HGJ203-83 化工机器安装工程施工及验收规范-通用规定-中文版(DOC版).doc

中华人民共和国化学工业部部标准Ministerial Standard of the Ministry of Chemical Industryof the Peoples Republic of China化工机器安装工程施工及验收规范通用规定The Specification for the Implementation and Takeover ofChemical Machine Installation WorksGeneral ProvisionsHGJ203-831984 BeijingDocumentation issued by the Ministry of Chemical Industry(83)H.J.Z NO.1352Notice on Issuing the Specification for the Implementation and Takeover of Chemical Machine Installation Works (General Provisions)The Specification for the Implementation and Takeover of Chemical Machine Installation Works (General Provisions) complied by Beijing Yanshan Petrochemical Corporation Construction and Installation Engineering Company under the entrustment of our ministry has been examined and finalized. Now hereby we approve its issuance as a standard of our ministry with the serial NO. HGJ203-83 from the first day of October 1984.This Specification shall be governed by the basic construction bureau under the Ministry of Chemical Industry. The Ministry of Chemical Industry of the P.R.C December 12 1983Ministerial Standard of the Ministry of Chemical Industryof the Peoples Republic of ChinaThe Specification for the Implementation and Takeover ofChemical Machine Installation WorksGeneral ProvisionsHGJ203-83Prepared by: Beijing Yanshan Petrochemical Corporation Construction and Installation Engineering CompanyApproved by: The Ministry of Chemical IndustryExecuted on: October 1 1984Compilation ExplanationIn accordance with the arrangement made in the (81) H.J.S.Z.NO.364 documentation issued by the Ministry of Chemical Industry, Beijing Yanshan Petrochemical Corporation Construction and Installation Engineering Company was entrusted to compile the Specification for the Implementation and Takeover of Chemical Machine Installation Works (General Provisions).This Specification was prepared against the characteristics of the chemical industrys production, considered the actual conditions of our countrys current machinery manufacturing and installation technology, and absorbed advanced technology and construction experiences developed and accumulated in the construction of imported projects in the past years since reform. During the course of compilation, research was carried out extensively, opinions and suggestion from nationwide scientific institutes, manufacturers, designers, constructors and higher-learning institutions were collected for many times, coordination and suggestion meetings were held, and related domestic and foreign standards were used as references. After many times of modifications, the final version was determined at an examination and approval meeting.As a general provision documentation for the implementation and takeover of chemical machine installation works, this Specification serves as basic technical requirements for the common part of the implementation and takeover of installation works of all kinds of chemical machines (opposed compressors, centrifugal compressors, small and medium-size piston compressors, chemical pumps, etc). When installing special-purpose chemical machines, relevant installation code for the installation of such machines shall also be executed, in addition to this Specification. This Specification is arranged in accordance with the implementation procedure for the installation of chemical machines and includes seven chapters and fourteen schedules. In Chapter 1, the applicability of this General Provisions is defined. From Chapter 2 to Chapter 6, basic stipulations in terms of the preparation prior to the installation, placement and centering, cleaning and assembling, installation and trial run of auxiliary equipment and pipelines are made. Chapter 7 defines the documents that should be provided at the time of completion and takeover.In consideration of the sustained development of the machinery manufacturing industry and related installation technology, we hope that during the implementation of this Specification all unit can carefully summarize experiences and actively provide improvement suggestions, for the purpose of addition and revisions later.The basic construction bureau under the Ministry of Chemical Industry shall govern this Specification. The right of construing shall be vested in the construction technology research institute under the Ministry. As for the issues of consultation, please contact the research institute at Middle of Huaizhong Road, Shijiazhuang, Hebei. Basic Construction Bureau under the Ministry of Chemical Industry November 25 1983Chapter 1 General RulesClause 1.0.1 This Specification governs the installation and takeover of chemical machines, such as compressors, fans, pumps, centrifugal machines, agitators, filters, dryers, etc.Clause 1.0.2 During the installation of all chemical machines, relevant special chemical machine specifications (hereinafter referred to as the Special Specifications) under the Specification for the Implementation and Takeover of Chemical Machine Installation Works must be executed, in addition to this Specification.Clause 1.0.3 Clauses under this Specification shall serve as the basic technical requirements for the installation and takeover of all chemical machines. In case of the unconformity with a machines technical documents, the machines technical documents shall prevail when carrying out installation and takeover.Clause 1.0.4 As for special installation and takeover works in connection with a machines piping, electricity, meter and instrument, anti-corrosion, heat insulation and degreasing, they shall be carried out in accordance with relevant codes and technical specifications.Clause 1.0.5 Requirements in respect of safety technology, labor