TTK. Installation of metal air ducts for internal ventilation systems

Typical flow chart for installation and
mounting internal systems ventilation and
air conditioning with supply and exhaust
installations and equipment systems
refrigeration

Typical technological map
(TTK)

Project code: 1012/40

Explanatory note

2012 r.

1. GENERAL DATA

This technological map is designed for the installation and installation of internal ventilation and air conditioning systems with air handling units and equipment for refrigeration systems in industrial, administrative, public and residential buildings.

The technological map was drawn up taking into account the requirements of the following regulatory documents:

Air ducts made of thin sheet roofing steel with a diameter and size of the larger side up to 2000 mm, should be made:

Spiral-lock or longitudinal seam on rebates;

Spiral welded or longitudinal welded.

Air ducts made of thin sheet roofing steel with a side size of more than 2000 mm should be made panel (welded, glue-welded).

Air ducts from metal-plastic should be made on folds, and from of stainless steel, titanium, as well as from sheet aluminum and its alloys - on folds or on welding.

Air ducts made of sheet aluminum and its alloys with a thickness of up to 1.5 mm should be performed on folds, with a thickness of 1.5 to 2 mm - on folds or welding, and with a sheet thickness of more than 2 mm - on welding.

Longitudinal folds on air ducts made of thin-sheet roofing and stainless steel and sheet aluminum with a diameter or size of a larger side of 500 mm or more must be fixed at the beginning and end of the duct link spot welding, electric rivets, rivets or bulging.

Folds on air ducts with any metal thickness and manufacturing method must be cut-off.

The end sections of the seam seams at the ends of the air ducts and in the air distribution openings of the metal-plastic air ducts must be fixed with aluminum or steel rivets with an oxide coating, ensuring operation in aggressive environments specified in the working documentation.

Seam seams should have the same width along their entire length and be evenly and tightly upset.

In rebated air ducts, as well as in cutting plans, there should be no cross-shaped joints of seams.

On straight sections of rectangular air ducts with a side cross-section of more than 400 mm, it is necessary to constructively perform rigidity in the form of bends (ridge) with a step of 300 - 500 mm along the perimeter of the air duct or diagonal bends (ridge). If the side is more than 1000 mm and the length is more than 1000 mm, in addition, it is necessary to install external stiffening frames, with a step of no more than 1250 mm. Stiffening frames must be securely fixed by spot welding, rivets or self-tapping screws.

Stiffening frames should be installed on metal-plastic air ducts using aluminum or steel rivets with an oxide coating, ensuring operation in aggressive environments defined by the working documentation.

Elements of fittings should be connected to each other on zigzags, folds, welding, rivets.

Elements of fittings made of metal-plastic should be connected to each other on the folds.

Zig joints for systems transporting air of high humidity or with an admixture of explosive dust are not allowed.

The connection of the sections should be performed:

for round air ducts in a flangeless way (nipple / sleeve), shroud connection or on flanges;

for rectangular ducts: busbar (large / small) or on flanges. The connections must be strong and tight.

Fastening the tire to the air duct should be done with rivets with a diameter of 4 - 5 mm, self-tapping screws (in the absence of fibrous components in the moving medium), spot welding, bulging every 200 - 250 mm, but not less than four. The inner corners of the tire should be filled with sealant.

Fastening of flanges to air ducts should be carried out by flanging with a persistent ridge, by welding, spot welding, on rivets with a diameter of 4 - 5 mm or self-tapping screws (in the absence of fibrous components in the transported medium), placed every 200 - 250 mm, but not less than four.

Regulating devices (dampers, throttle valves, dampers, regulating elements of air distributors, etc.) must be easy to close and open, as well as be fixed in a given position.

Air ducts made of non-galvanized steel, their connecting fasteners (including inner surfaces flanges) must be primed (painted) at the procurement company in accordance with the working documentation. The final painting of the outer surface of the air ducts is carried out by specialized construction organizations after their installation.

Ventilation blanks must be completed with parts for their connection and fastening means.

2.2. Preparatory work

2.2.1. General Provisions

Rice. 1. Slings

a - lightweight sling with loops; b - lightweight sling with hooks;
в - four-branch sling

The load to be lifted should be kept from rotating by braces from hemp ropes with a diameter of 20 - 25 mm or braces from steel ropes with a diameter of 8 - 12 mm. For horizontal elements of ventilation systems (enlarged units of air ducts), two guys should be used, for vertical ones (sections of air conditioners, roof fans, air ducts, etc.) - one.

The most common slinging methods are shown in fig. -.

Rice. 2. Slinging VPA-40

Rice. 3. Slinging of an autonomous air conditioner KTR-1-2.0-0.46

Rice. 4. Slinging of radial (centrifugal) fans of version No. 1

Rice. 5. Slinging of fans Ts4-70 No. 6 - 8 version No. 1

Rice. 6. Slinging of fans Ts4-70 No. 6 - 8 version No. 6

Rice. 7. Slinging of fans Ts4-70 No. 10, 12.5

Rice. 8. Slinging the air duct

For the entire installation period, areas for storing air ducts must be equipped.

The device of an on-site air duct warehouse must meet the following basic requirements:

Be located near access roads or railways;

The boundaries of the warehouse must be at least 1 m from the road;

To be at the minimum distance from the installation object, if possible, in the area of the tower crane;

Do not interfere with the production of construction and installation works;

Air duct storage areas should be carefully planned with a slope of 1 - 2 ° to drain surface water, covered with drainage sand or gravel, and, if necessary, have ditches;

Passages, driveways and loading and unloading areas must be cleared of debris, construction waste (in winter - from snow and ice) and sprinkled with sand, slag or ash;

Storage of ventilation equipment must be organized in compliance with the requirements of work safety and fire protection;

At the corners of the open warehouse, protective posts should be installed, warning signs for drivers of vehicles and signs with the name of the installation department or the site and the location of the receiver of goods should be posted;

The warehouse needs to be lit.

