船舶电装预制件制作及电缆贯穿件隔堵工艺.doc

船舶电装预制件制作及电缆贯穿件隔堵工艺
TECHNOLOGY OF CABLE PENETRATION&SEALING FOR STEEL SHIP page 10 total 10

预制件的工艺要求Technology of cable penetration

1. 电缆贯穿件Cable transit
若托盘表中没有特别注明，贯穿件的材料为普通A级钢。
贯穿件制成后，将锐边及毛刺打磨，并进行防腐蚀处理，一般涂防锈底漆二度。
The material of penetration is ordinary steel (class A) in generally, if no specify.

The transit should be grinded, and coating two layers.
普通电缆贯穿件(无防火，及水密要求) 见下图1
Ordinary transit (no-fireproof no-watertight) see drawing 1.

1.1普通电缆框 Horizontal ordinary transit
表示方法Express： DK L×B×H×δ
DK--普通电缆框 Horizontal ordinary transit

1.2 普通电缆筒（无防火，水密要求） 见下图1。
Vertical ordinary transit (no-fireproof no-watertight)see drawing 1.
表示方法Express： DT L×B×H×δ
DT --普通电缆筒Vertical ordinary transit
L—长length B—宽wide H—高high δ—板厚thickness

小型普通电缆框、筒可用镀锌管压制代用。
Mini ordinary transits can be taken placed by pressed galvanized tube.

1.3 耐火电缆框Fire-proof horizontal transit
表示方法Express： AWn L×B×250×δ
AW--耐火电缆框Fire-proof horizontal transit
L—长length B—宽wide 高height --250mm δ—板厚thickness
n—耐火等级详见下表type number, see followed table
电缆框高度固定为the is fixed：250mm
类型参数Type
名称Name
耐火等级
Fireproofing grade
使用场所site
AW1
DMT-W水密式A-60级耐火电缆框DMT-W watertight grade A-60 fireproofing transit
A-60，A-30，A-15
舱壁bulkhead
AW3
DMT-W水密式A-0级耐火电缆框DMT-W watertight grade A-0 fireproofing transit
A-0
舱壁bulkhead

标记示例Signature:
A W n ────型式序号fire-proof grade
└─────── 无机型填料watertight
└───────── A级水密耐火结构fire-proof mark
制作双侧型耐火电缆框(灌注孔和透气孔在舱壁两侧)的具体要求如下图2:
一般情况下，选用如图2的耐火电缆框。
Double side fireproof transit (perfusion hole and ventilate hole in two sides), see: drawing 2:
In generally, this kind of fire-proof transit will be priority used (see drawing 2),

图 2 AW1，3 双侧型耐火电缆框
若为保证电缆必要的弯曲半径，在某些特殊区域，可选用如图3的单侧型耐火电缆框(灌注孔和透气孔在舱壁同侧)。
For keep the necessary bend radius, use the Fireproof transit of single side ( perfusion hole and ventilate hole be same side deck) in some special space. see drawing 3.

图3 AW1，3 单侧型耐火电缆框

1.4 耐火电缆筒Vertical fireproof transit
表示方法为express: AWn L×B×215×δ
AWn耐火电缆筒Vertical fireproof transit
L—长length B—宽wide height高215mm δ--板厚thickness
n—耐火等级详见下表type number, see followed table
电缆筒高度固定为the is fixed：215mm
类型参数Type
名称
Name
耐火等级
Fireproof class
使用场所site
AW2
DMT-W水密式A-60级耐火电缆筒 DMT-W watertight grade A-60 Fireproofing penetration
A-60，A-30，A-15
甲板deck
AW4
DMT-W水密式A-0级耐火电缆筒DMT-W watertight grade A-0 Fireproofing penetration
A-0
甲板deck
制作具体要求如下图4：
AW1、AW2型的电缆贯穿件的制作、安装要求同AW3、AW4型的贯穿件，只是在填料结束后，在船体包覆耐火绝缘层的一侧包覆耐火绝缘毡。包覆厚度按舾装专业的防火绝缘布置图的相应要求来定，一般不低于40mm厚。
Requirement as following drawing 4:
Make and installation of AW1、AW2is same as AW3、AW4, after stuffing ,the difference is only covered fireproof insulation. The thickness not less than 40mm normally, the detail is according to fireproof insulation drawing.

