耐火材料施工方案 翻译.docx

南通开发区固体废物综合处理工程项目焚烧系统（含烟气处理）工程Incineration System Project of Solid Waste Integrated Utilization Project in Nantong Development Zone(Flue-Gas Treatment Included)耐火材料施工方案 Installation Scheme of Refractory Material编制：Formation审核：Verification审批: Approval濮阳濮耐高温材料（集团）股份有限公司二零一五年七月 目 录Content一、 安全保证措施Safety Assurance Measure21.技术组织措施Technical and Organizational Measure2二、质量保证措施Quality Assurance Measure4三、工程概述Project Overview51、耐火材料概况Refractory Material Overview52、编制、执行依据Reference for Formation and Implementation63、施工机具、人员计划Installation Machines, Personel Plan7四、施工内容Content of installation81、安装施工顺序Installation Order82、施工准备工作及施工方案Installation Preperation and Installation Scheme83、施工质量控制点Installation Quality Control Point13五、事故应急救援预案Emmergency Response Programme141、应急组织机构与职责Emmergency Organization and Responsibility142、事故应急救援预案Emmergency Response Programme14六、进度计划Scheduled Plan151、 安全保证措施Safety Assurance Measure1.技术组织措施Technical and Organizational Measure1.1现场施工管理人员、工程技术人员必须熟悉本职工作的安全操作规程。All site operation management personnel and engineering technical staff should strictly observe the rules for safe operation.对于施工中的安全一刻也不能松懈，必须明确“生产必须安全，安全促进生产”的道理，在管理人员的心中应“安全第一，警钟长鸣”。Safety issues during the installation cannot be neglected or slacked off. It should be stated clearly that safety in production promotes productivity. All staff should keep in mind that safety comes first and alarm bell rings.不断通过对工人操作班组的安全示范、安全教育、安全引导，去提高他们的安全意识，不能一味抓生产而忽视安全，当安全和工期发生矛盾时，必须保证安全。Through demonstration, guidance and education on safety, operation team should enhance their safety consciousness. Safety comes the first when it conflicts with the schedule.现场施工管理人员还必须以身作则，不违章指挥，制止违章行为，经常组织安全检查，发现隐患及时采取整改措施，对职工进行定期安全教育和安全隐患事故分析会，并作好记录。现场职工有权劝阻违章行为，并向领导报告，接受有关人员安全检查，实行互相监督。Site operation management personnel must lead by example, avoid commanding against rules, organize constant safety examination, and discover and rectify all hidden danger. Site staff have the authorization to stop acts in violation of regulation and report to higher level. Also, they should cooperate on safety inspection from related personnel and execute mutual supervision. 2.安全技术交底Safety Technique Disclosure2.1分部、分项工程开工前，针对工作特点、施工方法、使用机械和环境的实际情况，施工技术人员必须编制具体的安全措施，并根据安全技术措施和安全操作规程，向工人班组进行安全技术交底，给他们讲清楚安全重要性，讲清楚“三宝”的使用方法，“四口”、“五临边”处安全的防护以及不幸发生事故后安全自救方法等，安全员要向班组“喊话”。Before starting subsection work and projects, installation technicians must propose specific safety measures and conduct safety technique disclosure with regard to operating features, methods and operational environment and tools. It should be stated clearly about the importance of safety, application of “Three Safety Keys”, defendable measures for the place of “Four Openings”, and “Five Edges” and safety self-rescue method after unfortunate accidents, etc. Safety personnel should propagandize safety knowledge to the whole group. 班组在每一道工序施工前或每日作业前均应向工人进行安全技术交底，安全应和工资收入挂钩。Each group should conduct safety technique disclosure before every installation procedure and the safety issues should be linked with wages.2.2按照安全操作规程操作设备Operate under Safety Operation Specification 在使用操作电动、液压或氧割等设备时，应严格按照各类设备的安全操作规程正确操作，避免安全事故的发生。When using electric rigs, hydraulic devices and oxygen cuttingEquipment, workers should strictly follow the safety operation specification and avoid safetyaccidents.2.3安全检查 Safety Check 由现场安全员定期或不定期地检查，查出施工过程中的违章违纪行为，应给予批评教育，对累教不改者有权按公司文件进行处罚。