Warehousing and storage of air ducts must be organized in accordance with applicable standards and in compliance with the following requirements:

Rectangular air ducts must be stacked; straight sections with a height of no more than 2.7, shaped parts - no more than 2 m;

Circular air ducts should be installed vertically;

Air ducts delivered in inventory containers should be stored in these containers at specially organized container yards. It is prohibited to store air ducts and other products in railway containers;

During storage, each air duct should be laid on wooden inventory pads;

Air ducts in stacks should be placed taking into account the sequence of installation: stacks and containers - provided with signs;

Passages with a width of at least 1 m must be left between the stacks; every three stacks, driveways for vehicles with a width of 3 m should be arranged.

The movement of air ducts along the floors of multi-storey buildings is carried out using lifting equipment or manual transport.

2.3. Works of the main period. Mounting

2.3.1. Installation of internal ventilation and air conditioning systems. General Provisions

Installation of internal ventilation and air conditioning systems should be carried out in accordance with the requirements of SP 73.13330.2012, SP 48.13330.2011, SNiP 12-03-2001, SNiP 12-04-2002, standards and instructions of equipment manufacturers, as well as in accordance with fire safety requirements of SP 7.13130.2009.

Installation must be carried out by industrial methods from air duct assemblies and equipment supplied as a complete set of large blocks.

Installation of systems should be carried out when the facility is ready for construction (seizure) in the amount of:

For industrial buildings- the entire building with a volume of up to 5000 m 3 and a part of the building with a volume of over 5000 m 3;

For residential and public buildings up to five floors - a separate building, one or more sections; over five floors - five floors of one or more sections.

Another scheme of installation organization is possible, depending on the adopted constructive scheme.

2.3.2. Installation of air ducts

The method of installation of air ducts should be selected depending on their position (horizontal, vertical), location relative to structures (near the wall, near columns, in the interfarm space, in the shaft, on the roof of the building) and the nature of the building (one- or multi-storey, industrial, public and etc.).

As fittings complex geometric shape, as well as for connection of ventilation equipment, air distributors, silencers and other devices located in false ceilings, chambers, etc., flexible air ducts made of fiberglass SPL, metal fabric, aluminum foil etc. The use of flexible air ducts as straight links is not allowed.

In order to reduce aerodynamic drag, parts from flexible sleeves in the mounted position must have a minimum compression ratio.

Installation of metal air ducts should be carried out, as a rule, in enlarged blocks in the following sequence:

Marking of installation sites for fastening means for air ducts;

Installation of fastening means;

Coordination with the builders of the locations and methods of fastening the lifting equipment;

Delivery of air duct parts to the installation site;

Checking the completeness and quality of the delivered air duct parts;

Assembly of air duct parts into enlarged blocks;

Installation of the unit in the design position and fixing it;

Installation of plugs on the upper ends of vertical air ducts located at a height of up to 1.5 m from the floor.

The length of the block is determined by the dimensions of the section and the type of connection of the air ducts, the conditions of installation and the availability of lifting equipment.

The length of enlarged horizontal air duct units connected on flanges should not exceed 20 m.

Organization diagrams working area when installing air ducts are given in Fig. -.

Rice. 9. Diagram of the organization of the working area during the installation of air ducts
on outside wall building

1 - console with block; 2 - winch; 3 - auto-hydraulic elevator;
4 - traverse; 5 - guy line; 6 - block

Rice. 10. Diagram of the organization of the working area during the installation of horizontal
air ducts in the building

1 - winch; 2 - traverse; 3 - enlarged unit of the air duct; 4 - pendants

2.3.3. Fan installation

The fans must be installed in the following sequence:

Acceptance of ventilation chambers premises;

Delivery of the fan or its individual parts to the installation site;

Installation of lifting equipment;

Slinging the fan or individual parts;

Lifting and horizontal movement of the fan to the installation site;

Fan installation (fan assembly) on supporting structures (foundation, platform, brackets);

Checking the correct installation and assembly of the fan

Fastening the fan to supporting structures;

Checking the fan operation.

During the installation of fans, a step-by-step operational control should be carried out in accordance with the operational control cards.

2.3.4. Installation of equipment for refrigeration systems

When setting up ventilation and air conditioning systems for the design air flow, you should perform:

Check the compliance of the actual design of ventilation and air conditioning systems with the design documentation and requirements SP 73.13330.2012 ;

Testing of fans during their operation in the network, checking the compliance of the actual technical characteristics with the passport data, including: air flow and total pressure, rotation speed, power consumption, etc.;

Checking the uniformity of heating (cooling) of heat exchangers and checking the absence of moisture carryover through the drip catchers of the irrigation chambers or air coolers;

Determination of the flow rate and resistance of dust collecting devices;

Checking the operation of natural ventilation exhaust devices;

Testing and adjusting the ventilation network of systems in order to achieve design indicators for air consumption in air ducts, local suction, for air exchange in rooms and determination of air leaks or losses in systems.

Deviations of air flow rates from those provided for in the design documentation after adjustment and testing of ventilation and air conditioning systems are allowed:

Within ± 8% - in terms of the air flow passing through the air distribution and air intake devices of general ventilation and air conditioning installations, provided that the required backpressure (vacuum) of air in the room is ensured;

Up to +8% - according to the air flow rate removed through local suction and supplied through the spray nozzles.

For each ventilation and air conditioning system, a passport is issued in two copies (Appendix G, SP 73.13330.2012).

2.4.2. Refrigeration testing

Testing of water cooling systems should be carried out with the heat generators and expansion vessels turned off by the hydrostatic method with a pressure equal to 1.5 working pressure, but not less than 0.2 MPa (2 kgf / cm 2) at the lowest point of the system.

The system is recognized as having passed the test if, within 5 minutes of keeping it under test pressure:

The pressure drop will not exceed 0.02 MPa (0.2 kgf / cm 2);

There are no leaks in welds, pipes, threaded connections, fittings and equipment.

3. REQUIREMENTS FOR QUALITY AND ACCEPTANCE OF WORKS

Quality control of work on the installation of ventilation and air conditioning systems should be carried out by specialists or special services that are part of the construction organization or attracted from outside, equipped with technical means providing the necessary reliability and completeness of control.

Quality control of work is carried out at all stages of the technological chain, starting from the development of the project and ending with its implementation at the facility on the basis of PPR and flow charts. Quality control should include incoming control of working documentation, structures, products, materials and equipment, operational control of individual assembly processes or production operations and assessment of the conformity of the work performed.