DRAWING 4
1.5 电缆管 见下图5 Cable pipe ( see: drawing 5).
电缆管用镀锌钢管切割或弯制成，分直管和弯管两种，切口的毛刺及锐边打磨光滑。直管用于单根电缆的贯穿, 弯管用于多根电缆的贯穿。直管上口须根据电缆外径配相应尺寸的填料函。机舱或露天区域用热缩套管密封，其它区域用橡皮泥封堵。露天甲板的电缆管须配相应规格的套管以防腐蚀。
Cable pipe made of galvanized steel tube, there are two types, one is straight pipe with gland for single cable, another is goose neck pipe for multi-cables. The cut edge should been grinded to smooth. The tube stuff using thermal shrink tube in E/M or on open deck, for other area, the pipe should been stuffed plasticene.
表示方法为Express: DGФ×H
Ф--管子通径diameter H--- 高height

drawing 5

1.6 填料函见下图6 Cable gland ( see: drawing 6).

单根电缆需贯穿B-0级水密壁时,可采用填料函并加焊长100的钢管。
Single cable passes through WT B-0 class bulkhead, the gland can be welded on 100 mm pipe.

表示方法Express : TH X d
TH--填料函Cable gland d--填料函尺寸dimension of gland

drawing 6

2. 电缆支承件Cable support

2.1扁钢支架 见下图7, Flat steel ( see: drawing 7)
用相应规格的扁钢弯制而成，切口的毛刺及锐边打磨光滑，镀锌20~30μ。
It made of smooth flat steel ,galvanized 20~30μ
表示方法为Express: DB L×B×H×δ or DB B×δ
L—长length B—宽wide H--脚高height δ—厚度thickness

如L、H的值缺省，则相应代表扁钢长度为550、扁钢高度现场定
If no showing the data of L and H, please refer to the followed table.

Type
L
B
H
δ
1
550
20
现场定
No requirement
3
2
550
40
4

Drawing 6

2.2 电缆托架Cable tray

制作托架的材料通常为钢质，且经镀锌防蚀处理
In general, material of cable tray is galvanized steel, and the material.

电缆托架可分为单层托架和多层托架：
Cable tray divide monolayer tray and Multi-layer tray：

表示方法为express: DZ L×H 单层电缆托架 monolayer tray. L—宽wide H--脚高high
或or 2DZ L×H 双层电缆托架 double layer tray L—宽wide H--脚高high
或or 3DZ L×H 三层电缆托架 three layer tray L—宽wide H--脚高high

为便于船上安装，电缆托架一般可在车间预制成，见下图7。
Cable tray may be prefabricated in workshop for easy installation. See drawing7

电缆的U型托片之间的间距参照表ａ确定。
Space between of U-type tray refer to the followed table .
组装件底脚之间的距离要求 如下：
Space between support as followed:
DZ150 ~ DZ300 ≤ 900mm，
DZ400 ~ DZ800 ≤ 1500mm

多层托架：折算为单层托架后，再按相应要求确定规格 。
For the selection for Multi-layer tray, please calculate to monolayer.

Drawing 7

电缆托架组合骨架及支脚的材料按下表来选择：
Material of cable tray combination frame and support:

电缆托架规格Cable tray type
电缆托片规格
Bracket
组合骨架 framework
支脚support
DZ150
U-150
Z-2

U-2
DZ200
U-200
Z-2
U-2
DZ300
U-300
Z-2
U-2
DZ400
U-400
Z-3
L30X30 angle iron
DZ500
U-500
Z-3
L30X30 angle iron
DZ600
U-600
Z-3
L45X45 angle iron
DZ700
UT-700 30X30 angle iron bracket
L30X30
L45X45 angle iron
DZ800
UT-800 30X30 angle iron bracket
L30X30
L45X45 angle iron

3. 防火、水密隔堵Sealing

3.1使用橡皮泥、热缩套管using of plasticene, thermal shrink tube

舱室内的电缆管使用橡皮泥进行封堵；机舱、露天甲板处的电缆管、填料函等的密封使用热缩套管，居住区域内电气箱上的填料函一般不须封堵。热缩套管施工工艺参照制造厂标准要求如下：
Cable pipe in cabinet to be sealed with plasticene; cable pipe and cable gland in engine room and open deck to be sealed with thermal shrink tube, the cable gland on electrical panel no need seals in accommodation area normally. Technology of thermal shrink tube should be according to maker’s standard.