施工现场安全员应定期排查施工现场安全隐患，安全隐患整改率应达90%，对于重大安全隐患应及时上报并备案。在日常安全检查活动中提高安全意识，贯彻“安全第一，预防为主”的安全生产方针，以此保证安全工作得到具体落实。Site safety officer should conduct regular and irregular inspection and point out acts of violation of regulations. Penalty should be given to those who refuse to obey the rules after re-education. Site safety officer should regularly screen the hidden danger, ensure the reform rate of 90% for potential safety hazard and report serious potential safety hazard timely for record. Safety consciousness needs to be enhanced in daily work. “Safety first, precaution primarily” is the safety production policy, which can assure the specific safety work.2.4注意事项Notice 1）进入现场必须遵守安全生产纪律。All personnel should follow the safety production discipline entering the working site. 2）高度重视安全隐患，现场严禁吸烟及酒后作业，一经发现予以罚款。Pay high attention to hidden dander and no smoking at site and no operating after alcohol. Once violated, fine must be paid. 3）施工现场通风照明良好，施工时注意周围环境，防止挤压、碰撞事故发生. Working site should guarantee good ventilation and lighting. Pay close attention to surroundings and avoid extrusion and collision accidents.4）每个施工部位至少安装2台安全排风扇，保证炉内通风。炉内用36负电压的照明灯。Each installation site should be equipped at least two electric fans to guarantee the ventilation in the furnace. The exciter lamp in the furnace should be 36 volt.5）认真进行“三级教育”，对可能发生安全事故的安全隐患进行排查，对施工现场进行长期性巡视，发现违章及时制止。Site safety officer should regularly screen the hidden danger and all violation acts should be noticed and forbidden once discovered. 6）检查小工具及连接电缆绝缘是否完好，使用木工刨时必须加防护罩，并戴眼镜。木工刨必须有良好的接地，并且间歇使用，防止电动机过热。Check the isolation of the tie cable. Protective casing and glasses should be added whenusing woods plane. Woods plane should possess goof grounding and work intermittentlyin case the motor go too hot. 7）用砂轮机打磨砖面时，戴好防护镜，身体必须侧对砂轮机，打磨时，严防用力过猛，砂轮机停转，引起烧机。When sanding the brick surface with the grinder, please wear glasses and their bodies should be broadside on the grinder. Forbid using too much strength in case the grinder stops and the motor burns. 8）搅拌机应有倒顺开关，刀闸型开关在闭、合时，须侧脸、戴好手套，防止起弧伤人。Stirring machine should be equipped with two direction switch. When opening and closing the switch, workers should face broadside and wear gloves in case of arcing accidents. 2.5防止高空坠落措施 Anti- High Falling Measures1）吊装人员应戴安全帽；高空作业人员应佩五点式带缓冲包安全带，穿防滑鞋，带工具袋。Lifting personnel should wear safety hats. Aloft workers should wear five points buffered packet belts and anti-slippery shoes and take tools bags with them.2）吊装工作区设有明显标志，并设专人警戒，与吊装无关人员严禁人内。起重机工作时，起重臂杆旋转半径范围内，严禁站人或通过。 Put clear signs in lifting areas and arrange someone to stop irrelevant personnel entering. Withintheradiusofcranejibrotation, no standing nor passing.3）运输、吊装构件时，严禁在被运输、吊装的构件上站人指挥和放置材料、工具。 During the transportation and lifting of the components, no workers, materials and tools placed on them.4）高空作业施工人员站在操作平台或轻便梯子上工作时吊装层设临时安全防护栏杆或采取其他安全措施。Lifting layers should be installed temporary safety railing or other equipment for aloft workers when they are standing on operational platform or portable ladder. 2.6防物体落下伤人措施Measures for avoiding falling objects1）高空往地面运输物件时，应用绳捆好吊下。吊装时，不得在构件上堆放或悬挂零星物件。零星材料和物件必须用吊笼或钢丝绳、保险绳捆扎牢固后才能吊运和传递，不得随意抛掷材料物体、工具，防止滑脱伤人或意外事故。 Delivering goods from higher places to ground, ropes should be applied. No stacking or hanging objects on the components when lifting. Fragmentary material and objects should be lifted only in suspension cage or tied up firm with steel wire ropes. Materialand tools shallnotbe arbitrarilythrowingaway.2）构件必须绑扎牢固，起吊点应通过构件的重心位置，吊升时应平稳，避免振动或摆动。