静止设备安装方案 static equipment installation procedure.doc

SCC CNCEC 土耳其天然气项目静止设备 施工方案目录1 编制依据12 工程概况23 施工技术方案44 施工准备55 设备安装76 设备的二次灌浆97 附属构件、附件与内件的安装99 大型设备吊装人员组织体系图1110 安全技术措施1111 施工工机具一览表1212. 施工措施用料计划1313 施工所需劳动力一览表141 编制依据 reference1.1 设备安装图纸（中国天辰工程有限公司提供的施工图纸）drawings of equipment installation( provided by TCC)1.2 机械设备安装工程施工及验收通用规范（GB50231-2009）Construction and general acceptance specification for mechanism equipment installation 1.3 中低压化工设备施工及验收规范（HGJ209-1983）construction and acceptance specification for medium or low pressure chemical equipment 1.4 化工塔类设备施工及验收规范（HGJ211-1985）construction and acceptance specification for chemical tower equipment 1.5 石油化工换热设备施工及验收规范（SH3532-2005）construction and acceptance specification for petrochemical exchangers 1.6 现场设备、工业管道焊接工程施工及验收规范（GB50683-2011）welding construction and acceptance specification for field equipment and industrial pipe 1.7 施工现场临时用电安全技术规范（JGJ462005）security specification of temporary utilization of electric power on construction site2 工程概况 project overview2.1 Project name:Tuz Gl Underground Natural Gas Storage Project2.2 工程参建相关单位：Relevant units jointing into the project 建设单位： Development organization 设计单位design unit：中国天辰工程有限公司 TCC施工单位construction unit：中国化学工程第六建设有限公司SCC CNCEC3 施工技术方案 technical scheme of construction3.1 施工方法 construction methods设备一般采用吊车就位，对于安装位置不宜用吊车的设备，采用卷扬机或倒链就位，安装顺序应结合钢结构的施工程序进行。Crane is generally used to position equipment. Windlass or chain fall shall be adopted in position that crane is not suitable. Installing sequence shall comply with construction procedure of steel structure. 图纸会审 joint checkup on drawings 3.2 安装在混凝土基础上的设备安装程序：Installation procedure of equipment on concrete foundation 方案编制 project programming工机具准备 instrument preparation设备就位及找正，找平 equipment positioning, leveling and alignment设备基础处理 treatment for equipment foundation设备验收equipment acceptance基础验收foundation acceptance二次找正 secondary alignment二次灌浆 secondary grouting地脚螺栓孔灌浆 grouting of anchor bolt holes设备操作平台，支架，附件安装 installation of operating stage, bearer and accessory of equipment内件安装 installation of internal parts检查封闭 inspection and sealing交工验收 submission and acceptance4 施工准备 preparation for construction4.1 施工技术准备 preparation for construction technology4.1.1 参加由建设单位组织的四方（设计单位，建设单位，监理单位，施工单位）图纸会审，并做好记录。Contractor shall take part in the joint checkup conducted by development organization, joined by design unit, supervision unit and construction unit and keep proper record.4.1.2 编制并报审施工方案，施工前对施工人员进行详细的技术交底。Construction scheme shall be compiled and reported to the authority. Construction personnel shall subject to technical clarification before construction.4.1.3 组织施工人员认真熟悉图纸，施工方案，技术资料和安全技术措施。Construction personnel shall be organized to acquaint drawings, construction scheme, technical document and security technique measures.4.2 施工现场准备 preparation of construction site4.2.1 施工现场应符合施工技术方案的要求，施工现场应平整，基础周围不得积水，供电、供水系统的布置，应符合安全技术规程的规定。Construction site shall be in accordance to technical scheme of construction. The site shall be leveled. There is no hydrop surrounding the fundament. The disposal of electric and water system shall comply with security technique specification. 4.2.2 工装设施准备 tooling facilities preparation施工应配备下列工装设施，并应满足施工工艺的要求。