At input control working documentation is checked for completeness and sufficiency of the technical information contained in it for the production of work.

During the incoming inspection of products, materials and equipment, it is checked by external examination that they comply with the requirements of standards or other regulatory documents and working documentation, as well as the presence and content of passports, certificates and other accompanying documents.

3.1. Requirements for the quality of work on the installation of air ducts

Air ducts should be installed in accordance with design references and elevations. The connection of the air ducts to the technological equipment must be carried out after its installation.

Air ducts intended for transporting humidified air should be installed so that there are no longitudinal seams in the lower part of the air ducts.

Areas of air ducts where dew may fall from the transported humid air, should be laid with a slope of 0.01 - 0.015 towards the drainage devices.

The spacers between busbars or duct flanges must not protrude into the ductwork.

Gaskets should be made of the following materials: foam rubber, tape porous or monolithic rubber with a thickness of 4 - 5 mm, polymer mastic bundle (PMZh) - for air ducts through which air, dust or waste materials move with temperatures up to 343 K (70 ° C) ...

To seal flangeless air duct connections, use:

Sealing tape of the "Guerlain" type - for air ducts through which air moves with a temperature of up to 313 K (40 ° C);

Mastic such as "Buteprol", Silicone and other certified sealants - for circular air ducts with temperatures up to 343 K (70 ° C);

Heat-shrinkable cuffs, self-adhesive tapes - for circular air ducts with temperatures up to 333 K (60 ° C);

Other sealing materials specified in the working documentation.

The bolts in the flange connections must be tightened with all the bolt nuts on the same side of the flange. When installing bolts vertically, the nuts should generally be on the underside of the joint.

Fastening of air ducts should be carried out in accordance with the working documentation.

Fasteners of horizontal metal non-insulated air ducts (clamps, hangers, supports, etc.) on a bandage flangeless connection should be installed:

At a distance of no more than 4 m from one another with circular duct diameters or dimensions of the larger side of a rectangular duct less than 400 mm.

At a distance of no more than 3 m from one another - with diameters of a circular duct or dimensions of the larger side of a rectangular duct of 400 mm or more.

Fasteners of horizontal metal non-insulated air ducts on a flange, nipple (sleeve) connection should be installed at a distance of no more than 6 m from one another:

For circular cross-sections up to 2000 mm diameter,

For rectangular section on flanges, bus on flange connection of circular section with a diameter of up to 2000 mm or rectangular section with dimensions of its larger side up to 2000 mm inclusive.

The distances between the fasteners of insulated metal air ducts of any cross-sectional size, as well as non-insulated air ducts with a circular cross-section with a diameter of more than 2000 mm or a rectangular cross-section with a larger side of more than 2000 mm, should be assigned by working documentation.

The fastening of the nipple (coupling) should be carried out with rivets with a diameter of 4 - 5 mm or self-tapping screws with a diameter of 4 - 5 mm every 150 - 200 mm of a circle, but not less than three.

The clamps should fit tightly around the metal air ducts.

Mounts for vertical metal ducts should be installed at a distance of no more than 4.5 m from one another.

Fastening of vertical metal air ducts inside the premises of multi-storey buildings with a floor height of up to 4.5 m should be carried out in the interfloor ceilings.

Fastening of vertical metal air ducts indoors with a floor height of more than 4.5 m and on the roof of the building should be determined by the working documentation.

Fastening of guy wires and hangers directly to the duct flanges is not allowed. The tension of the adjustable hangers must be uniform.

The deviation of the ducts from the vertical should not exceed 2 mm per 1 m of the duct length.

Freely suspended air ducts should be braced by installing double hangers every two single hangers with a suspension length of 0.5 to 1.5 m.

For hangers longer than 1.5 m, double hangers should be installed through each single hanger.

Air ducts should be reinforced so that their weight is not transferred to the ventilation equipment.

Air ducts should generally be connected to fans through vibration-damping flexible inserts made of fiberglass or other material that provides flexibility, density and durability.

Anti-vibration flexible inserts should be installed immediately prior to individual testing.

When making straight sections of air ducts from a polymer film, bends of the air ducts are allowed no more than 15 °.

To pass through the enclosing structures, the air duct made of plastic film must have metal inserts.

Air ducts made of plastic film should be suspended on steel rings made of wire with a diameter of 3 - 4 mm, located at a distance of no more than 2 m from one another.

The diameter of the rings should be 10% larger than the diameter of the duct. Steel rings should be fastened with a wire or plate with a cutout to a supporting cable (wire) with a diameter of 4 - 5 mm, stretched along the axis of the duct and fixed to the building structures every 20 - 30 m.

To exclude longitudinal movements of the duct when it is filled with air polymer film should be pulled until the slack between the rings disappears.

Table 1. Map operational control installation of metal air ducts

Technological process	Controlled indicators	Measuring tool	Control type
Delivery of air duct parts to the installation site	Checking the completeness of the ventilation system (availability of control devices, fasteners, etc.)		Permanent 100%. Visually. Compliance with the picking list, sketches
Marking of installation sites for fixing air ducts	Installation step of fasteners in accordance with SNiP 3.05.01-85	Roulette I= 10 m Cord Plumb line M = 200 g	Permanent 100%
Drilling holes in building structures	Drilling depth	Steel meter	Permanent 100%
Installation of fasteners	Fastening strength		Permanent 100%. Visually
Assembly into enlarged units of parts of air ducts, regulating and air distribution devices at the site	Correctness of assembly in accordance with the project. Tightness of connections		Visually. Permanent 100%
Ascent to the design level and interconnection of enlarged units of air ducts with preliminary fastening	The position of transverse seams and detachable duct connections relative to building structures. Verticality of risers. Absence of kinks, curvature in straight sections of air ducts	Plumb line M= 200 g	Visually Permanent 100%
Alignment of the mounted air ducts and their final fixing	The horizontal installation of the air ducts and the observance of the slopes in the distribution sections of the air ducts. Density of coverage of the duct with clamps. Reliability and appearance of fasteners	Metal meter, tape measureI= 10 m, level I= 300 mm	Permanent 100%. Visually
Connection of air ducts to ventilation equipment	Correct installation of soft inserts (no slack)		Permanent 100%. Visually
Testing the operation of regulating devices	Smooth operation of regulating devices		Output 100%. Visually

3.2. Requirements for the quality of work on the installation of fans

Radial fans on vibration bases and on a rigid base, installed on foundations, must be fixed with anchor bolts.