3.1.1热缩套管的规格参见下表Type of thermal shrink tube
序号
NO.
型号规格
TYPE
缩前内径ORIGINAL DIA
缩后内径FINALLY DIA
缩前壁厚ORIG. THICKNESS
1
RSG-30/8
30
8
0.3
2
RSG-40/12
40
12
0.3
3
RSG-50/15
50
15
0.35
4
RSG-60/18
60
18
0.35
5
RSG-7022
70
22
0.4
6
RSG-90/27
90
27
0.4
7
RSG-100/30
100
30
0.45
8
RSG-110/37
110
37
0.45

3.1.2根据电缆及填料函的规格选用热缩套管，可参照下表进行。
The thermal shrink tube can be selected as the correlation table between cable gland and thermal shrink tube.

电缆外径CABLE OUT DIA.
填料函内径CABLE GLAND INNER DIA
填料函D尺寸
D DIMENSION OF CABLE GLAND
安装后总外径TOTAL OUT DIA AFT FITTING
选用热缩套管Thermal shrink tube dia.
5-7
8
M16×1
21.9
30/8
6-12
13
M20×1
27.5
30/8
11-15
16
M27×1.5
36.9
40/12
14-18
19
M30×1.5
41.6
50/15
17-23
24
M36×1.5
47.3
50/15
22-27
28
M42×2
53.2
60/18
26-33
34
M48×2
63.5
70/22
32-41
42
M56×2
75.0
90/27
40-49
50
M64×3
80.7
100/30
48-57
58
M72×3
92.4
110/37

3.1.3热缩套管使用说明Manual of Thermal shrink tube
(1) 根据上表选择合适规格的热缩套管，通常所选热缩管收缩后的内径应小于电缆外径1mm以上，热缩管长度应大于要包覆长度的5-10%。
Select the Thermal shrink tube according above table, the dimension of Thermal shrink tube should be smaller 1mm than cable out diameter normally, length of the Thermal shrink tube should be longer 5-10% than the cover length.

(2) 在要包覆的电缆部位的两端做上标记用干净抹布去除灰尘和污物。
Marked the cable before seal, outer sheath of cable should be cleaned.

(3) 必要时可在预热后的电缆部位均匀缠绕上一层热熔胶带(厚度约为0.3mm左右)，热熔胶带要压紧
Preheating the outer sheath of cable, then wrap one layer thermal melt tape tightly (thickness about 0.3 mm) if necessary.
(4) 套好热缩套管，定位后用塑料焊枪或喷灯从热缩套管的中部开始沿园周方向加热使其均匀完全收缩，然后由中间往一端逐步加热至完全收缩，端口有热熔胶溢出，一端收缩完全后，用同样的方法加热收缩另一端，注意加热时一定要沿园周方向移动，待完全收缩后依次向外扩展，以免产生皱折和气泡。
After fit the thermal shrink tube, use the blowtorch to heat. Heating the middle part of thermal shrink tube at first, when it shrink uniformly, then heating from middle to one end, after thermal melt tape extravasation and shrink fully, then do the other end as the same way. The cable and tube should be move around during heating to avoid rumple and bubble.

(5) 热缩套管收缩后，再重复加热一遍，使表面光滑平整，整个加热过程要快速移动塑料焊枪。
Reheating once again after shrink fully, during whole process, please move the blowtorch quickly to keep the surface lubricity and to avoid temperature too higher.

(6) 在大、小头按连处，若尺寸相差过大或有尖锐角过渡，可在小头一端尺寸较小的热缩管，用第(5)条的方法先使其收缩好，再套上另一根热缩管。或用热熔胶缠绕紧，使其圆滑过渡，再套热管。
For the reducer, if dimension discrepancy is too large or there is acuity corner transition, fitted one small dimension tube or thermal melt tape on the small end at first, then use the big size thermal shrink tube cover the whole part.

