产品名称
DFT: microns
干膜厚度：微米
Prime Coat
底漆
Surface Tolerant Epoxy Intergard670HS
低表面处理环氧漆 Intergard670HS
100-150
Mid-Coat
中间漆
Surface Tolerant Epoxy Intergard670HS
低表面处理环氧漆 Intergard670HS
100-150

Top-Coat
面漆
Polyurethane color:meet spec”s requirements
聚氨酯面漆 颜色：符合规范要求
50-75

Typical Minimum/Maximum DFT Range
典型最小/最大干膜厚度范围
250-375

DC202A：Galvanized surface,handrais(-5 to 600C).(can not use abrasive basting).

Location 部位
DC202
Surface preparation
表面处理
清理基层表面油污到SSPC-SP1标准要求。
Coating System 涂层配套
Coat Name
涂层名称
Product Name
产品名称
DFT: microns
干膜厚度：微米
Prime Coat
底漆
蚀刻底漆 Interprimer539
10-25
Mid-Coat
中间漆
环氧底漆 Intergard269
30-50

Top-Coat
面漆
Polyurethane color: meet spec”s requirements
聚氨酯面漆 颜色：符合规范要求
50-75

Typical Minimum/Maximum DFT Range
典型最小/最大干膜厚度范围
90-150

Painting SystemDC203
油漆系统DC203
DC203：steel piping and fabricated equipment under insulation （-30 to 1550C）
Location 部位
DC203
Surface preparation
表面处理
Abrasive blast cleaning to ISO8501-1 Sa2.5, (Roughness 40-75
microns)
喷砂处理至 ISO8501-1 Sa2.5，粗糙度达到Rz=40-75 微米
Coating System 涂层配套
Coat Name
涂层名称
Product Name
产品名称
DFT: microns
干膜厚度：微米
Prime Coat
底漆
Phonolic epoxy intertherm228
环氧酚醛高温漆 intertherm228

90-120
Top Coat
面漆
Phonolic epoxy intertherm228
环氧酚醛高温漆 intertherm228
90-120

Typical Minimum/Maximum DFT Range
典型最小/最大干膜厚度范围
180-240

Painting System DC204
油漆系统DC204
steel piping and fabricated equipment under insulation （155 to 4000C）
Location 部位
DC204
Surface preparation
表面处理
Abrasive blast cleaning to ISO8501-1 Sa2.5, (Roughness 40-75
microns)喷砂处理至 ISO8501-1 Sa2.5，粗糙度达到Rz=40-75 微米

Coating System 涂层配套
Coat Name
涂层名称
Product Name 产品名称

DFT: microns干膜
厚度：微米
Prime Coat
底漆
Inorganic copolymer intertherm751CSA
冷喷铝高温漆 intertherm751CSA

90-120
Top Coat
面漆
Inorganic copolymer intertherm751CSA
冷喷铝高温漆 intertherm751CSA
90-120

Typical Minimum/Maximum DFT Range
典型最小/最大干膜厚度范围
180-240

9 Main Equipment & Tools 主要机具
A、主要施工工具
Description机具名称
Qty.数量
Wheel Grinding Machine砂轮磨光机
As necessary按需
Manul blasting machine 手动喷砂机
As necessary按需
Internal Grinding Machine内磨机
As necessary按需
Power Blender动力搅拌机
As necessary按需
Scraper刮刀
As necessary按需
File锉刀
As necessary按需
Wile Brush钢丝刷
Several若干
Abrasive Cloth铁砂布
Several若干
Paint Bucket油漆桶
As necessary按需
Brush刷子
As necessary按需
B、main inspection facility 主要检测工具
编号NO
Name 名称
Use 用途
Remarks 备注

1
Thermometer 温度计
Test temperature
检测温度
-15~50℃, need to
be calibrated
termly 需定期校准
2
Sling psychrometer 手摇湿度计

Test temperature and humidity 检测温度和
湿度
need to be
calibrated termly
需定期校准
3
Dew point calculator 露点计算表
Calculate dew point
计算露点

need to be
calibrated termly
需定期校准
4
超生波测厚仪
测量涂层厚度
need to be
calibrated termly
需定期校准
5
Holiday tester 漏涂检测仪