When installing fans on spring vibration isolators, the latter must have a uniform settlement. Vibration isolators do not need to be fastened to the floor.

When installing fans on metal structures, vibration isolators should be attached to them. Elements of metal structures to which vibration isolators are attached must match the corresponding elements of the fan unit frame.

When installed on a rigid base, the fan frame must fit snugly against the sound insulating pads.

The gaps between the edge of the front disc of the impeller and the edge of the inlet pipe of the radial fan, both in the axial and in the radial direction, should not exceed 1% of the impeller diameter.

Radial fan shafts must be installed horizontally (shafts roof fans- vertically), vertical walls of casings centrifugal fans should not be skewed or tilted.

The gaskets for the split fan shrouds should be of the same material as the gaskets for the ductwork of this system.

The motors must be precisely aligned with the installed fans and secured. The axes of the pulleys of electric motors and fans with a belt drive must be parallel, and the center lines of the pulleys must coincide. The belts must be tensioned according to the manufacturer's requirements.

The motor skids must be mutually parallel and level. The support surface of the slide must be in contact over the entire plane with the foundation.

Couplings and belt drives should be protected.

The fan suction opening not connected to the duct must be protected metal mesh with a cell size of not more than 70 × 70 mm.

Table 2. Map of operational control of installation of centrifugal fans

Technological process	Controlled indicators	Measuring tool	Control type
Supply of the fan unit to the installation site	Checking the availability and quality of component parts		Permanent 100%.
Installation of the frame on the stands. Installation of vibration isolators under the frame	The horizontality of the foundation, frame	Level I= 300 mm	Permanent 100%
Installation of fans on a frame with vibration isolators	Pulley vertical, shaft horizontal	Plumb line M= 200 g	Permanent 100%
Assembly of fans on the frame: installation of the fan frame; installation of the lower part of the fan casing; installation of the turbine with fastening of its frame to the frame; installation of the inlet pipe	Fastening strength. Clearance between the edge of the front disc of the impeller and the edge of the inlet. Fastening strength	Ruler	Visually. Permanent 100%
Installation of the upper part of the casing and connection on the flanges of individual parts of the fan casing	Tightness of the connection		Visually. Permanent 100%
Adjustment and final fastening of vibration isolators to the frame	Uniform settlement of vibration isolators. The strength of fastening vibration isolators to the frame		Visually. Permanent 100%
Balancing the turbine before starting	Correct position of the turbine wheel		Permanent 100%. Visually, testing by hand (when scrolling, the risks should not coincide)
Installing the skid and the electric motor on the skid	Parallelism of the sled. The strength of the fastening of the electric motor to the slide. The strength of the connection between the electric motor and the fan. Parallelism of the axes of the fan and motor shafts. Ease of rotation of the shafts of the fan and electric motor	Level I= 300 mm	Permanent 100%. Visually
Installing the skid and the electric motor on the skid		Cord
Installing a belt drive on pulleys. Belt drive guard	Coaxiality of grooves for V-belts of fan and motor pulleys. Correct belt tension	Cord (tension of the cord in the plane of the ends of the pulleys), steel meter, testing by hand	Permanent 100%
Connecting air ducts to the fan with the installation of flexible connectors	Tightness of connections. No slack in flexible joints		Visually. Permanent 100%

Table 3. Map of operational control of installation axial fans

Technological process	Controlled indicators	Measuring tool	Control type
	Quality (no mechanical damage), completeness		Permanent 100%. Visually, compliance with the passport data of the fan and electric motor
Installation of the fan unit on metal brackets. Fan mount	The strength of the supporting structures. Fastening strength of the fan to the supporting structures. Verticality, horizontal	Plumb line M= 200 g	Visually. Permanent 100%
Checking fan operation	The gap between the ends of the blades and the shells. Correct direction and ease of rotation of the impeller	Ruler	Permanent 100%. Visual, freehand testing

Table 4. Map of operational control of installation of roof fans

Technological process	Controlled indicators	Measuring tool	Control type
Supply of a fan complete with an electric motor to the installation site	Completeness, quality (no mechanical damage)		Permanent 100%. Visually, compliance with the passport data of the fan and electric motor
Checking the horizontal position of the cup support flange	Horizontality	Level I= 300 mm	Permanent 100%
Connecting the self-opening valve to the fan	Ease of valve movement		Permanent 100%. Visual, freehand testing
Installation of the fan casing on the glass with its fastening with anchor bolts	Fastening strength of the fan to the supporting structures. The verticality of the shaft. Ease of rotation of the shafts of the fan and electric motor. Clearance between inlet and impeller	Plumb line M= 200 g	Permanent 100%. Visual Freehand Testing
		Ruler	Permanent 100%
Checking fan operation	Correct direction of rotation of the wheel		Permanent 100%. Visually (in accordance with the project)

3.3. Requirements for the quality of work on the installation of air conditioners

Air heaters of air conditioners should be assembled on gaskets made of certified material, with a heat resistance corresponding to the temperature of the heating medium. The rest of the blocks, chambers and units of air conditioners should be assembled on gaskets made of tape rubber 3-4 mm thick, supplied with the equipment.

Air conditioners must be installed horizontally. The walls of chambers and blocks should not have dents, distortions and slopes.

The valve blades should turn freely (by hand). In the "Closed" position, a tight fit of the blades to the stops and to each other must be ensured.

Supports of chambers and air conditioner units must be installed vertically.

Flexible air ducts should be used in accordance with the working documentation as fittings of complex geometric shapes, as well as for connecting ventilation equipment, air diffusers, silencers and other devices located in suspended ceilings and chambers.

The use of flexible air ducts as main air ducts is not allowed.

Fastening of fan coil units, door closers, split systems should be carried out in accordance with the recommendations of the manufacturers.

4. REQUIREMENTS FOR SAFETY AND LABOR PROTECTION, ENVIRONMENTAL AND FIRE SAFETY

Mounting ventilation ducts must be carried out in accordance with the requirements of safety, sanitation and occupational health, established by building codes and rules for occupational safety in construction.