(7) 若有弯角，应先从弯角处开始加热热缩管，使其先完全收缩后再向两边扩展。
If there is bended corner, it should be heating thermal shrink tube from the bended parts, then extend to both sides.

(8) 待热缩管完全冷却后方可进行下一步操作，最好冷却时间在15分钟以上。
After thermal shrink tube cooling fully, it can be done next operation; it is better the cooling time over than 15 minutes.

3.2耐火电缆框（筒）的隔堵工艺Sealing Technical for fireproof penetration
3.2.1准备工作Prepare Working

3.2.1.1检查主要材料的出厂合格证件是否齐全
Check the relative certificate of the materials.

3.2.1.2如对保管的或来料质量有疑问，可进行小样检验，取少量填料样品，按规定比例，将A、B二组份混合调匀，如产品一天内不固化，即为失效
If you doubt the quality of the stuff, please do the sample test, according proportion, mix part A and part B, if it can not solidify in one day, it must be no used.

3.2.1.3按照相关图纸将贯穿件内部的电缆敷设齐全，整理平直并保证清洁。
Finished the cable layout according the drawings , keep straight and cleaning.

3.2.2 PD100膨胀堵料的施工Construction of PD100 caulking
3.2.2.1为灌注液态堵料的需要，先将防火电缆框两端或防火电缆筒下端填充膨胀堵料Before pour the sealing slurry, please fit the expansion caulking at the end of penetration. For the fire-proof horizontal penetration, it is both end; or for the vertical penetration, it is only low end.
3.2.2.2用膨胀堵料填入每根电缆之间以及与贯穿件内壁之间，大的间隙可重叠堵塞，应使堵料与贯穿件端面相平，梳齿面必须向内放置，然后对膨胀堵料喷洒膨胀促进液，约法30分钟后即可封堵开口，灌注密封填料。
Being under the construction, put PD100 caulking to the space between cables and transits, then spraying expansion liquid to the caulking, the caulking start expands and after 30 minutes, the space can be fully blocked, then it is possible to pour the sealing slurry.

3.2.3 DMT-W型无机电缆密封填料的施工Using way of the DMT sealing

3.2.3.1填料的配制DMT sealing consists
填料的配方包括A、B二个组份，A组份为粉料，B组份为溶液，A组份与B组份的调配比例为6：4（重量比），出厂时已按比例分别装于（A）（B）二个容器内，施工时只需将B组份溶液倒入粉料中调匀后便可使用。
Sealing consists of A part (powder) and B part (solution): usually the mixture ratio of A part to B part is 6:4. when it is dispatched from the factory, the sealing has been separately packed into two (A) (B) containers with above mentioned ratio. Being under the construction, put B part into A part and mix them fully for use.

3.23.2填料的使用时间Sealing used time
填料在-5~40℃配制环境温度下其固化时间为30分钟左右，因此，配料后通常要求在15分钟内用完。
In surroundings temperature -5~40℃,the mixed sealing will solidifies in 30 minutes, so it should be used up within 15 minutes.
3.23.3填料的灌注sealing poured
一般可一次或数次将电缆贯穿件灌满。
It can be done one time or several times.
灌注方法可以采用自流法或加压法均可，一般采用自流法，对电缆框（筒）如限于施工条件困难，不便采用自流法时，可采用加压法。
Mixture sealing shall be poured by flow automatically or by air pressure. Generally used the poured by flow automatically, if it is no enough space above the penetration, it can be done by pressure.
压入空气压力保持在0.05Mpa左右，压力过大易造成喷溅。
Air pressure should be kept about 0.05Mpa, the sealing will spray if the pressure is too large.

3.2.3.4清洗Cleaning
DMT-W填料和PD100堵料，均为无机材料，施工完毕后工具和人手均可用自来水清洗干净。
Both DMT-W sealing and PD100 caulking are inorganic stuff, the tools and hands should be washed after end of the working.