Check holidays of
coatings 检测涂层漏涂点
need to be
calibrated termly
需定期校准
6
Replicate tape profile tester 复膜
胶带法粗糙度检测仪
Check the anchor
profile of substrate
检测底材表面粗糙度

7
Tape for test cleaning 清洁度测试
胶带
Cleaning test 检测清
洁度

8
Flash magnifier 放大器

9
Knife 刀

四、 Painting Process 涂漆工艺
Local Area Touchup for Piping 管道局部损伤及焊缝修补工艺
Confirm damaged positions and exact location of site weld
确认油漆损伤部位以及现场焊口的具体位置
Inspection with pachometer & record检查：漆膜测厚仪检测并记录
Finish Coat Touchup面漆修补
Intermediate Touchup (If needed)中间漆修补(若需)
Primer Touchup底漆修补
Manual Surface preparation or sandblasted 表面手工处理及喷砂处理

1、 确认油漆损伤区域 Confirm damage regions need to repair

A、 Areas need to repair需要进行涂层修补的区域
Area of welding seam where welding has been done after painting and unqualified local coating area caused by every kind of reason need to be repaired. Generally components shall be repaired include:
对于涂装后进行焊接的焊缝区域和各种原因造成的不合格局部涂层，应进行修补，一般情况下需要进行修补的构件为：
Welding seam area: area after construction coating finished.
焊缝区域：主要针对主要涂层已施工完毕的焊缝区域。
Damaged coating area: damaged by hot working transportation, lifting and loading etc. damaged local part of coating.
涂层损坏区域：由于热工作业和运输，吊装，装卸等原因造成的涂层损伤或损坏局部涂层部位。
Over thickness coating cause crack on inorganic zinc silicate coating.
由于涂层厚度超厚，而导致无机硅酸锌涂层龟裂部位。
Local coating with defects: sagging, omission, pin hole caused by unsuitable construction.
有涂层缺陷的局部涂层：由于施工过程中施工不当造成的流挂，漏涂，针孔等局部涂层的位置。
Seriously polluted part of coating: Any contamination has already damaged coating (polluted by cement)or the local area where contamination can be removed by easy cleaning.
涂层被严重污染的部位：被污染物严重污染，污染物已造成涂层损坏（被水泥污染），或污染物已无法通过简单的清洗就能除去的局部涂层区域。
B、 Method of painting repair涂层修补的方法
For weld seam are or damaged area of coating: Use power sand paper disc to grind the weld seam area or damaged area of coating to Grade St3(damaged coating has been removed entirely ), the pipe welding joint will be treated by manual blasting machine by a level of Sa2.5.Damaged area and unbroken area shall have a overlapping slope. Overlapping area shall appear new and fresh surface of coating to enlarge bonding force between repair coating and raw coating. Repair position shall be cleaned adequately after preliminary surface treatment, then repair painting as per the whole set of painting repair system and arrive the designed film thickness. For small area, brush painting shall be used. But spray coating shall be used for mid-coating and final coating when more coating areas connected together. Brushing style will be taken to the touch up works to ensure the appearance of the coating.
对于焊缝区域或者涂层损坏区域：应用动力砂纸片将焊缝区域和涂层损坏区域打磨处理到St3级（被损坏的涂层应完全清除），管道焊口采用手持式喷砂机，除锈等级Sa2.5。损坏区域与完好区域涂层应的边缘部位应砂磨出搭接坡度，搭接区域的原涂层应砂磨漏出新鲜的涂层表面，以增加修补涂层与原涂层的结合力。修补位置基层表面处理结束后，应充分清洗该表面，然后按修补油漆配套系统进行涂层修补并达到设计要求的干膜厚度。油漆涂层修补采用刷涂，确保修补涂层的外观。
对于涂层缺陷，涂层龟裂，涂层污染的部位修补：先砂纸片，砂布或其他方法清除缺陷涂层和严重污染涂层。然后按照对该部位涂层进行砂磨和清洗，并保证搭接涂层边缘一定的搭接坡度和新鲜的涂层表面。再按照修补涂层系统进行修补，涂层修补的其他要求同上节。

