电伴热施工技术方案（中英文版）
Technical Scheme for Construction of Electric Heat Trace Project
一、工程概况 ⅠProject Overview
本工程为船舶涂料公司5000万升/年船舶涂料机电安装工程，工程位于青岛高新技术产业新城区内新材料团地。
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.
工程环境为防爆区域，需严格按照设计、规范要求施工，本方案为施工技术、质量、安全做出指导。
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.
电伴热是利用伴热电缆输出的热量来补偿管道、容器、罐体等储运系统所耗散的热量，以维持系统操作介质始终处在工艺要求的适宜温区。所以，热工设计首先要确定工艺装置的热损失即散热量，然后根据散热量确定所需伴热电缆的功率和长度。本工程伴热电缆约为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、编制依据ⅡCompilation Basis
施工图纸及相关技术文件Construction drawings and relevant technological documents
GB50254-96《电气装置安装工程低压电器施工及验收规范》
GB50254-96 Code for Construction and Acceptance of Low-Voltage Apparatus Electric Equipment Installation Engineering
GB50258-96《电气装置安装工程 1kV 及以下配线工程施工及验收规范》
GB50258-96 Code for Construction and Acceptance of 1KV and Lower voltage Wiring Project Electric Equipment Installation Engineering
GB50150-91《电气装置安装工程电气设备交接试验标准》
GB50150-91 Acceptance Trial Norm for Electric Apparatus Installation Project Electrical Device
GB50168-92《电气装置安装工程电缆线路施工及验收规范》
GB50168-92 Code for Acceptance and Construction of Electric Apparatus Installation Engineering Cable Line
GB50171-92《电气装置安装工程盘柜及二次回路接线施工及验收规范》
GB50171-92 Code for Acceptance and Construction of Electric Apparatus Installation Engineering Cabinet Secondary Circuit
三、施工技术 Ⅲ Construction Technique
1、安装前的准备The preparations before installation
1) 安装前首先要查看设计图纸，确认发热电缆及配件配备齐全，并与设计相一致。
Before installation, you have to check the drawings to make sure that heating cable and accessories are complete and consistent with the design.
2) 安装管道系统并验收完毕。管道及阀门等附配件均已安装完毕，并且按相关安装规范试压验收完毕。
Install piping system and complete acceptance check. Pipes and accessories, such as valves, have already been installed and accepted through pressure test.
3) 管道外刷防锈层、防腐层完毕并彻底干透。检查管道外表面确认无毛刺、锐角，以免在安装时对电缆造成损坏。
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) 管道穿墙处预留好电缆穿墙套管，套管位置与数量根据该处穿越电缆位置数量确定。
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) 检查控制箱安装位置是否符合设计要求。与其它专业协调，确保安装过程中与其它专业无冲突。
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、进场材料检查与保管 The inspection and management of newly-arrived Materials
1) 检查收到的电缆型号和功率输出是否正确。所有电缆外套都标有部件号、电压等级和功率输出。
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) 视察货物在运输中是否有破损。
Check whether the goods are damaged in transit
3) 电伴热电缆和附件应储藏在干净和干燥的环境中。
Electric heating cable and accessories should be stored in clean and dry place.
3、电伴热电缆施工 The Construction of electric heating cable
1）单根电热带施工方法 The Method of Construction of Single Ribbon Heater
a.在电伴热电路的送电点开始安装，玻璃纤维压敏胶带或铝胶带每隔约300mm处绑扎一次。在阀门、 泵、过滤器等部位做可以使设备移动的安装。
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.所有散热体（如支架、阀门、法兰等）应按设计图要求预留所需电热带长度，将此段电热带缠绕于散热主体上并固定。
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.
下列各点应注意：The following points should be noticed
*散热体应有设计所需电热带的长度。The heating body should have a ribbon heater of the length required by the design.
*电热带可互相重叠或交叉。Ribbon heaters could overlap or intersect.
*缠绕方法应尽可能使散热体必要时随时可拆除进行维修 或更换而不损坏电热带或影响其它线路。
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处，电热带各端应预留40cm长度。
At the points using two-way or three-way accessory, 40cm should be reserved at the ends of ribbon heater.
2）螺旋缠绕 Spiral winding
如缠绕系数为1.4，即5m管道需要布7m的电热带，施工时先将7m长的电热带两端固定于一段长度为5m的管道上，然后将松驰的电热带缠绕在管道上，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、安装注意事项 Notes on installation
1) 电热带安装时，不要在地面上拖拉，以免被锋锐物损坏。不要与高温物体接触，防止电焊熔渣溅落到电热带上。
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) 电热带有良好的柔性，但不允许硬折，需要弯曲时，弯曲半径不得小于伴热电缆厚度的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) 电热带严禁用重物硬砸，如被砸 伴热电缆应重新进行电气测试，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) 电热带应与被伴热管道(或设备)贴紧并固定，以提高伴热效率。固定电伴热带时应用专用尼龙扎带，严禁用金属丝绑扎。
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）非金属管道应在管外壁与伴热电缆之间贴一层铝胶带，用来增大接触传热面积。
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) 电热带的安装要充分考虑管道附件(或设备)的拆卸可能性，且电伴热带又不需要被切断。电热带被剪断或接头时要注意接头的密封。
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) 每米管道热损失大于每米伴热电缆输出功率时，采用缠绕方式，以利维修时拆卸。
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）法兰处易产生泄漏，缠绕电伴热带时，应避开其正下方。
Leakage is common around flange. Therefore, ribbon heater shouldn’t be wound right under it.