Before being admitted to work on the installation of ventilation ducts, the heads of organizations are required to provide training and briefing on occupational safety at the workplace.

Persons at least 18 years of age who have undergone a medical examination without contraindications to work at height, have professional skills, have been trained in safe methods and techniques of work and have received an appropriate certificate are allowed to work at heights.

Individuals (workers and engineers and technicians) at least 18 years of age who have passed a medical examination and recognized as fit for performance of climbing work, having experience of climbing work for at least one year and tariff category not lower than the third.

Workers admitted to climbing work for the first time must work for one year under the direct supervision of experienced workers appointed by order of the organization.

Electric welding works are allowed to persons who have undergone appropriate training, instruction and testing of knowledge of the rules of safe work with registration in a special magazine and having a qualification certificate. Persons with medical contraindications are not allowed to work on electric welding at a height.

Persons at least 18 years of age who have passed a medical examination, trained in the rules of using the tool, labor safety and have an electrical safety group of at least II, and for connecting and disconnecting electric outlets with a group of at least III are allowed to work with an electrified tool. All electrified tools are subject to registration and registration in a special journal. Each copy of the instrument must have a reference number. Monitoring the serviceability and timely repair of electrified tools is assigned to the department of the chief mechanic of the construction organization. Before issuing an electrified tool, it is necessary to check its serviceability (no short circuit to the body, insulation at the supply wires and handles, the condition of the working part of the tool) and its operation at idle speed.

Responsibility for the correct organization of the safe conduct of work at the facility rests with the contractor and the foreman.

The admission of unauthorized persons, as well as drunken workers to the territory of the construction site, to production, sanitary premises and workplaces is prohibited.

Work on the installation of ventilation and air conditioning systems, as well as equipment for refrigeration systems are carried out according to the permit for work in conditions of hazardous and (or) harmful production factors.

Installation should be carried out only if there is a work production project, flow charts or wiring diagrams... In the absence of these documents installation work lead is prohibited.

The procedure for performing the installation, determined by the project for the production of work, must be such that the previous operation completely excludes the possibility of industrial hazards when performing subsequent ones. Installation of air ducts and equipment parts for ventilation, air conditioning and refrigeration systems should, as a rule, be carried out in large blocks using lifting mechanisms.

No people should be under the elements to be installed. Do not secure the suspended duct or duct unit to trusses, ceilings, etc. building construction in places not provided for by the work production project.

Installation of air ducts from scaffolds, scaffolds and platforms must be carried out by at least two workers.

Alignment of flange holes when connecting air ducts should be done only with mandrels. Do not use your fingers to check the alignment of the holes of the flanges to be connected.

To prevent swaying or twisting of the lifted air duct blocks, hemp rope braces should be used.

Installation work on ventilation ducts may only be carried out with serviceable tools. Wrenches must exactly match the sizes of nuts and bolts, have no bevels on the edges and burrs on the handle. Do not unscrew or tighten the nuts with a wrench of large (compared to the head) size with a lining of metal plates between the edges of the nut and the wrench, as well as lengthen spanners by attaching another key or pipe.

Workplaces and work areas during installation in the dark should be illuminated. Illumination should be uniform, without the glare of lighting fixtures on workers. Work in unlit areas is not allowed.

Before starting work on the installation of internal systems, places that are dangerous for work and the passage of people should be fenced, provided with inscriptions and signs, safety signs should be installed, and when working at night, marked with light signals.

When installing the air ducts, it is necessary to provide for the installation of fasteners, for which the air duct installer can fix himself when working at height.

Operation of construction machines (lifting mechanisms, small-scale mechanization equipment), including Maintenance, should be carried out in accordance with the requirements of SNiP 12-03-2001 and the instructions of the manufacturers. The operation of lifting mechanisms, in addition, must be carried out taking into account PB 10-382-00 "Rules for the device and safe operation hoisting cranes ".

The places where electric welding works are performed with an open arc should be fenced with fireproof screens, shields, etc.

When electric welding works are performed in the open air, sheds made of non-combustible materials should be erected over the installations and welding stations. In the absence of sheds, electric welding work should be stopped during rain or snowfall.

To protect against drops of molten metal and slag falling during electric welding, a dense platform covered with sheets of roofing iron or asbestos cardboard must be installed under the welding place in places where people pass.

When installing ventilation ducts on roofs with a slope of more than 20 °, as well as regardless of the slope on wet and frosty or snow-covered roofs, workers must use safety belts, as well as ladders with a width of at least 0.3 m with transverse strips to support the legs; the ladders must be secured during operation.

Loading and unloading operations should be carried out in accordance with GOST 12.3.002-75 *, GOST 12.3.009-76 *.

Loading and unloading operations must be carried out in a mechanized way using lifting and transporting equipment and small-scale mechanization. It is necessary to lift loads manually in exceptional cases, observing the norms established by the current documents.

When loading and unloading ventilation air duct blanks and their parts, containers should be used. During lifting, lowering and moving of the container, workers should not be on it or inside it, as well as on adjacent containers.

Slinging and unfastening of goods should be carried out in accordance with PB 10-382-00.

The supply of materials, ventilation blanks, equipment to workplaces should be carried out in a technological sequence that ensures the safety of work. Workpieces and equipment should be stored at workplaces in such a way that they do not create a hazard during the work, the passages are not constrained, and it would be possible to assemble the air ducts into enlarged blocks. You need to follow correct placement equipment and workpieces on the floors, avoiding concentration and not exceeding the permissible loads per 1 m 2 of the floor.

Ventilation blanks should be stored in stacks no more than 2.5 m high on spacers and pads. Oversized and heavy equipment should be stored in one row on pads.

Storage area for billets and ventilation equipment on construction site must be fenced and located in the area of an operating crane. The storage area should be planned, have slopes for water drainage, and in winter time it should be cleared of snow and ice.

Explosive or harmful paints and varnishes and other materials are allowed to be stored at workplaces in quantities not exceeding the replacement requirement. Such materials must be stored in tightly closed containers.

Between the stacks (racks) on sites and in warehouses, there should be at least 1 m wide passages and passages, the width of which depends on the dimensions of transport and handling facilities serving the warehouse or site.