C、由于固化后的无机锌涂层很难进行自覆涂，因此，对于有缺陷和损坏的无机锌涂层应采用环氧富锌进行修补。
D、 被修补的涂层或基层表面应清洗干净，无污染物，如存在油污应充分清洗油污（达到SSPC-SP1标准）。
E、 为确保修补涂层的外观，建议较大面积的涂层采用喷涂的方法施工。
注：
l 检查管道外观，对所有在运输、倒运、现场焊接等过程中破坏的涂漆用记号笔做好标记，并标记出打磨处理的范围。
l 确定现场焊口，未试压管段焊口以及不锈钢管的具体的位置。做好标记。
2、Surface Preparation 表面处理
Surface preparation before painting涂漆前的表面处理
u Surface preparation request: grade. St3, thorough rust removal by hand or power machine or arrive Grade Sa2.5 by mechanical rust removal.
表面处理粗糙度要求： St3级 彻底的手工和动力工具除锈或者采用机械除锈达到Sa2.5级。
u Treatment by hand: Unwound scale, rust and aging coating on pipes can be removed in using wire brush or rubber paper or manual machine or spade.
人工处理：管道表面上松散的氧化皮、锈蚀和老化涂层可用钢丝刷刷掉、砂皮纸砂去、用手工工具刮掉或铲除
u Power treatment: It’s better to use power machine than manual machine when removing scale, rust or aging coating. But it can’t be used to remove the rust or scale attached to pipe surface firmly. Normally used power machine includes :wire brush, impulse tools, grinding machine and rubber sharpening machine. Pay more attention not to polish the metal surface, especially when using power wire brush, or it will destroy the required surface roughness.
动力处理：在清除松散的氧化皮、锈蚀和老化涂层时，用动力工具比用人工效果好，而且省力。但是动力工具不能除去紧紧附着在管道表面的锈蚀和氧化皮。通常采用的动力工具，包括钢丝刷、冲击工具、砂轮机及砂皮磨光机。但是必须注意，不要抛光金属表面，尤其是在使用动力钢丝刷时，否则会破坏涂覆所需的表面粗糙度。
u For cracked coats，grind the coat in the crack area comletely to reach required roughness ， and then commerce the repair paint work 。 对于龟裂的涂层，需将龟裂处涂层彻底打磨，并达到规定的粗糙度要求后再进行油漆的修补。
u For cracked and slightly scratched coats，do not grind too hard 。 Only grind to the base coat for repairing with Interthane 990 top-coat 。对于轻微损伤的涂层，不需打磨过深，只需要适度打磨即可进行修补，可直接用Interthane 990 面漆。
u The repairing area should have 30—50mm adjoining area with the pre-existing coat 。 The grinding should have some gradient to insure the repaired coat connects well with the pre-existing coat。修补区域与原有涂层有30—50mm 的搭接，要求打磨成一定的坡度，用于修补涂层与原有涂层平滑过渡。
3、Painting涂漆
Ø Painting must be done in a nice weather; doing in raining, fogging, snowing and heavy dust is forbidden.涂料须选择在晴好天气的条件下施工，在雨，雾，雪和较大灰尘的条件下禁止施工。
Ø Ensure the surface to be painted is clean. The surface can be cleaned with dust collector or brush etc. The same treatment shall be done again after each film is dry. Then next coating can be applied.涂料表面必须保证清洁干净。涂漆前用吸尘器，刷子等清理干净，每层涂膜干燥后需经同样处理后，方可涂下一层涂料。
Ø Ensure the seperation from other components around in the event that any contamination occur prior to painting, and especially much attention to ground pretection shall be taken in case of any soil pollution. Separateing material can use tape (small range),color clothing and wood board.
Ø 涂漆前必须对周围其它部件进行隔离以免造成周围部件的污染，特别注意对地面的保护以免造成土壤的污染。隔离材料可采用胶带（小范围）、彩条布、木板等.
Ø The painting surface must be dry. The next paint can be applied only when the last paint film is complete dry.涂漆表面必须干燥。前一道涂膜实干后，方可涂下一道漆。

不同温度条件下Interseal 670 HS 重涂间隔时间
Interseal 670 HS re-coat interval time under different temperatures
温度 temp.
表干 Touch Dry
硬干 Hard Dry
自重涂间隔Re-coat by self
最小 Min.
最大 Max.
10℃
8小时 hrs
32小时 hrs
32小时 hrs
无 Extended
15℃
7小时 hrs
26小时 hrs
26小时 hrs
无 Extended
25℃
5小时 hrs
18小时 hrs
18小时 hrs
无 Extended
40℃
2小时 hrs
6小时 hrs
6小时 hrs
无 Extended