9) 电热带在管道上的安装方法与固定，扎带材料应根据管道的温度选用。
The installation method and fixation of ribbon heater on pipe, and ribbon should be chosen according to the temperature of pipe.
10) 电热带安装完毕后，必须逐个回路进行电气测试合格后，再进行通电试验，检查电热带发热情况。确认正常后，才允许保温。
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) 保温材料应干燥。潮湿的保温材料不但影响伴热效果，还会导至对电热带的腐蚀，缩短使用寿命，未包外保护层的保温管道，被雨雪浇湿后，应风干后再施工外保护层。
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) 伴热系统施工完毕，应在管道的外保护层做出明显的电伴热标记，以提醒人们注意。
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) 电热带安装时，当电缆一端接入电源前应将母线另一端用配套的封头套封好，两条母线不得短路。
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) 多回路电热带从同一接线盒接出时，各母线都要有绝缘套隔离以防短路。
When multi-loop ribbon heaters extend from the same junction box, every bus bar needs an insulation bush to avoid short circuit.
15) 接线盒应密封，防止雨水进入。
The junction box should be sealed to keep it from rainwater.
5、伴热控制报警箱的安装 The Installation of Alarm Box of Heat Tracing Control
根据相关规范，结合工程实际情况，我公司摸索制定了电伴热控制报警箱定位原则：① 依据配电室所在位置；②不影响其它电气设备的安装；③安装的墙为实墙，陶粒或空心砖墙要加装支架；④高低位置原则以易观察、易维修为佳。 对于伴热控制报警箱要严格按设计要求安装，箱体安装高度、垂直误差等均应控制在规范允许的范围内。箱内配线应整齐美观、走向合理、绑扎成束并适当固定。导线与电器的连接头必须符合规范的规定即多股导线压接后应镀锡、单股导线按螺旋方向盘圈。采用螺栓顶按时应双线径插入，线端绝缘边裸露导体长度应不大于3 mm。25mm2及以上的截面的导线，不宜采用开口式接线端子。控制电器可动触点端必须是负荷端。各配电支路、控制回路应在专设的铭牌框内标注明确。
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、电伴热系统的现场测试与检查 The Spot Test and Inspection of Electric Heating System
1) 测试要求 Testing requirements
所有电缆和相关组件均应按下列要求进行测试。下面的"检查单"应填写。
All wires and relevant components should be tested according to the following requirements. The inspection list below should be completed.
a) 最初检查和绝缘抗阻测试报告, 表格 SH3503J543。
The report of initial inspection and insulation resistance test, form SH3503J543
b) 安装测试报告，表格 ITR-01.
The report of installation test, form ITR-01
2) 测试工具 Testing equipments
a) 摇表, 500V~1000V DC magneto-ohmmeter, 500V~1000V DC
b) 电压表 voltmeter
c) 便携电流表 portable ammeter
3) 测试 test
在进行测试前确认所有电路连接和接地都已正确完成。在测试后，确认所有接线盒、控制器等正确关闭，潮气不能进入。
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.
绝缘抗阻测试: 用一个500V或1000V的直流摇表,测量电缆导体与外金属套(金属屏蔽层)之间的绝缘电阻值,应得到最小 20MW 的数值。
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) 在电伴热安装后,保温层安装前,重复绝缘电阻测试.测试人员应完成安装测 试报告,表格 ITR-01 的记录,有任何问题应立即报告。
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) 电伴热带长度应记录在安装测试报告,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) 安装完成后(保温层已安装完毕),作为预运行检查的一部分，重复绝缘抗住测试。执行测试的人员应完成安装测试报告，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) 确认告示标签已每隔 3 米安装在气候防护层外。
Make sure that notice labels have been installed on the climate protection layer every 3m.
4) 运行步骤及系统操作 Operating procedure and system operation
在系统投入使用前，确认对每一个伴热回路已进行测试，报告已完成。
操作电伴热系统包括如下步骤
Before the system goes into service, make sure that every heating loop has been tested and respective report has been completed.
a)在通电前，确认所有的接线盒、温控器、电缆密封是正确安全的。
Before the current is switched on make sue all junction boxes, temperature controllers, and cables are sealed correctly and safely.
b)设置温控器的参数为设计值。参见温控器安装指导手册。温控器参数的设置值应在单管图或电伴热安装图上找到。
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) 接下来，给伴热回路送电，记录电流值。将记录与电伴热计算书进行比较。测试人员应完成安装测试报告,表格 ITR-01 的记录,有任何问题应立即报告。
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)建立以项目经理为主的安全生产保证体系，完善安全管理网络，强化全员HSE教育培训，增强员工HSE管理意识；开展危害控制和隐患治理，防止事故发生和环境污染；创造良好的工作生活环境，确保安全施工和员工健康。
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)进入现场工人施工时应正确、合理使用工具。安全帽、工作服、防护眼镜、安全鞋及必要的安全防护用品必须带齐配齐。
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)冬季雨雪天气不得运输设备、控制装置及开展现场施工作业。设备到货开箱后要集中放置设备库房,并做好防冻、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)现场材料堆放整齐，要做到工完料尽场地清。
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)当日工作当日清理，保证施工现场清洁。
The work of that day should be finished without delay, and ensure the cleanliness of construction site.
3)施工中所产生得废料集中堆放，不得随意乱丢。
The waster material produced during construction should be piled in the same location and couldn’t be thrown away freely.