上海某乙烯装置项目950-960管廊钢结构施工方案(中英文对照).doc

档案号 file no：上海赛科石油化工有限公司90万吨/年乙烯装置900 kt/a ethylene plant of shanghai secco petrochemical co. ltd950/960管廊钢结构施工技术方案execution statement for steel structure of 950/960 pipe rack编 制： 张金冬 zhang jindongoriginated by: 施工技术审核： 洪庆根 hong qinggentech. reviewed by: 质量保证审核.： 戴东明 dai dongmingqa reviewed by: 安全技术审核： 边长刚 bian changganghse reviewed by: 审 定： 徐庆海 xu qinghaichecked by: 批 准： 杜振东 du zhendongapproved by: 编制时间 date： 2003-5-20 中国石化集团第十建设公司上海化学工业区项目部shanghai chemical industry park project department of the tenth construction company of sinopec 目 次 index1.工程概况 general introduction12.施工程序 construction procedure13.施工准备 the construction preparation24.工厂化预制 factorial prefabrication25.材料验收 raw materials acceptance86.基础的验收与处理 foundation acceptance and treatment117.钢结构安装structure erection148.连接固定 connecting and fixing169.防腐 corrosion prevention1810.安装质量检查与验收 inspection and acceptance of installation quality1811.交工验收 handing over2012.hse管理 hse management2413.劳动力组织 labor force organization2514.施工机具 construction equipment and tool2615.施工进度计划 construction schedule261.工程概况 general introduction1.1 概述 general上海乙烯裂解装置950/960管廊共有钢结构约1450吨，钢结构主要由h型钢柱和钢梁构成，节点的连接采用20mntib，10.9级摩擦型高强度螺栓连接，选用扭剪型高强螺栓。设计单位中国石化工程公司（以下简称sei），监理单位齐鲁石化工程公司，我公司对钢结构进行工厂化预制，同时负责现场安装工作。there is total 1450 tons steel structure for 950/960 pipe racks in shanghai ethylene cracking plant. all the main steel structures are made of h-shape columns and beams. 20mntib 10.9 grade twist-shear type of high strength bolts is used for the connecting of joint. the responsible company for design is sinopec engneering incoration (sei) and the responsible company for supervision is qilu engneering company. we tenth construction company are responsible for the factory-prefabrication and the site erection of the steel structure 。1.2 编制依据 reference（1） sei提供的950/960管廊钢结构图纸及钢结构总说明 ；950/960 steel structure drawings supplied by sei;（2）钢结构工程施工及验收规范gb50205-2001；“specification for construction and acceptance of steel structure” gb50205-2001;（4）石油化工钢结构工程施工验收规范sh3507-1999；“specification for construction and acceptance of steel structure for petrochemical industry ” sh3507-1999;（5）钢结构高强度螺栓连接的设计、施工及验收规程jgj82-91；“specification for design, construction and acceptance of high strength bolt connection of steel structure” jgj82-91;（6）赛科相关施工管理规定。the secco related rules for construction management.2.施工程序 construction procedure管廊钢结构的施工程序见图2-1. the procedure of construction for the steel structure see figure 2-1.施工准备 construction preparation材料、构件验收materials and steel parts acceptance工厂化预制factorial prefabrication吊 装lifting基础验收foundation acceptance现场组对 assembling on site钢结构检验steel structure acceptance补漆、涂面漆 repair and painting final layer 连接固定connecting and fixing交工验收handing over图2-13.施工准备 the construction preparation3.1 施工前技术准备 technical preparation before construction（1）施工前参加由业主组织的设计交底会及图纸会审会，明确设计意图，了解施工注意事项。将设计存在的问题尽可能消除在施工之前。take part in the design turnover meeting and drawings censorial meeting organized by the owner to make clear of the design intentions and the construction notice items before construction. the existing design problems should be got rid of before the construction as much as possible.（2）由责任工程师对参加施工的人员进行详细的技术交底。the responsible engineer carries out the detailed turnover to the workers. 