protection and fire-fighting of installation works shall be executed pursuant to relevant regulations currently in force.Chapter 2 Preparations Prior to InstallationSection 1 Technical DocumentsClause 2.1.1 Prior to the installation, the following technical documents in respect of machines or equipment shall be prepared:1. Ex-factory certificate of approval;2. Manufacture and assembly certificates of quality for relevant important parts and accessories, and trial run records;3. Plane layout, installation drawings, foundation drawing, master assembly drawing, drawings for easily worn parts, and installation and operation manuals;4. Packing list;5. Related installation codes and technical requirements or schemes.Section 2 Open-package Inspection and ManagementClause 2.2.1 A machines open-package inspection shall be carried out with the participation of related personnel, in accordance with the packing list. The inspection shall cover:1. Examination of the machines name, model, specification, package number, number of cases, and packing status;2. Examination of the number of the technical documents and special tools provided with the machine;3. Examination of the appearance of the main equipment item, accessory item and parts and accessories; and the examination of type, specification and quantity of parts and accessories;4. A signed inspection report shall be presented after the inspection.Clause 2.2.2 Proper protection measures shall be taken for the machine and its parts and accessories, if not installed temporarily, against deformation, damage, rust, aging, confusion or missing.Clause 2.2.3 All the electric equipment and meters and their parts that are auxiliary to a machine shall be inspected by professionals and kept appropriately.Section 3 Required Site ConditionsClause 2.3.1 Prior to the installation of a machine, the Site shall have the following conditions:1. Civil engineering works have been completed basically, i.e. the foundation is ready for the installation, the underground works near the foundation have been completed in the main, and the site has been made flat;2. Construction-used transportation roads and fire-fighting passes have cleared;3. Lighting, water and power supply facilities for construction are ready;4. Hoisting and transport equipment for installation are ready;5. Storage facilities are ready for parts, accessories, spare parts and tools;6. All large equipment around the machine and the large pipelines on the pipe gallery above have been hoisted and installed.7. Necessary fire-fighting apparatus have been prepared. Section 4 Acceptance and Treatment of FoundationClause 2.4.1 The foundation shall be handed over against the presentation of the certificate of quality and measurement records. On the foundation, these signs shall be obviously marked: elevation reference and the center lines horizontally and vertically. Coordinate axial lines shall be marked on the building. The foundation of important machines shall have subsidence observation points.Clause 2.4.2 Observe the appearance of the foundation and no defects such as cracks, honeycombs, cavities and pockets, exposed reinforcement, etc shall be found.Clause 2.4.3 Based on the foundation drawings of relevant civil works and technical documents of machines, re-examine the dimension and location of the foundation; its difference allowance shall comply with Table 2.4.3.Table 2.4.3 Difference allowances for the foundations dimension & location (mm)ItemsItem name Difference allowance1Location of foundation coordinate (horizontal and vertical axial lines)202Elevation of the foundations planes+0-203Dimension of the plane on the foundationDimension of the plane on the bossDimension of the recess20-20+204Levelness of the plane on the foundation (including the part on the terrace to be installed equipment):Per meterFull length5105Vertical difference: per meter Full height5206Embedded ground bolt:Elevation (top)Center distance (measure at the bottom and top)27Reserved ground bolt hole:Center locationDepthPlumbing degree (full depth)10108Embedded move ground bolt with anchor plates:ElevationCenter locationLevelness (grooved anchor plate)Levelness (anchor plate with screw hole)552Clause 2.4.4 Prior to a machines installation, the following work shall be done for the foundation:1. Bug holes shall be made on the surface of the foundation that needs the second grouting, with the depth of bug holes of at least 10mm and the density of 3-5 holes per square meters. No oil sludge and tectorium shall be found on the surface;2. The surface of the foundation on which sizing blocks will be placed (approximate 50mm around the surface) shall be shoveled flat, with the difference allowance of levelness of 2mm/m;3. Reduced stone, soil and accumulated water inside a screw bolt hole must be removed and cleaned.Note: The second grouting refers to the infusion of grout between the bed of a machine and the foundation.Chapter 3 Installation of MachineSection 1 Installation with Sizing BlocksClause 3.1.1 The principle for the arrangement of sizing block sets is: put one set of sizing blocks at each side of the ground bolt and make the them close to the bolt as much as possible. If the distance between ground bolts is smaller than 300mm, a set of sizing blocks can be placed at the same side of a ground bolt. As for the sizing block set putting at each side of the ground bolt with anchor plates, they shall be positioned at two sides of the preserved hole.The spacing between two adjacent sets of sizing blocks can be determined in accordance with the weight, bed structure and load distribution in respect of the machine, and is generally set at around 500mm.Clause 3.1.2 The