MCFB半干法烟气净化工程主要设备的安装手册(英文版） .doc

mcfb-fgdmcfb-fgd installation manual 1 contents 1general remarks-2 2.steel structure instatllation-2 3.electrostatic precipitator installation-11 4. .bag-type precipitatior installation-25 5desulphuration tower installation-41 2 1general remarks 1.1 the installation manual applies to coal-burning boiler, municipal solid waste incineration boiler (mcfb) and engineering equipment for semi-dry flue gas purification, including steel structure, electrostatic precipitator, bag precipitator and absorbing tower. 1.2 the minimum technical requirements described by this manual does not make specifications on all the technical details, but the guidebook guarantee precipitator are the quality products that complies with its requirements and current industrial standard. 1.3 supplements and modifications in the manual caused by the changes of standard and regulations shall be discussed by buyer and seller. 1.4 if the standard described by the guidebook does not conform with the one accepted by buyer, the higher standard shall be carried out. 2. steel structure installation 2.1 steel structure installation sequence 3 施工准备 基础验收 主框架分片式组对、吊装 底座板安装 基础处理及垫铁埋设 钢结构找平 各楼层花纹板铺设 各楼层型钢构件安装 楼梯安装 设备预留孔开孔 验 收 钢结构防腐 楼梯、栏杆安装 h型钢验收 梯子制作 材料检验 构件预制 构件防腐 图 2-1 钢结构安装顺序 2.2 foundations acceptance and base mounting according to the materials of foundations acceptance check data and mark figures on the surface of foundations before steel structure installation. your attention shall be drawn to the fact that backfill around the foundations shall be tamped table2-1 allowable deviation of bearing surface and anchor bolt itemallowable deviation (mm) elevation3 bearing surface levelness l/1000 bolt center deviation5 anchor bolt bolt exposed length 20, 0 when columns are lifted and dropped down on concrete, putting shim group on both sides of every anchor bolt to align and level columns. 钢结构在形成空间钢度单元后，应及时对柱底板和基础顶面的空隙采用细石混凝土二 次浇灌。 4 after steel structure is formed into space rigid unit, fine aggregate concrete 2.3 material and steel components acceptance 2.3.1 inspection of materials 1) there must be warranty and certificate with inspection for materials. if there are changes in material, material list of replacement is required. 2) the surface and section of steel must be free of cracks, fold, bubbles, slag and delamination, and the depth of surface defects shall be less than half of steel plates under- thickness tolerance 3) high strength bolt, nut and gasket demand certificates which comply with specification of design and national standard. 2.3.2 steel components acceptance upon the delivery of h steel to the job site , the manufacturer shall provide the following files : 1）the certificate of quality for products 2）construction drawings and the files of design change 3）agreement about technical problems handling 4）quality certificate or test report of steel, connection material and coating material. 5）test report of slip coefficent of faying surface of high strength bolt and coating material files table 2-2 allowable size deviation of steel components itemallowable deviation column bending rise5 mm connection3 mm column distortion the other connection8 mm connection3 mm the dimension of column cross-section the other connection4 mm connection1.5 mm flange plates verticality to web plate the other connection5 mm web plate center offset2 mm 5 2.4 storage of steel components 1） in principal, the steel components shall be padded with wood and stored according to its type and installation sequence to avoid the secondary transportation. the padded wood shall provide enough bearing surface to prevent supporting point settleing. 2）steel components of the same model should be stacked in such a way that the support of layers is on the same vertical line to prevent the possible damages and deformation. 3）high strength bolt connections shall be stored according to lot number and the bolts of the same lot number shall be used. at stages of storage, transportation and erections, they shall be handled carefully and should not be used in the mixed way, so that the surfaces are protected from corrosion, damages and dampness. 2.5 steel components fabrication the procedure of fabrication of steel components 材料检验 构件制作检查焊接检查 返修 焊接组装检查组装 矫正弯曲和边 缘加工 号料、切割放样检查放样 除锈 构件验收构件堆放 防腐、编号 figure2-2 the procedure of fabrication of steel components 2.5.1 assemblage platform put the wood on the tamped soil at 1m intervals, and then put steel i-beam after leveling, then floor the platform with steel plate. the allowable deviation of platforms flatness is 5mm, and there shall not be welding beading and dirt left in its surface. 