3.2施工机具准备 the preparation of the construction machine and tools（1）机具使用计划详见表15-1。machine and tools arrangement plan see table14-1.（2）施工现场达到“三通一平”。obtaining 3-available and 1-flat in construction site4.工厂化预制 factorial prefabrication 4.1图纸详细设计 detailed design drawings使用芬兰tekla oy公司开发的、世界知名钢结构三维拆图软件x steel，进行绘制、出版与结构设计图样一致、更适于工厂化生产的钢结构构件加工详图（车间大样图）和材料清单。we prepare the materials bill and the detailed machining drawings （shop detail drawings）coordination with the structure design drawings and more suitable to factory-prefabrication with the world famous 3d steel structure drawing softwarex steel developed by finland tekla oy co. 4.2下料cutting off根据详细设计的节点图、大样图及构件图，在板材或型材上进行1：1号料划线，保证尺寸精度。并根据工艺要求预留制作安装时的焊接收缩余量及切割、刨边和铣平等加工余量marking on the plates or sectional bar should be on the scale of 1：1 according to the detailed joint drawings ，detailed drawings and component drawings to ensure the accurate dimension。otherwise the welding allowance for shrinkage and the metal allowance for cutting ，edge planning and milling flat should be pre-hold while fabricating and erecting in accordance with the process regulations。钢材的下料采用机械剪切（shear cutter）、火焰切割（gas cutter）和带锯切割（saw cutter）三种方法。the cutting methods of steel material include three manners such as: shear cutter, gas cutter and saw cutter.厚度不大于12mm的钢板采用机械剪切，12mm厚度以上的钢板采用火焰切割。the shear cutter will be adopted for the steel plate with thickness not more than 12mm and gas cutter for which over 12mm.h型钢和其他大规格的型钢采用带锯切割，小规格型钢采用火焰切割。the saw cutter is applied to hshape steel and other large steel cutting while the gas cutter to the small steel.切割后，清理切割表面的熔渣、氧化层和飞边等残余物。clean the remains on the cutting surfaces such as slag, oxide layer and trims after cutting operation. 4.3加工machining螺栓孔采用三轴钻床、摇臂钻床和磁力钻等机械方法加工。the bolthole should be fabricated by means of machining method with triaxial driller, beam drilling machine and magnetic driller.螺栓孔的允许偏差应符合表4-1的规定。the allowable deviation of boltholes should comply with the data shown in the table 4-1.螺栓孔的允许偏差（单位：mm）表4-1allowable tolerance of bolt holes table4 - 1螺栓的公称直径nominal size of bolts162024基础螺栓直径diameters of foundation bolts螺栓孔直径diameter of bolt holes17.52226d+6孔径偏差deviation of hole diameter00.4300.5200.8402圆度circularity1.01.51.52.0同一组内任意两孔间距允差allowable tolerance of the distance between any two holes in the same group间距clearance 500，1.0；间距 clearance 500，1.2相邻两组的端孔间距允差allowable tolerance of the distance between terminal holes of any two group间距 clearance500时，1.2；间距 clearance5001200，1.5；间距clearance 12003000时，2.0；间距 clearance 3000，3.0制孔后，应清除螺栓孔边缘的毛刺。不合格的螺栓孔不得采用钢块填塞，可采用与母材材质相匹配的焊条补焊后重新制孔。remove burrs on the edge of fabricated boltholes. unqualified boltholes cannot be filled up with steel blocks, but can be refabricated after markup welding by electrodes accordant material.焊接坡口可采用机械加工或火焰切割加工。h型钢接长焊缝坡口应采用机械加工，与柱连接的梁两端的焊缝坡口必须采用端铣机加工。the welding grooves should be made by means of the gas cutter or shear cutter, the shear cutter for fabricating long welding bead groove of hshape steel, and the welding groove of two end of beam connecting with the column must be prepared by an end-milling machine. 火焰切割后的坡口表面必须用砂轮清除坡口表面氧化皮并打磨平整，不得有深度大于1.0mm的凹痕。坡口表面的粗糙度应不大于50 m。the grinding wheel should be used to dismantle the oxide and grind after gas cutter, no permission to the cave with depth more than 1.0mm. the roughness of groove surface should not more than 50 m.