All components should be tied up firmly. Lift points shall be their center-of-gravity positions. The lifting procedure shall be steady and flat and shall avoid vibration and swinging.二、质量保证措施Quality guarantee measurement1、确保工程质量，是一个塑造过程精品的过程。不仅要精心设计，还要精心施工，在施工环节上狠抓施工质量，确保各个环节质量在一个可控范围，并且请建设单位和监理单位参与检查施工过程中的各个环节。To guarantee the quality is the process of building excellence. The design is as important as the installation. Among all installation aspects should pay much attention to the installation quality. Qualities for all the aspects should be kept in controllable range. Installation unit and supervision unit should involve to check in all the aspects in installation process.2、技术负责人制定合理先进的施工方法，并对施工操作人员进行详细的技术交底，在施工中进行技术指导，完工后进行记录和总结。 Technical leader is responsible for making out an advanced and reasonable installation plan and conduct detailed technical disclosure to operators. Technical leader should give technical guidance during the installation and record and summarize after installation3、项目部设立质检员。施工中的每道工序都必须经过自检、互检、质检工程师检查、报驻地监理工程师检查确认后，方可进行下一道工序的施工。 Establish inspection system in the department. Each procedure shall be inspected through self-check, cross-check and engineer check. After reporting to the supervision engineer, the procedure may move forward. 4、严格按照施工图纸和施工规范进行安装，努力推广使用有利于提高工程质量的先进技术和施工方法，对工程的重要结构部分和隐蔽工程要进行质量预检和复检。 Strictly follow the installation drawing and regulations and spread advanced techniques and methods that improve the installation quality. Conduct pre-check and double-check to important parts and concealed work. 5、凡隐蔽工程必须填写工程检查验收记录，并邀请监理工程师、总包工程师参加活动联合检查，检查合格后，方可进行隐蔽。 Fill in the recordings of engineering check and acceptance and invite supervision engineer including chief engineer to conduct mobile joint inspection. After passing the check the work shall be concealed. 6、雨季施工时，应保证施工人员防雨、防水、防滑的需要，特别是用电安全防护。 When constructing in raining season, make sure to satisfy workers need to keep off rain, water and slip, especially the safety to use electricity. 7、每天应做全面的安全检查，检查内容包括个施工部位的脚手架、安全防护设施、各种机械运作、电缆电线、水管及储水装置等安全情况进行检查，发现问题并提出并整改。 Conduct comprehensive safety check everyday including scaffolds, security protection facilities, physical machinery, cable wires and pipes and water storage device. Identifytheproblemsandproposerectification.8、加大资源投入，并及时调度调整，积极应用新技术、新工艺、新材料，施工积极推广和采用新技术、新工艺、新材料，开展技术革新，探索总结工法，努力缩短各具体工序的施工周期，加快施工进度。 Enlarge the input. Timely adjust the plan. Apply the latest techniques, process, and materials and conduct technical reformation and discover and summarize new methods. Dedicated to shortening the installation period is of great importance.9、各种耐火材料堆放处标有材料名称，防止使用混乱。 Mark the materials names in refractory stack place to prevent mess.三、工程概述 Project Overview1、耐火材料概况 Refractory Overview 1）回转窑 Rotary Kiln操作温度在10001100范围进行运转。在此温度下，形成的废物灰可以熔化，并从回转窑尾部流出，回转窑内衬耐火材料，运行时在回转窑耐火层表面保持约50-100毫米的稳定渣层起到保护耐火层的作用。The operational temperature ranges from 1000 to 1100. In this range of temperature, the waste ashes will melt and outflow from the bottom of the rotary kiln. During working, the lining refractory will form a stable slag which is 50-100mm thick in the surface of flameretardantcoating to protect it.a.回转窑壳体内径3800mm 3800mm inner diameter of rotary kiln shellb.回转窑耐火材料内径3200mm 3200mm Inner Diameter of Rotary Kiln refractoriesc.回转窑长度13000mm 13000mm Length of Rotary Kiln d.