2.5.2 setting-out, marking and cutting 1) as regards to setting-out and marking, there shall be shrinkage allowance for welding and cutting according to techniques requirements. 2) allowable deviation of cutting wire and marking wire for manual cutting is 2mm 6 3) rust and dirt shall be removed from the steel surface before cutting. the surface of steel shall be free of fused piece and welding spatter and there are no cracks and damaged edge which is bigger than 1.0mm on the fracture. 4) the verticality between cutting section and steel surface should not exceed 10% of the depth of steel plate, and it should not exceed 2.0mm 5) the components after cutting must be marked and stored according to the construction drawing to avoid confusion. 2.5.3 steel components correction 1） the inclination of flange of steel i-beam shall be less than b/80( b means the flange width of steel i-beam ) 2） the bending rise of angle steel, channel steel and steel i-beam should not exceed 5mm .( hl/1000) 3）the local bending rise of steel plate and flat steel shall be less than 1.5mm (f1.5mm) 4）the local bending rise of steel plate and flat steel could be corrected by thumper method on the special platform. 5） 对于型钢，应根据型钢制作专门的矫正胎具用千斤顶进行冷矫正，如果冷矫正有 困难，可以进行热矫正，其加热温度严禁超过正火温度（900） 焊接 as regards to shaped steel, make special correcting clamping fixture to do cold correcting on shaped steel by jack. if it is difficult for cold correcting, hot correcting is also ok, but its heating temperature is forbidden to be over the welding temperature 900 1） he technical-qualified welder shall make the quality product to satisfy the needs in construction. 2） drying the welding wire according to the certificate of quality before use .the low hydrogen electrode shall be put in 100150 thermostats after drying. 3） if there is no protection measures in either case, welding should not be done. a、wind speed is 10m/s b、raining or snowing c、relative humidity is 10m/s 4） tack welding and regular welding shall have the same techniques. 5） welding must be done in strict accordance with process specificatio and depending on 7 components set down reasonable welding sequence o avoid deformation. 6） the inspection of welding shall be done in accordance with requirements of design documents and specification , and correct and repair the unqualified weld. 7） 构件制作完，经检查合格后，对钢结构安装无防碍部位进行除锈防腐，除锈经检 查合格后才能防腐，防腐按设计规定进行，湿度大于 90%或下雨天不能除锈防腐。 8 2.6 quality control 2.6.1 common quality diseases table 2-3 common quality diseases and precautions ite m common quality diseases precautions 1position shift a.横纵中心调整后紧固地脚螺栓， b.基础二次灌浆前还应复查中心位置，逐个检查地脚螺栓的紧固情 况，确认无误后才能进行灌浆。 c.对于因结构、施工方法或其他原因有可能发生移位的柱脚板，还 应采取加固措施。 2elevation deviation a.使用的水平仪必须准确，每次使用时必须进行比较校对。 b.所有柱脚板的标高测量，都必须使用一个基准测量点进行测量， 不得随意使用或变更测量点，以保证层量的统一性、准确性。 c.柱脚板的安装标高，应依据柱子现场测量后确定的 1m 标高来确定， 安装时要考虑柱子 1m 标高划线后的制造误差。 3 incorrect bolt installation a. 严格按照图纸要求穿装高强螺栓。 install the high strength bolt according to the requirements of drawings b. 每一节点的螺栓规格应统一，不得用长短不一规格的螺栓相互代 用。 c. 螺栓紧固，应由中间向四周逐一禁锢，不能无绪的乱紧，螺栓的 紧固应严格按技术要求进行。 4 bad flatness of beam and connections a.安装前应检查调整梁的扭曲和弯曲。 b.与柱或梁连接时经测量合格后方能拧紧螺栓或点焊。 c.发现梁与梁连接处不平时，可采取扩孔、加垫或修改托架的方法 尽可能的消除不平缺陷。 5 construction deficiency a. 禁止在设备上随意焊接，必须焊接时需经有关技术负责人同意方 可施焊。 b. 因施工需要，在设备上进行点固焊接时，施工后必须全部清理掉， 用砂轮磨平，并检查有无施工缺陷，有缺陷必须处理。 6 installation of platform and ladder a. 栏杆、扶手安装应横平竖直，立杆间距应一致，安装时用水平仪 或拉线的方法进行测量找正。 b. 栏杆、扶手的直管、弯头等对接处不得有错口，过渡应平滑，焊 接后应用砂轮打磨光滑。生根部位的焊接，焊后及时清理药皮。 c. 平台的支吊梁、柱安装应横平竖直。 d. 珊格板的拼装，应横平竖直，拼缝一致，间隙均匀。不得随意乱 切乱割，必须切割时采用机械切割方法。机械无法切割，用乙炔切 割。切割部位恢复时其接口应平滑，焊后应做补漆处理。 