坡口表面的水分、油污、熔渣等污物应清理干净。clean the sewages including water, oil spots and slag remained on the groove surface. 4.4组焊 assembly welding构件组焊前，零、部件应经检查合格，沿焊缝边缘每边3050mm范围内的铁锈、油污等污物应清除干净。check whether parts are qualified or not and get rid of sewage in terms of rust and oil spots etc. within the range of 3050mm along each side of welding seam before assembling.构件组装顺序应根据结构型式、焊接方法及焊接的顺序等因素确定，尤其要考虑焊接变形的影响，防止出现组焊后产生难以弥补的变形。the assembling sequence of parts should depend on structure types, welding methods and procedures etc., especially considering the effect of welding deformation avoiding irremediable deformation after assembly welding. 结构预制焊接采用手工电弧焊和二氧化碳气体保护焊工艺方法。manual electric arc welding and co2 gas shielded welding will be adopted.焊条使用前进行烘干处理，药皮脱落、焊芯生锈的焊条不得使用。dry electrodes before use. rusted core electrodes and electrodes with sloughing coat cannot are forbidden.焊接过程中，不得在焊道外的母材上引弧。焊接完毕后清理焊缝表面的熔渣，打磨母材表面的电弧擦伤和熔合性飞溅物。generating arc on base metal beyond the scope of welding bead is not allowed during welding. clean the slag on the surface of welding seam and grind the scrape and fusion spatter on the surface of base metal. 多层焊缝应连续施焊，每层焊道施焊完后应及时清理检查，消除缺陷后再进行下道焊缝的施焊，层间接头应错开。apply continuous welding to mutilayer weld; clean and check each welding seam in time after welded, and then welding activities can be gone on after eliminated defects. joints between layers should be staggered.焊接完毕后，所有焊缝进行100%的外观检查，所有坡口焊缝进行超声波检测。after welding, visual inspection should be performed on 100% of all the welding seams. ultrasonic test should be performed for all grooved welding seams. 4.5矫形 straightening构件在组焊过程产生的变形可采用机械矫形和热矫形两种方法。the parts deformation produced during assembly welding could be straightened in two ways: mechanical straightening and heating straightening.一般构件以机械矫形为主，无法采用机械矫形的大型构件，则采以热矫形方法。mechanical straightening is main for common parts and heating straightening for those large to which the mechanical straightening cannot be applied.h型钢采用热矫形时，对侧弯变形，应在翼板外侧局部以尖形加热方式矫正成直线；对挠度变形，在腹板部以尖形加热，翼板处以圆形加热方式矫正至成直线；见图4-1所示。during the heating straightening of h-steel, perform tip heating outside of flange to straighten the deformation of side bending; perform tip heating at web and roundness heating at flange to straighten the flexibility deformation; please see figure of 4-1.基准线 base line尖形加热图5.4h型钢热矫形示意图图4-1 h型钢热矫形示意 tip heating figure 4-1 sketch of heating straightening for h-shape steel 4.6除锈、防腐 rust removal and anti corrosiona 除锈防腐前，钢构件应经质量检验合格。steel parts should be qualified by checking before performing rust removal and preservation.b钢结构采用喷砂除锈处理，除锈等级应达到sa2-2.5级.rust removal can take the method of sand blasting, and the grade of rust removal should reach sa2-2.5.c 除锈完成且经检验合格后立刻进行底漆涂刷工作。油漆作业必须在表面处理后4小时内完成，否则应重新做表面处理。apply a primer at once as soon as finished rust removal and qualified by checking. painting activities should be completed within 4 hours after surface prepared, otherwise, the surface should be treated again.d 油漆涂刷采用无气喷涂方式施工，补漆部分采用手工涂刷施工。airless spray coating shall be applied to painting construction, and markup painting should adopt the manual painting. e 油漆喷涂必须均匀，底漆厚度一律为90m，分两道喷涂。sprayed painting should be uniformly and all the thickness of primers should be 90m.painting is spayed in twice.f 多组分油漆应使用厂家配套的稀释剂或固化剂，严格按厂家规定的比例进行配比，并搅拌均匀，配比后的油漆在厂家规定的时间内使用。