The heads of the installation organizations are obliged to provide workers, engineering and technical workers and employees with overalls, footwear and other personal protective equipment in accordance with regulatory requirements.

All persons on the construction site are required to wear safety helmets. Workers and engineers without protective helmets and other necessary personal protective equipment are not allowed to perform work on the installation of air ducts.

When working at heights, ventilation installers must always wear safety belts.

Workers and employees receiving personal protective equipment (respirators, gas masks, safety belts, helmets, etc.) must be trained in how to use them.

All work on the installation of ventilation ducts should be carried out in the presence and under the guidance of responsible engineers in accordance with the rules for the production and acceptance of work in accordance with SP 73.13330. 2012 with strict adherence to labor safety requirements in accordance with:

P / p No.	Name of machines, mechanisms, machine tools, tools and materials	Brand	Unit rev.	Quantity
	Paint spray gun with a productivity of 600 m 3 / h	SO-72	PCS.
	Compressor with a capacity of 20 - 30 m 3 / h	SO-7A
	Open end wrenches, double-sided		kit
	Flat square, triangular, round, semicircular files with notches No. 1, 2, 3
	Steel bench hammer		PCS.
	Chisel
	Fitting screwdriver (set)		kit
	Combination pliers 3 E 1
	Welder's shield
	Mounting and traction mechanism	MTM-1.6
	Rack jack	DR-3.2
	Drilling machine	IE-1035
	Grinder electric	Sh-178-1
	Electric wrench	IE-3115B
	Electric screwdriver	IE-3602-A
	Electric puncher	IE-4712
	Electric scissors	IE-5502
	Assembly device for moving loads	PMPG-1
	Manual winch	STD 999/1
	Hydraulic jack	DGS-6.3
	Blind riveting gun	STD 96/1
	Safety steeplejack device	PVU-2
4 digits
Ventilation systems installer:
4 digits
3 ranks
2 discharges

As an example of the installation of ventilation ducts, we will take the installation of vertical air duct risers measuring 800 × 800 mm with an area of 100 m 2 using a hand winch.

Labor and machine time costs for the installation of ventilation ducts are calculated according to the "Uniform norms and prices for construction, installation and repair and construction work" (presented in table 7)

Measurement unit 100 m 2 ventilation ducts.

Table 14 - Calculation of labor costs and machine time

P / p No.	Justification (ENiR and other norms)	Name of technological processes	Unit rev.	Scope of work	Time rate		Labor costs
P / p No.	Justification (ENiR and other norms)	Name of technological processes	Unit rev.	Scope of work	workers, man-hours		workers, man-hours	driver, man-h. (machine operation, machine-hour)
	E9-1-46 No. 1a	Drilling holes with an electric drilling machine in building structures	100 holes
	E1-2 Tab. 3 No. 1ab	Delivery of air duct parts to the installation site	100 t	0,0083		1,8 (1,8)	0,034	0,034 (0,034)
	E10-5 Tab. 12 No. 4c	Assembly of air ducts into enlarged blocks, installation of fastening means, lifting and installation of blocks, connection installed unit with previously mounted, alignment and final fixing of the system	1 m 2		0,62		62,0
	E10-13 Tab. 2d Will apply.	Installation of plugs on the upper ends of vertical air ducts	PCS.		0,59		0,59
		TOTAL:					64,8	0,034 (0,034)

The duration of work on the installation of ventilation ducts is determined by the work schedule presented in the table.

Technical and economic indicators are.

Ministry of Education and Science of the Russian Federation

State educational institution

higher professional education

Samara State Architectural

university of construction

Department of Heat and Gas Supply and Ventilation

Technological maps of installation of ventilation and air conditioning systems

Methodical instructions

to course and diploma design

Approved by the Editorial and Publishing

university council

Samara 2011

UDC 697.912 (035.5)

Compiled by: Yu.I. Kasyanov, G.I. Titov, E.B. Filatova

Technological maps for the installation of ventilation and air conditioning systems: methodological instructions for course and diploma design. - Samarsk. state architect-builds un-t. - Samara, 2011 .-- 61 p.

These guidelines are for 5th-year and 6th-year students. distance learning directions "Heating, ventilation and air conditioning" specialty 27.01.09-65 "Heat and gas supply and ventilation" for the implementation of the course project on the discipline "Organization of construction production" and the same section of the diploma project.

Methodological guidelines have been developed in accordance with the educational and methodological complex of a higher school and include general rules for conducting installation work, the composition and procedure for developing technological maps, as well as standard technological maps for the main processes of installing ventilation and air conditioning systems.

These guidelines cannot be completely

or partially reproduced, duplicated (including photocopied)

and distributed without permission

Samara State University of Architecture and Civil Engineering.

Editor

Technical editor

Corrector

Signed to print

Format 6084. Offset paper. Operational printing.

Uch.-ed. l. CONV. print l. Circulation 100 copies. Order no.

Samara State University of Architecture and Civil Engineering.

443001 Samara, st. Molodogvardeyskaya, 194.

Printed in a typography

architectural and construction

university, 2011

Rules for conducting assembly and assembly work at the facility

The assembly production process can be divided into the following main stages:

development of installation drawings, work production projects, flow charts;

preparation of production in the assembly organization;

execution of assembly units and parts at the procurement enterprise and the acquisition of the necessary materials and equipment;

preparation of the construction object for the smooth and fast execution of installation work;

installation and assembly works at the facilities;

testing, adjustment and commissioning of mounted systems and devices.

Execution of works in such a sequence ensures the rhythm and economic efficiency of the assembly production. Preparation of production in the installation organization and preparation of the object itself for installation can and should be carried out in parallel and at the same time.

At present, the installation of systems at sites is carried out mainly from enlarged units coming from procurement enterprises. However, if the blanks are delivered to the objects in the form of separate elements, then the installation should begin with the assembly of these elements into enlarged units and blocks at the object itself. Modern equipment of installation organizations with truck cranes, hydraulic lifts, various drive and manual winches allows you to operate large assemblies.

Thus, there are four basic rules for organizing the installation of internal sanitary systems.

First rule - installation is carried out in three steps: pre-assembly, installation in the design position and connection of assembly joints, not counting the installation of fasteners by a specialized team.

Second rule - the order of performance of work must be carried out in a firm sequence, due to considerations of construction technology.