The following tooling facilities shall be provided for construction, complying with construction process.-吊装施工机具和脚手架、梯子；Lifting implement, scaffold and ladder-工装卡具、胎具及临时支架；Fixtures, clamping and temporary bearer-焊接防护设施；welding protective facilities-检测工具。Test tool4.2.5 基础验收。Fundamental acceptance1、 基础施工单位应提供基础测量记录及其它施工技术资料；基础上应明显的画出标高基准、纵横中心线，相应的建筑物上的应标有坐标轴线；设计要求作沉降观测的设备基础应有沉降观测水准点。设备基础外管尺寸允许偏差见附表3 Civil construction unit shall offer measure record of fundation and other construction technique documents. The foundation shall be clearly marked with elevation datum line and longitudinal and latitudinal center lines. The allowable deviation for outer pipe size of equipment foundation please see table 3.附表3 设备基础的允许偏差 allowable deviation for equipment foundation dimension 项次itme偏差名称 description允许偏差值（毫米）allowable deviation (mm)1基础坐标位置（纵、横轴线）Foundation coordinate position (longitudinal and latitudinal axial line)202基础各不同片面的标高Elevation of different locations of foundation0 203基础上平面外形尺寸 plane dimension on fundation凸台上平面外形尺寸 convax dimension凹穴尺寸 concave dimension2020+204基础上平面的不水平度（包括地坪上需安设备的部分）unlevelness of plane on foundation (including the section requiring to install equipment) 每米per meter全长 total length5105竖向偏差：vertical deviation每米 per meter全高 total height 5206预埋地脚螺栓：embedded anchor bolt标高（顶端）elevation(top)中心距（在根部和顶部两处测量）center distance (measured on both root and top) +20 027预留地脚螺栓孔：preformed hole for anchor bolt中心位置 center 深度 depth孔壁铅垂度 verticality of hole wall 10+20 0108预埋活动地脚螺栓锚板 embedded movable anchor plate标高 elevation 中心位置 center 不水平度（带槽的锚板）unlevelness (for anchor plate with groove)不水平度 （带螺栓孔的锚板）unlevelness (for anchor plate with bolt hole) +20 05524.2.3 垫铁准备 shim is ready.4.2.3.1 垫铁加工：根据设备的规格、垫铁承受力的形式进行加工。Shim machining: machine the shim according to the specification of equipment and the form of shim tolerance.4.2.3.2 垫铁规格可参照中低压化工设备施工及验收规范由下式计算出所需面积后，参照HGJ209-83中附表选用 shim square can be calculated by following formula, referring to construction and acceptance specification for medium or low pressure chemical equipment. Then the specification shall be chosen as per attached table of HGJ209-83. AC100(G1+G2)/nR毫米2 A一组垫铁的面积毫米2、 C系数，C=2.3A-square of a shim unit mm Ccoefficient C=2.3G1设备附件及物料等的重量,公斤力；G1weight of accessory, materiel and etc. kgf G2全部地角螺栓紧固后，作用在垫铁上的总压力,公斤力。 G2total pressure on shim with all anchor bolts being fastened4.2.4 现场设备材料验收acceptance of equipment and material on site进入现场的成品、半成品必须具备下述出厂技术文件。装箱单、压力容器产品安全质量监督检验证书、产品合格证、容器说明书、质量证明书、其它有关产品技术更改的技术说明。The following ex-factory technical documents of finished product and semi-finished product on field must be available: packing list, safety and quality supervision certificate for pressure vessel, product qualification certificate, vessel instruction, certificate of quality and other technical illumination involved to the modification of product technology.4.2.5 设备验收完毕后，按指定地点运输到位，设备在运输途中必须有保护措施。After acceptance, equipment shall be shipped to the stated point. Protection shall be provided for the equipment during transportation. 4.2.6 设备在安装前办理设备出库、报验手续，设备随机证明文件齐全，备齐相应的施工记录表格。Output and inspection record for equipment shall be made before installation. Certificates associated with equipment shall be complete. Corresponding forms for recording construction shall be prepared well. 4.2.7 设备吊装时，应注意当时的气候变化，遇有五级大风时，不得进吊装作业。