不同温度条件下Interthane 990 表干、硬干和覆涂间隔时间：Touch dry ， hard dry and re-coat interval time of Interthane 990 under different temperatures
温度 temp.
表干 Touch Dry
硬干 Hard Dry
自重涂间隔Re-coat by self
最小 Min.
最大 Max.
5℃
5小时 hrs
24小时 hrs
24小时 hrs
无 Extended
15℃
2．5小时 hrs
10小时 hrs
10小时 hrs
无 Extended
25℃
1．5小时 hrs
6小时 hrs
6小时 hrs
无 Extended
40℃
1小时 hrs
3小时 hrs
3小时 hrs
无 Extended
不同温度条件下Interzinc22重涂间隔时间
Surface
Temp
温度计
Touch Dry
表干温度
Hard Dry
硬干时间
Over-coating interval with recommended top-coat 推荐面漆覆涂间隔时间
Minimum 最短时间
Maximum最长时间
50C
30min 分钟
3Hrs 小时
36-48Hrs 小时
Extended 无限制
150C
20min 分钟
90min 分钟
24-36Hrs 小时
Extended 无限制
250C
10min 分钟
60min 分钟
16-24Hrs 小时
Extended 无限制
400C
5min 分钟
30min 分钟
8-12Hrs 小时
Extended 无限制
不同温度条件下Intertherm228、Intergard475HS重涂间隔时间
Touch dry, Hard dry and Over-coating interval 表干，硬干，覆涂间隔时间：
Surface
Temp
温度计
Touch Dry
表干温度
Hard Dry
硬干时间
Over-coating interval with recommended top-coats 推荐面漆覆涂间隔时间
Minimum 最短时间
Maximum最长时间
50C
1.5 hrs
16Hrs 小时
16Hrs 小时
Extended 无限制
150C
1 hrs
10 hrs
10 Hrs 小时
Extended 无限制
250C
1 hrs
5 hrs
5 Hrs 小时
Extended 无限制
Intertherm 228 and 751CSA layer application interval under different temperature conditions
不同温度条件下Intertherm228、Intertherm751CSA重涂间隔时间
Surface
Temp
温度计
Touch Dry
表干温度
Hard Dry
硬干时间
Over-coating interval with recommended top-coat 推荐面漆覆涂间隔时间
Minimum 最短时间
Maximum最长时间
100C
8 Hrs 小时
16Hrs 小时
36Hrs 小时
5 days 天
150C
7Hrs 小时
12 Hrs 小时
24Hrs 小时
4 days 天
250C
5Hrs 小时
8 Hrs 小时
16Hrs 小时
3 days 天
400C
3Hrs 小时
6 Hrs 小时
16Hrs 小时
2 days 天

五 Quality control and Inspection 质量控制及检查

Project Manager
项目经理
QA/QC Manager
质检经理

Doc. Clerk
资料员
Construction Team Manager
施工队长
Quality Inspector
质检员
Construction Teams
各施工班组
Materials Inspector
材料员
Dispatcher
收发员

6.2 Technical Requirement for Painting 油漆施工的技术要求
为保证涂装质量，油漆的调配必须由专人操作，严格依照说明书进行调配。
Ø The sort, color, film layer applied, thickness and the mark of the coating shall be as per the design document.
涂料的种类，颜色，涂敷的层数、厚度和标记应符合设计文件的规定；
Ø Quality of coating shall according to following requirements:
涂层质量应符合下列要求：
a) Coating shall be uniform and with identical color.
涂层应均匀，颜色应一致；
b) Coating shall be integrity without damage and dripping.
涂层应完整，无损坏，流淌；
c) Film applied shall firmly adhere to and free of scale, wrinkle, porosity, pinhole and other defects.
涂膜应附着牢固，无剥落，皱纹，气泡，针孔等缺陷；
d) The color ring shall be applied with uniform space and identical width.
涂刷色环时，应间距均匀，宽度一致。

QC procedure:质量控制步骤：
1、Treatment of damaged surface of pipe: QC inspector and supervision engineer shall inspect the damaged pipe surface after treatment. Then the next final painting can be done. The time of final painting shall be controlled in 4 hours.管道损