耐火砖厚度230mm，粘土砖厚度70mm。Brick Thickness 230mm Clay Brick Thickness 70mm注明：回转窑耐火砖砌筑按照图纸要求施工。Note: The laying should be constructed according to the drawing.2）二燃室Second Combustion Chamber二燃室为立式圆筒形结构，回转窑通过一个二燃室预留孔插入二燃室中，二燃室内的温度控制在1100-1200之间。最高可达1300，主体耐火材料为高铝砖；底部为抗剥落高铝砖；顶部为炼钢电炉顶用高铝砖。The second combustion chamber possesses a vertical cylindrical structure. The rotary kiln is inserted in the second combustion chamber through the preformed hole. The temperature in the second combustion chamber is controlled between 1100 and 1200, the highest can reach 1300. Main refractory applied is high alumina brick. The bottom uses anti-stripping alumina brick while the upper part uses high alumina brick for EAF roof.二燃室内径为5500mm，砖衬内径为4570mm，总高度为14964mm。Inner diameter of second combustion chamber is 5500mm. The inner diameter of brick lining is 4570mm. The overall height is 14964mm.筒体部分的耐火层及保温层厚度合计为465mm（硅酸钙板120mm保温砖115mm耐火砖230mm），设计的耐火层正常操作温度在1100-1200，最高可达1300；The overall thickness of refractory for the barrel is 465mm (calcium silicate board 120mm, insulating brick 115mm and refractory brick 230mm). Normal running temperature of the designed refractory lining is between 1100-1200 and the highest temperature can reach 1300.二燃室顶部设有紧急排放烟囱见图（W12SYS-S18.02-03-00），该烟囱内衬耐火砖；There equips an emergent drainage smoke chimney with refractory brick lining at the top of the second combustion chamber. See chart（W12SYS-S18.02-03-00）紧急排放烟囱主体金属内径为1800毫米，耐火层及保温层内径1224毫米，耐火层及保温层厚度为288毫米，总高度1275毫米.The metal inner diameter of the emergent drainage smoke chimneys main body is 1800mm. Inner diameter of refractory and insulating layer is 1224mm. Thickness of refractory and insulating layer is 288mm and the overall height is 1275mm. 二燃室顶部设计成由特殊吊挂砖块砖承载结构。The top of the second combustion chamber is designed as the hanger brick bore structure.3）急冷塔 Quench Tower550高温烟气，经烟道从上方进入急冷塔，经双流体喷头喷水后降为195。由于烟气中含有大量腐蚀性成分，要求内衬材料具有耐温、抗腐蚀性、耐磨损和隔热性能。Hot gas at the temperature of 550 enters into the quench tower from the top through flue pipe. After the water spraying by the two-fluid spray nozzle, the temperature drops to 195. Due to the large amount of corrosive ingredients in the hot gas, it is required that the lining material should have good refractoriness, corrosion resistance, abrasion and heat resistance.急冷塔主体金属内径为3200毫米，耐火层内径2880毫米（隔热层60mm，耐酸浇注料100mm，总厚度160mm）。筒体部分的耐火层及保温层厚度为160，塔体总高度16029毫米。The metal inner diameter of the quench tower is 3200mm. The inner diameter of the refractory layer is 2880mm (insulating layer is 60mm, acid-resistant castable is100mm and the overall thickness is 160mm). The thickness of refractory and insulating layer for the barrel is 160mm. The overall height of the quench tower is 16029mm.4）循环流化床脱酸塔及急冷塔出口烟道Circulating Fluidized Bed Extracting Tower and Quench Tower Outlet Duct来自急冷塔下部的烟气，由循环流化床脱酸塔下部进入烟气进口温度：195，脱酸塔出口烟气平均温度：165左右。Gas from quench towers bottom goes into the gas entrance through the bottom of the circulating fluidized bed extracting tower at the temperature of 195. The average temperature of the outlet gas from the exit of extracting tower is around 165.塔体内部浇筑100mm厚的耐磨浇注料，内筒壁的抓钉由脱酸塔制造厂负责焊好。Cast 100mm thickness wear resistant castable inside the tower. The manufacture of extracting tower is responsible to weld the clasp nail used in the inner cylinder wall.5）再循环管道内衬 Lining of the Recirculation Pipe内部浇筑50mm厚的耐酸浇注料。Cast 50mm thickness acid-resistant castable.6）再循环管风机入口道内衬Lining of Entrance of the Recirculation Pipe Wind Turbine内部浇筑50mm厚的耐酸浇注料。