maximum area of a single sizing block can be approximately calculated with the following formula:Where, A- the maximum area of a single sizing block, mm2; (the bearing area of every set of sizing blocks placed at each side of a ground bolt) Q1- the load on the set of sizing blocks causing by the machines weight, kgf; G - the machines weight, kgf; n1 - the number of sizing block sets; Q2 - the pressure distributed on the set of sizing blocks after the tightening of the ground bolt, kgf; F - the axial force arisen after the tightening of a single ground bolt (see Schedule 3), kgf; n2 - the number of sizing block sets at each side of a single ground bolt (generally, 2). R - the compression strength per unit area of the foundation or terrace concrete (may adopt the design label of concrete), kgf/cm2;Based on the calculated value of A, choose the sizing block with a bigger value than A from Table 3.1.2 (when the sizing block has an excess of bearing capacity but a shortage of length, may choose a sizing block with bigger specification).Table 3.1.2 Specifications of common sizing blocks (mm)Tilting sizing blockFlat sizing blockArea (cm2)Symbol LbcaMaterial Symbol LbMaterial ANo.1 tiltingNo.2 tiltingNo.3 tiltingNo.4 tiltingNo.5 tilting100120140160200506070801005555546888Common carbon steelNo.1 flatNo.1 flatNo.1 flatNo.1 flatNo.1 flatNo.1 flat10012014016020050607080100Common carbon steel507298128200Note: (1) The thickness of the sizing block (h) can be determined according to actual conditions. Usually, the thickness of the underlying flat sizing block is not smaller than 10mm; (2) The tilting sizing block under Table 3.1.2 can cooperate with the flat block with the same or a little bigger size; (3) In order to prevent the sizing block from curling when knocking it, its lower and upper edges shall be chamfered in advance; (4) Simple drawings of the sizing blocks (see Figure 3.1.2) Tilting Block Flat BlockFigure 3.1.2 Drawings of Sizing BlocksClause 3.1.3 The sizing blocks surface shall be flat, and no scale and fash shall be found on the surface. The fineness of a titling blocks bevel shall not be smaller than 3, and the inclination usually is set at 1/201/10. As for the machine with a higher center of gravity or bigger vibration, it is advised to set the inclination at 1/20.Clause 3.1.4 Tilting sizing blocks shall be used in pair. When forming a set of sizing blocks with a flat block, the layer number shall not exceed 4 generally. The thinner sizing block (s) shall be placed between the tilting block and thicker flat block. The height of a sizing block set usually is set at 3070mm.Clause 3.1.5 Sizing blocks shall be placed directly on the foundation and shall contact the foundation evenly. The percentage of contact area shall not be smaller than 50%. The difference allowance for the levelness of a flat sizing block is 2mm/m. The elevation of the super-face of sizing blocks shall be in line with the actual installation elevation of the machines sub-face.If adopting the mud-jack method to place sizing blocks, the placing method refers to Schedule 1.Clause 3.1.6 After the leveling of the machine, the sizing block set shall be exposed 1030mm above the bed. As for the sizing block sets at each side of the ground bolts, the length of the part of a sizing block inserted under the machines bed shall exceed the ground bolt. At the same time, the bearing proportionality of the machines bed shall be guaranteed. If the sub-face of the machines bed doesnt contact the sizing blocks well enough in width, the placement location of sizing blocks shall guarantee that the bed is located above the central part of the bearing plane of sizing block sets.Clause 3.1.7 The overlapping length of a pair of tilting sizing blocks shall not be smaller than 3/4 of the full length, with the angle of declination not exceed 3 (see Figure 3.1.7).The angle of declination shall not exceed 3.Figure 3.1.7 Placement location diagram for titling blocksClause 3.1.8 After the leveling and centering of a machine with sizing blocks, knock with a 0.25 or 0.5 kg hand hammer to knock and examine whether the sizing block sets are tightened. No loose shall be found in this case. Use a 0.05m feeler gauge to examine the spacing between sizing blocks and the spacing between the sizing block and the beds sub-face. At the same cross-section of a sizing block, the total length of the insertions from each side shall not exceed 1/3 of the sizing blocks length (width). If approved, carry out an interlayer spot welding at each side of the sizing block sets. No weld joints shall be found between the sizing block and the machines bed. Section 2 Installation without Sizing BlocksClause 3.2.1 The form, method and applicability about the installation without sizing blocks refer to Schedule 2.Clause 3.2.2 When adopting a smaller lifting jack or temporary sizing blocks to make adjustment, their location and quality shall be determined in accordance with the machines weight, bed structure and other conditions.Clause 3.2.3 If there are set screws on the machines bed, the super-faces levelness shall not exceed the difference allowance of 2mm/m after the placement of the steel back-up plate.Clause 3.2.4 Related provisions concerning the part of the second grouting see Section 5 of Chapter 3.Clause 3.2.5 Only after the second grouting layers strength exceed 75% of the design value, the set screws can be loosed, or take out the temporary backup parts. At the same time, the levelness of the machine shall be re-measures and fill out the cavity.Clause 3.2.6 The recommended proportion of the slight-expansion concrete used in the second grouting to the shrinkage-free soil mortar refers to Schedule 6.Secti