the diluting and solidified agent matched by manufacturer should be used for multicomponent paint which mixed uniform strictly matching the ratio specified by manufacturer, mixed paint should be applied within the time specified by manufacturer.g 涂漆时，钢构件表面必须干燥，工作环境的相对湿度不得大于85%。the surface of steel parts should be dry and relative humidity of working environment cannot over 85% during painting.h 涂漆时，一次涂刷厚度不宜太厚，以避免发生起皱或流挂现象；上道漆膜完全干燥后，才能涂刷下道油漆。漆膜采用自然烘干法干燥。at one time painting, the thickness of paint should not be too deep in order to avoid rumpling and flowing down; next layer of painting can be applied only the preceding layer is dried completely during painting. drying of paint film can adopt natural drying.i 在工厂不予涂漆部位 unpainted position at work shop:工地焊接处在两侧各50mm之处；each 50mm of both sides of welding line where will be welded on site.螺栓连接面。joint face of bolt油漆干膜厚度检测应使用膜厚测定仪，漆膜厚度不得小于规定值的10%。film thickness measuring gauge shall be used for checking dried paint film. the film thickness cannot be less than 90% of specified value.j 补漆 touch up油漆涂装后，漆膜如发现有龟裂、起皱、裂纹、流挂、粉化等现象时，应将漆膜刮除或以砂纸研磨后，重新补漆；if defects of drying crack, rumpling, flowing down, crack, powdered etc are be found after finished painting, remove the paint film or paint it again after grinding by an emery paper.5.材料验收 raw materials acceptance5.1高强螺栓、螺母、垫片应有质量证明书，机械性能和化学成分应符合设计和专业标准的要求。螺纹不得有损坏部分，螺杆应能自由旋入螺母中。扭剪型高强螺栓按出厂批号复验螺栓连接副的紧固轴力，每批复验8套。8套紧固轴力的平均值和变异系数应符合表5-1的规定。there must be the quality certificates to the high strength bolts; nuts and gaskets. the mechanical properties and chemical components shall be conformity with the requirement of the design and professional standards. the thread shall not be damaged and bolts shall circumgyrate through nuts smoothly. for the twisting and shearing type of high strength bolts, the fastening axial force at the bolting point will be re-inspected according to patch and 8 sets of each patch will be selected for re-inspection. the average value and variation coefficient of 8 sets of the fastening axial force shall be in conformity with the stipulations of table 5-15.2工厂制作的钢构件应有质量证明书、出厂检验试验报告、和高强度螺栓摩擦面抗滑移系数试验报告，并按批附3套与构件同材质、相同处理方法的试件，在安装前复验高强度螺栓摩擦面的抗滑移系数。检查构件的外形尺寸，柱梁等杆件的尺寸偏差应符合表5-2的要求，高强螺栓连接孔的尺寸偏差应符合表4-1的要求。the steel parts made in manufacturer shall be of quality certificate and ex-work test and the friction slip coefficient test report of high strength bolts. and three sets of test pieces same as the steel parts in material and treatment methods will be enclosed with each batch. recheck the friction slip coefficient of high strength bolts before erection. check parts outside dimensions. the dimension deviation of the columns and beams should be in accordance with the requirement of table 5-2. the dimension deviation of the connected holes of high strength bolts should be in accordance with the requirement of table 4-1.扭剪型高强螺栓紧固轴力（kn） 表5-1fastening axial force of twisting & shearing type of high strength bolt table 5-1螺栓规格bolt size. mm162024每批紧固轴力的平均值average value of the fastening axial forcefor each patch公称值nominal109170245最大max.120184270最小min.99154222紧固轴力变异系数variation coefficient of fastening axial force(标准偏差/紧固轴力平均值)standard deviation/average value of fastening axial force10柱、梁等杆件的外形尺寸允许偏差 表5-2allowable tolerance of column and beam outline dimensions table5 - 2项 目items允许偏差（毫米）allowable tolerance（mm）图 例legend杆件的长度 length3杆件的弯度、拱度bend & span