9 2.6.2 quality control point in construction table 2-4 quality control point in construction inspection authority itemon-site control teamcompany quality examinat ion departm ent supervis or provment 1 quantity check and inspection of equipment *r 2check the dimension of equipment* 3 reference elevation installation ,reference point confirmation and correcting * 4 hoist apparatus and rigging device checking * 5 钢架砼基础几何尺寸、标高复查 the dimension of steel frame and recheck elevation *w 6基础划线 mark baseline*w 7correction of bearing plate mounting*w 8high strength checking mr li mr zhang mr wang w 9 the installation and acceptance of steel plate mr li mr zhang mr wang w 10overall acceptance*h 11secondary grouting*w r record；w witness；h work shut down for checking；s continuous monitoring 2.6.3 quality standard and requirements “code for erection and acceptance of electric power construction” and “specification for construction quality checkout and evaluation of power plant” are fully carried out. 10 figure 2-5 implementation standard nu mb er item name acceptance standardpages 1 code for erection and acceptance of electric power construction of steam boiler set 2 code for accepance of construction quality of steel structures 3 code for erection and acceptance of electric power construction (welding section ) dl5007 4high strength bolt connection 验评炉3表p32 5column checking验评炉 33表 p33 6beam checking 验评炉 35表p35 7mark base line of steel frame and shim mounting验规炉 41表p49 8top-mounted steel frame and mark line验评炉 42表p50 9erection of single column of steel frame 验评炉 46表p55 10erection of single beam 验评炉 48表p58 11secondary grouting验评炉 49表p58 12mounting of platform and ladder 验评炉 419表p74 2.6.4 quality control point table 2-6 quality control point numberstagecontentinspection methodinspector 1 before construction 1.the joint check-up of drawing checking materials and records, inspection on site 2 the writing of working guidance which shall be approved 3. check work-start report 11 4.check whether equipment and materials meet requirements of design and whether there is material report and quality certificate 6.check if there is technical disclosure before working 7.check whether special operators hold certificates and their operation qualification comply with working 8. check whether supplier parts have quality certificates and whether they meet the design requirements 9.check whether spot construction conditions ( safety devices, site conditions and warnings )could satisfy the requirements of safety requirements 2check equipment r check equipment dimension erection of base elevation and confirmation of base point check hoist apparatus and rigging device checking reinspection of steel frame dimension and elevation w check foundation and mark base linew the correction of bearing plate mounting w foundation secondary grouting w inspection of high strength bolt w mounting and acceptance of each steel frame w during construction overall acceptanceh 3 completion of construction inspection of files rrecord；wwitness；hwork shut down for checking；scontinuous monitoring 2.7 safety requirements and environmental conditions in construction 12 2.7.1 the control and identification of the safety of hazardous factors in construction table 2-7 the description and predictive control measures of the safety of hazardous factors in construction number description of dangerous point predictive control measures responsibl e person 确认 签证人 job site and enviroment 1 lack of illumination on site install enough lighting that operate well on site。 2 the dangerous points around and under the welding working area take effective protective measures and make sure that fire-resistant blanket is used under the high attitude working area 3 welding machine left in the open air welding machine left in the open air shall be placed in dry area with shielding cover or use special box 4 the erection of temporary working platform the platform erected by professionals could not be put into use until it passes the acceptation inspection and the overload use is forbidden. 5 waste recycle could not be done in time clean up the waste in time , recycle and store them in designated place 6 梯子、栏杆、平台 不完善 在梯子、平台、栏杆不完善处加临时围 栏、盖板并挂警示牌 7 施工现场有孔洞、 沟槽 put cover plate above the holes and bars in working area and lay off safety net underneath construction and worker 1 在吊装物下接料或 逗留，坠物伤人 禁止在吊装物下通过停留，接料人员必 须按操作规程施工 2 hammer coming away and hurts people hammer and safety rope shall be used together and persons standing before hammer is forbidden. 3 垂直交叉作业层间 未设严密、牢固的 防护隔离措施，坠 落伤人 垂直交叉作业层间用脚手板隔离 4 飞溅伤人 welding spatters hurts people 从事有飞溅物的作业时，施工人员戴护 目镜 5 高处作业人员身体 不适 作业人员经体检无不适合高处作业的病 症方可参加施工 6 作业人员施工态度 不端正 施工人员严禁嬉戏、打斗，严禁酒后作 业。 13 7 高空作业不系安全 带或不正确使用安 全带 高处作业必须正确使用安全带 8 wrong power-line connections 严禁私拉乱接电源，电源拆接、维护由 专业电工负责。 9 高处作业人员站在 栏杆外工作，坐在 平台、骑坐栏杆等 施工前进行交底，禁止高处作业人员站 在栏杆外工作，坐在平台、骑坐栏杆等 进行施工 10 misuse of steel wire rope 钢丝绳必须有 8 倍以上保险系数并在与 吊物尖锐棱角接触处垫半圆板。 11 hanging things come off 钢丝绳与管道接触处垫防滑物，吊挂生 根牢固并进行二次保护。 12 起重区域、起重臂 下吊装通道有人 设警戒区域，设专门监护人，拒绝任何 人通过。 