Cast 50mm thickness acid-resistant castable2、 编制、执行依据 Formation and Implementation Reference 1） 工业炉砌筑工程施工及验收规范GB50211-2004Code for installation and acceptance of industrial furnace masonry engineering GB50211-2004 2） 工业炉砌筑工程质量检验评定标准GB 50309-1992Code for installation and acceptance of industrial furnace masonry engineering GB 50309-19923、 施工机具、人员计划 Installation Machines and Personnel Planning人员组织架构表：Format of personnel structure职位Position负责人Person in Charge项目经理Project Manager高恩步技术负责人Technical Leader刘长辉质量负责人Quality Director高建 安全员Safety Officer 涂剑施工人员计划表：Format of installation manpower plan根据工程进度要求及工程量，施工高峰时计划投入32人，各工种人数见下表(根据工程进展情况随时增减)：According to schedule requirements and amount of work, it is planned that 32 workers will be working in peak time. Numbers of workers in different specialties are as follow(scale based on progress ).工种Profession人数Number工种Profession人数Number焊工welder3人普工General Worker20人砌筑工Bricklayer7人木工Carpenter2人施工机具表：Format of installation machines根据现场情况合理使用工机具，以下为配备计划，不包括施工所用的附材。Properly use installation machines on the basis of site condition. Following is the equipment plan, not including attached materials during the construction.序号设备名称规格型号数量额定功率备注1搅拌机2台10KW2卷扬机2台8KW提升材料3焊机2台50KW焊接销钉等4切砖机1台3KW切砖用5高频震动器3台15KW浇注料振动6震动棒8条各种半径7灯具10个5KW内部照明8木工机械1台3KW木工用9高峰用电负荷60KW机械不同时使用NoDevice NameSpecificationAmountRated PowerRemarks1Blender2 sets10KW2Hoisting Machine2 sets8KWMaterial lifting3Welder2 sets50KWWelding pins4Brick Cutter1 set3KWBrick cutting5High Frequency Vibrator3 sets15KWCastable vibrating6Shaking Stick8 barsVarious radius7Lamps and Laterns10 5KWInterior lighting8Woodworking Machine1 set3KWCarpenter 9Peak Load60KWDifferent machines四、施工内容 Installation Content1、安装施工顺序 Installation OrderQuench towerSecond Combustion ChamberRotary kilncyclonedustcollectorFlue PipeCirculating Fluidized Bed Extracting Tower2、施工准备工作及施工方案InstallationPreparationWorkandInstallationScheme 1）施工用水要求 Water Supply forInstallation本工程的施工用水必须是生活洁净水，通常情况下搅拌料用水要求不低于10，不高于25。The water must be clean water for life. Under normal conditions, water for mixing shall be from 10 to 25. 2）施工温度条件 Installation Temperature施工环境温度不低于5，如果在冬季施工，施工环境气温低于5，应采取加热保温措施，如在夏季高于35施工则应采取降温措施。（每个12小时轮流休息，施工口有人监护）。Temperature for installation environment shall be above 5.In winter, heating and insulating measures should be taken when the temperature drops below 5. In summer, cooling measures should be taken when the temperature is above 35.(Take turns to rest every 1-2 hours. Establish supervision at the site) 3）结构体验收 Constructs Inspection and Acceptance回转窑安装完成并校准，仪表、管件等安装结束，烟道接口支撑及焊接工作完成，具备耐火材料施工条件。Check the completion of Rotary Kilns installation and calibration, dashboards and pipe fitting. Check the support of the flue outlet and the welding condition. Make sure that refractory meets the request of installation condition. 4）材料储存、堆放与搬运 Material Reserve, Storage and Transport4.1 耐火的后续性能与储存条件密切相关，因此现场材料的堆放、保管和运输规则按GB10325-88执行。Refractorys subsequent performance is closely related to the storage condition. Thus the reserve, storage and transport of the refractory shall be executed under GB10325-88. 4.2 所有到现场材料应轻搬轻卸、不可抛掷，以免损坏包装，降低贮存时限、影响材料使用性能。These materials must be handled with care at site and do not throw them. Do not collide with packing materials so as not to affect the operation.4.3 现场堆放的材料都应有防雨、防潮、防污染措施。浇注料等不定形材料应放置在有盖的仓库内，并做好防雨、防潮、防污染措施，最好在地面上铺置一层防潮物件再堆放材料。Material stacked