Third rule - installation of pipelines, air ducts and equipment should be carried out on pre-installed fastening means. Advance installation of brackets, hangers, clamps, etc. ensures that the slopes of the system elements provided for by the project are observed either strictly horizontally or vertically.

Fourth rule - maximum mechanization of all types of work. This leads to a reduction in the timing of assembly and assembly work and a decrease in their labor intensity.

Most of the assembly operations are done manually, so Special attention should be directed to the mechanization of auxiliary work. This group of works includes the delivery of blanks and equipment to the interior of the facility or to the sites to the places of their final placement. In this case, the production process of installation can be accelerated by the maximum combination of transport operations with the installation of equipment (especially heavy) in the design position, i.e. with rigging works. At the same time, it is necessary to strive for a comprehensive mechanization of operations using several sequentially working mechanisms (for example, vertical lifting - a truck crane, horizontal movement - trolleys or rollers in combination with winches, straightening - hoists or jacks).

To reduce labor costs for assembly work, small-scale mechanization tools should be widely used: electric nutrunners, drilling machines, etc. These tools and devices are included in kits for assembly teams.

In addition, it should be emphasized that when organizing and installing various systems, including ventilation and air conditioning systems, the safe performance of work must be ensured... This implies the device of good lighting of workplaces, the presence of fences, if the installation is carried out at a height, the use of serviceable tools, mechanisms, construction machines, which must correspond to the nature of the performed construction process, as well as the use of individual means of ensuring labor safety.

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Typical flow chart for installation and
installation of internal ventilation systems and
air conditioning with supply and exhaust
installations and equipment systems
refrigeration

Typical technological map
(TTK)

Project code: 1012/40

Explanatory note

2012 r.

1. General data. 2

2. Organization and technology of the construction process. 2

2.1. Materials and manufacture of air ducts. 2

2.2. Preparatory work .. 4

2.2.1. General Provisions. 4

2.2.2. Delivery, warehousing and storage of elements of ventilation and air conditioning systems. 4

2.3. Works of the main period. Installation .. 8

2.3.1. Installation of internal ventilation and air conditioning systems. General Provisions. eight

2.3.2. Installation of air ducts. nine

2.3.3. Installation of fans. ten

2.3.4. Installation of equipment for refrigeration systems. eleven

2.4. Testing and commissioning ... 11

2.4.1. Testing and commissioning of internal ventilation and air conditioning systems. eleven

2.4.2. Testing of refrigeration systems. 12

3. Requirements for the quality and acceptance of works. 12

3.1. Requirements for the quality of work on the installation of air ducts. 13

3.2. Requirements for the quality of work on the installation of fans. 16

3.3. Requirements for the quality of work on the installation of air conditioners. eighteen

4. Safety requirements and labor protection, environmental and fire safety. eighteen

5. The need for material and technical resources. 22

6. Technical and economic indicators. 23

1. GENERAL DATA

The technological map was drawn up taking into account the requirements of the following regulatory documents:

Air ducts made of thin sheet roofing steel with a diameter and size of the larger side up to 2000 mm, should be made:

Spiral-lock or longitudinal seam on rebates;

Spiral welded or longitudinal welded.

Air ducts made of thin sheet roofing steel with a side size of more than 2000 mm should be made panel (welded, glue-welded).

Metal-plastic air ducts should be made on folds, and from stainless steel, titanium, as well as from sheet aluminum and its alloys - on folds or welded.

Longitudinal folds on air ducts made of thin sheet roofing and stainless steel and sheet aluminum with a diameter or size of the larger side of 500 mm or more must be fixed at the beginning and end of the duct link by spot welding, electric rivets, rivets or bulging.

Folds on air ducts with any metal thickness and manufacturing method must be cut-off.

Seam seams should have the same width along their entire length and be evenly and tightly upset.

In rebated air ducts, as well as in cutting plans, there should be no cross-shaped joints of seams.

Elements of fittings should be connected to each other on zigzags, folds, welding, rivets.

Elements of fittings made of metal-plastic should be connected to each other on the folds.

Zig joints for systems transporting air of high humidity or with an admixture of explosive dust are not allowed.

The connection of the sections should be performed:

for round air ducts in a flangeless way (nipple / sleeve), shroud connection or on flanges;

for rectangular ducts: busbar (large / small) or on flanges. The connections must be strong and tight.

Regulating devices (dampers, throttle valves, dampers, regulating elements of air distributors, etc.) must be easy to close and open, as well as be fixed in a given position.

Air ducts made of non-galvanized steel, their connecting fasteners (including the inner surfaces of the flanges) must be primed (painted) at the procurement company in accordance with the working documentation. The final painting of the outer surface of the air ducts is carried out by specialized construction organizations after their installation.

Ventilation blanks must be completed with parts for their connection and fastening means.

2.2. Preparatory work

2.2.1. General Provisions

Installation must be carried out by industrial methods from air duct assemblies and equipment supplied as a complete set of large blocks.

Installation of systems should be carried out when the facility is ready for construction (seizure) in the amount of:

For industrial buildings - the entire building with a volume of up to 5000 m 3 and a part of the building with a volume of more than 5000 m 3;

For residential and public buildings up to five floors - a separate building, one or more sections; over five floors - five floors of one or more sections.

Another scheme of installation organization is possible, depending on the adopted constructive scheme.

2.3.2. Installation of air ducts

Flexible air ducts made of fiberglass SPL, metal fabric, aluminum foil, etc., should be used as fittings of complex geometric shapes, as well as for connecting ventilation equipment, air distributors, silencers and other devices located in false ceilings, chambers, etc. flexible ducts are not allowed as straight links.

In order to reduce aerodynamic drag, parts from flexible sleeves in the mounted position must have a minimum compression ratio.

Installation of metal air ducts should be carried out, as a rule, in enlarged blocks in the following sequence:

Marking of installation sites for fastening means for air ducts;

Installation of fastening means;

Coordination with the builders of the locations and methods of fastening the lifting equipment;

Delivery of air duct parts to the installation site;

Checking the completeness and quality of the delivered air duct parts;

Assembly of air duct parts into enlarged blocks;

Installation of the unit in the design position and fixing it;

Installation of plugs on the upper ends of vertical air ducts located at a height of up to 1.5 m from the floor.