13 transportation for bulky cargo 路线检查合格，专人领车、监护设备与 车体捆牢。 use of tools 1 welding machine is not firmly grounded the protective connect to neutral and multiple grounding of the shell of welding machine. 2 leakage of electric tool check tool before use and make sure that it is in good condition and is equipped with leakage protector. 3 falling tools hurt people small tools put into tool bags and big tool 4 tools are defective or damaged check and repair before use 5 non-professional tools are used the use of non-professional tools is forbidden. 6electric shock 施工场所要干燥、电焊二次线使用胶皮 软线。电源线架空，或埋入地小下 7 lock in low safety factor safety factor shall be more than 8 times 8 misuse of chain blocks 使用前检查，修理合格；使用中必须受 力均匀，不超载使用；手链必须备牢， 防止滑脱。 14 2.7.2 environmental conditions table2-8 the description and predictive control measures of dangerous point number description of dangerous point predictive control measures responsible person 1 in case of windy days equip enough lights that could work well on each job site。 2 waste recycle could be done in time clean up the waste in time , recycle and store them in designated place. 3in case of windy days when scale of wind force is more than six, hoisting installation is forbidden. in case of windy days, windproof measures must be taken and construction area must be enclosed by fabric. 4 in case of rainy or snowy days clean off the construction area and remove standing water and snow, 3. esp installation 3.1 the structure of esp 图 3-1 esp structural sketch map 3.2 installation sequence 15 steel structure erection and acceptance of the level surface of column elevation calibration of diagonal lie for column head hopper installationcasing installation collecting electrodes installationdischarge electrode installation collecting electrode rapper installation discharge electrode rapper installation ladder and platform installation the installation of insulation layer and outer casing the installation of fly-ash transport system power distribution equipment and secondary system high voltage silicon rectifier transformer installation rapper and electric heater installation erection of grounding devie reactor installation porcelain components figure 3-2 installation flowchart for esp 3.23.2 lifting appliance its better to equip tower crane in need of movement of components. the beam could be lifted by truck crane 3.3 special tools in equipment to guarantee installation quality, the installation of esp is strictly regulated . special 16 tools must be used in storage, lift and assembling of key parts to prevent deformation in installation. different precipitator need different special tools as follows: (1)rack for assembling discharge electrode frames ( quantity: 2 ) (2)rack for storing discharge electrode frames ( quantity: 3 ) (3)rack for lifting discharge electrode frame ( quantity: 3 ) (4)platform 8m20m (quantity 1 ) 3.4 acceptance tools though esp is non-standard ,it has its own industrial standard. as regards to internal parts installation, deviation in spacing between electrodes is the main factor affecting esp efficiency. it is regulated that deviation in spacing between collecting plates is 4005mm and deviation in spacing between collecting plates and discharge electrodes is 20010mm. it is impossible to measure the above two figures, therefore we design the special acceptance tools for the deviation control. 3.5 preparation prior to construction 1) engineers shall receive training about structure and performance of the equipment and related design drawings before construction 2) all the equipment quality and quantity guaranteed must be transported to the job site and finish counting. 3) all tools including lifting apparatus, welding devices, special implements and power supply in accordance with design requirements of construction shall be transported to the job site. 4） construction is not allowed until all the workers received safety training. 5） steel support structure finished construction and pass acceptance inspection. 3.6 site arrangement 1）divide the site and clean the waste in centralized stack way. 2）check the location of precipitators bottom, and put up obvious warning signs around the construction site such as “ no passage this way” 3）grade construction site 4）check equipment and special tools for installation which need to be stored suitably. 3.7 tools setting-up 1）check tower crane location and concrete its foundation in accorda