degreel/1000且5.0l/1000&5.0连接板位置location of connecting plate2连接板方向direction of connecting plate与图纸相同same with drawings柱底面到柱端与梁连接的最上一个安装孔距离distance between the column base and the top erection hole connecting column end with beaml/1500，且12l/1500，&12柱底面到牛腿支撑面距离distance between the column base and the supporting surface of the bracketl1/2000，且8l1/2000，&8柱身弯曲矢高column bend vector heighth/1000且12柱身扭曲 column bend牛腿处3，其它处8bracket3,others8柱脚底板平面度level of column baseplate5柱脚螺栓孔中心线对柱轴线的距离distance between the central line of the bolt hole on column base and the column axial line3柱底板扭曲变形deformation of column base plate bending3.0每节柱长length of each segment of column3.05.3焊接材料应具有质量证明书，并符合设计和国家标准的规定。受潮变质、药皮破损、焊芯生锈的焊条严禁使用。there should be quality certificates for welding materials and the materials must be tally with specified stipulations of design and national code. electrodes with deteriorated by wetting, damaged coating and rusted core wire are forbidden to use.5.4涂装材料，应有出厂质量证明书和检验报告，并符合设计要求和国家现行标准。高强螺栓、螺母、垫片应有质量证明书，按规格分别存放，并防止锈蚀和损伤。painted materials should have ex-works quality certificates and inspection reports and tally with requirements of design and current national code. high strength bolt, nut and gaskets should have quality certificates, and which can be stored respectively as per specification preventing from corrosion and damage.6.基础的验收与处理 foundation acceptance and treatment6.1管廊基础施工完毕后，监理单位应组织土建施工单位向安装单位进行基础中间交接，并提供基础实测记录等中间交接资料。基础上应明显标出标高基准线和纵横中心线，基础混凝土强度达到设计强度的75%以上，基础表面的油污、泥土、积水等均清除干净。after the completion of the foundation construction, the supervisor should organize the civil construction company to hand the work over to the installation company and submit the actually measured records of the foundation. the elevation datum lines and the vertical and horizontal central lines should be marked clearly on the foundations and the strength of the foundation concrete should be over 75% of the design strength. the grease, soil and water accumulated on the foundation surface should be cleaned thoroughly. 6.2审核基础的交接资料，对基础进行全面检查，其质量应符合表6-1的要求。review the handover documents and carry out an overall check for the foundation. the quality should be in conformity with the requirement of table6-1基础质量要求 表6-1the requirement of the foundation quality table 6-1序号ser. no.项 目items允许偏差mmallowable tolerance1基础表面质量foundation surface quality不得有裂纹、蜂窝、空洞及露筋等缺陷;without the defects like cracking, honeycomb, hollow and reinforced bar baring2基础外观尺寸visual dimension of the foundation 203基础顶面标高elevation of the top of the foundation 0- 104相邻基础行列轴线间距clearance between the axial lines horizontally and vertically of two adjacent foundations 35与非相邻基础中心间距clearance between the centers of two foundation non-adjacent 56基础中心两对角线之差the difference between two diagonal lines of the foundation center 57地脚螺栓顶端标高elevation at the top of anchor bolts0+ 108地脚螺栓垂直度verticality of anchor bolts 1%l09相邻两螺栓间距clearance between two bolts 210螺栓中心位置偏差deviation of bolt central position 211螺栓螺纹长度length of bolt thread0+ 1012 相邻两基础轴线间距clearance between axial lines of two adjacent foundation 36.3垫铁安装采用座浆法，垫铁布置图见图6-1.steel pad will be set in the sloping method. the layout of iron pad see figure 6-1.6.3.1座浆前，基础表面应铲出麻面，垫铁顶标高为-10mm，保证垫铁与柱脚板接触良好，垫铁的水平度允许偏差为2mm/m.before the installation of the pad, the foundation surface should be scraped so as to keep the g