The length of the block is determined by the dimensions of the section and the type of connection of the air ducts, the conditions of installation and the availability of lifting equipment.

The length of enlarged horizontal air duct units connected on flanges should not exceed 20 m.

Diagrams of the organization of the working area during the installation of air ducts are given in Fig. 9 - 10.

Rice. 9. Diagram of the organization of the working area during the installation of air ducts
along the outer wall of the building

1 - console with block; 2 - winch; 3 - auto-hydraulic elevator;
4 - traverse; 5 - guy line; 6 - block

Rice. 10. Diagram of the organization of the working area during the installation of horizontal
air ducts in the building

1 - winch; 2 - traverse; 3 - enlarged unit of the air duct; 4 - pendants

2.3.3. Fan installation

The fans must be installed in the following sequence:

Acceptance of ventilation chambers premises;

Delivery of the fan or its individual parts to the installation site;

Installation of lifting equipment;

Slinging the fan or individual parts;

Lifting and horizontal movement of the fan to the installation site;

Fan installation (fan assembly) on supporting structures (foundation, platform, brackets);

Checking the correct installation and assembly of the fan

Fastening the fan to supporting structures;

Checking the fan operation.

During the installation of fans, a step-by-step operational control should be carried out in accordance with the operational control cards.

2.3.4. Installation of equipment for refrigeration systems

Installation of equipment for refrigeration systems should be carried out in the following sequence:

Acceptance of premises or sites for equipment;

Delivery of the installation or its individual parts to the installation site;

Installation of lifting equipment;

Slinging of the installation or its individual parts;

Lifting and horizontal movement of equipment to the installation site;

Installation (assembly) of equipment on supporting structures (foundation, site);

Checking the correctness of installation and assembly of equipment;

Fixing the unit to supporting structures;

Commissioning works

Checking the operation of the equipment.

2.4. Testing and commissioning

Upon completion of the installation work, the contractors must carry out tests of the internal systems. Tests must be carried out before finishing work begins.

Commissioning works are performed after completion of construction and installation works, during the preparation and transfer of systems to operation. As a rule, they consist of individual tests and complex trials.

Comprehensive testing of ventilation and air conditioning systems of a building (structure, etc.) is carried out according to the program and schedule developed by the general contractor or on his behalf by the commissioning organization. The results of complex tests are documented in the form of an act.

2.4.1. Testing and commissioning of internal ventilation and air conditioning systems

The final stage of installation of ventilation and air conditioning systems is commissioning and commissioning of systems. Acceptance of works is carried out in the following sequence:

Survey of hidden works;

Individual testing of ventilation equipment (running in);

Delivery for pre-start tests and commissioning.

Air ducts and

ventilation equipment hidden in mines, suspended ceilings, etc. The results of the acceptance of works hidden by subsequent works, in accordance with the requirements of the design and regulatory documents are drawn up by certificates of inspection of hidden works.

Check the tightness of the air duct sections hidden by building structures using the aerodynamic test method (if the requirements are specified in the working project); based on the results of a leak test, draw up an inspection report for hidden works.

Individual tests of ventilation equipment (running-in) are carried out in order to check the operability of electric motors and the absence of mechanical defects in the rotating elements of the equipment. As a rule, running-in is performed after equipment installation with a connected air duct network. In cases of installing large-sized equipment in hard-to-reach places (roofs of buildings, basements, etc.), it is recommended to run in before the equipment is delivered to the installation site (at the production base or directly at the construction site).

When running-in equipment with an unconnected mains, it is prohibited to switch on without creating an artificial resistance (plug 3/4 of the inlet opening).

The ventilation equipment is run-in within 1 hour, or by checking the current values of the motor operating in operation.

The discrepancy between the readings should not exceed 10% of the current values I n indicated on the engine.

In the absence of power supply ventilation units and air conditioning according to a permanent scheme, electricity connection according to a temporary scheme and a check of the serviceability of starting devices is carried out by the general contractor.

Based on the results of testing (running-in) ventilation equipment, an individual equipment test certificate is drawn up (Appendix E, SP 73.13330.2012).

When setting up ventilation and air conditioning systems for the design air flow, you should perform:

Check the compliance of the actual design of ventilation and air conditioning systems with the design documentation and the requirements of SP 73.13330.2012;

Checking the uniformity of heating (cooling) of heat exchangers and checking the absence of moisture carryover through the drip catchers of the irrigation chambers or air coolers;

Determination of the flow rate and resistance of dust collecting devices;

Checking the operation of natural ventilation exhaust devices;

Deviations of air flow rates from those provided for in the design documentation after adjustment and testing of ventilation and air conditioning systems are allowed:

Up to +8% - according to the air flow rate removed through local suction and supplied through the spray nozzles.

For each ventilation and air conditioning system, a passport is issued in two copies (Appendix G, SP 73.13330.2012).

2.4.2. Refrigeration testing

The system is recognized as having passed the test if, within 5 minutes of keeping it under test pressure:

The pressure drop will not exceed 0.02 MPa (0.2 kgf / cm 2);

There are no leaks in welds, pipes, threaded connections, fittings and equipment.

3. REQUIREMENTS FOR QUALITY AND ACCEPTANCE OF WORKS

Quality control of work on the installation of ventilation and air conditioning systems should be carried out by specialists or special services that are part of the construction organization or attracted from outside, equipped with technical means that ensure the necessary reliability and completeness of control.

Quality control of work is carried out at all stages of the technological chain, starting from the development of the project and ending with its implementation at the facility on the basis of PPR and flow charts. Quality control should include incoming control of working documentation, structures, products, materials and equipment, operational control of individual installation processes or production operations, and assessment of the conformity of the work performed.

During the incoming inspection of the working documentation, it is checked for its completeness and the sufficiency of the technical information contained in it for the production of work.

3.1. Requirements for the quality of work on the installation of air ducts

Air ducts should be installed in accordance with design references and elevations. The connection of the air ducts to the technological equipment must be carried out after its installation.

Air ducts intended for transporting humidified air should be installed so that there are no longitudinal seams in the lower part of the air ducts.

Air duct sections where dew may fall out of the transported humid air should be laid with a slope of 0.01 - 0.015 towards the drainage devices.