Before equipment lifting, attention shall be paid to the weather. Lifting work shall be prohibited in weather condition with wind force five or more.5 设备安装 equipment installation5.1 砼基础上的设备安装 (基础为预留螺栓孔) installation of equipment on concrete foundation (the foundation is preformed bolt hole)5.1.1 基础上的标高基准线加设垫铁，垫铁上表面即为设备底座标高；Place shims on the elevation datum line of foundation. The height of upper surface of shim is the elevation of equipment plate.5.1.2 地脚螺栓放在螺栓孔内，吊装设备就位，使其中心线与基础中心线重合。Place the anchor bolt on bolt hole, position the lifting equipment with its centerline coinciding with the foundation centerline.5.1.3 用水冲净孔内四壁上的尘土，清除孔内杂物、泥水和积水；Wash the hole wall with water, clear away the sundries, soil and hydrops in the hole.5.1.4 按设计给定的材料及配比配制混凝土，其标号应比基础混凝土标号高一级别；Confect the concrete as per given material and mixture ratio in design. Its grade shall be one class higher than that of foundation concrete. 5.1.5 灌浆必须按地脚螺栓孔对称顺序连续进行，中途不得间歇；grouting must be continuously performed without pause in symmetric order of bolt holes.5.1.6 浇灌时，必须边浇灌边对称捣实，排除混凝土内的气体，使混凝土浆饱满，并注意观察，不得使地脚螺栓歪斜或使设备移位；Concrete shall be symmetrically vibrated and compacted to eliminate the gas in it. The cement shall be filled to every corner. It shall be assured that the anchor bolts will not tilt and equipment will not shift.5.1.7 混凝土达到设计强度后，加设正式垫铁，对设备进行精确找正、找平； When the concrete reaches the specified strength, formal shims shall be placed. Precise leveling and alignment work for equipment shall be carried out.找正用垫铁，螺栓两侧各加一组及立筋下垫一组，相邻两垫铁组的间距，视设备底座的刚性程度确定，一般应为500毫米左右；Shims shall be used to align. A pair of shims shall be placed at both sides of bolts as well as under the stud. The distance between two adjacent shim units shall be set according to rigidity of equipment plate, in general about 500mm.垫铁组中应使用成对的斜垫铁，两垫铁的斜面要相向使用，搭接长度应小于全长的3/4，偏斜角度应不超过3度，斜垫铁下面应有平垫铁；The wedges shall be used in pair. The overlapping length shall be less than 3/4 of the total length and the inclination angle shall not exceed 3and plain plates shall be placed under the wedge. 每一组垫铁应放置整齐平稳，接触良好；垫铁表面的油污等应清除干净；Each pair of shim plates shall be placed stably in order and in good contact. The plate surface shall be clean up and free of oil, etc. 垫铁组高度宜为30 mm70 mm，每组垫铁块数不宜超过四块；The height of plate units shall be 30mm70mm. The quantity of each plate unit shall not exceed 4 layers. 设备调整后，垫铁应露出设备支座底板外缘1020毫米；垫铁组伸入长度应超过地脚螺栓，且应保证设备支座受力均衡；After the equipment is adjusted, the shim plates sets shall be 1020mm exposed out of the equipment baseplate. The insertion length of each shim plate shall exceed the position of anchor bolts. And the equipment baseplate shall be ensured to bear even force.5.1.8 设备的安装标高以基础上的标高基准线为基准，其允差为5mm，对有安装斜度要求的卧式设备应按设计图样要求进行施工。The installation elevation of equipment shall base on the elevation datum line of the foundation. And the allowable deviation is 5mm. The horizontal equipment requiring installing inclination shall be installed according to the specified drawings.5.1.9 立式设备的垂直度允差为H/1000而且不超过25，H为两测点间距。The allowable verticality deviation of vertical equipment shall be H/1000 and not exceed 25, H is the distance between two measured points.5.1.10 卧式设备的找平使用“U”型塑料管测量筒体四个中心点，以一个中心点为水平基准，分别测量其余3点的相对水平度，并通过垫铁调整水平度偏差。其轴向水平度偏差不超过L/1000，径向水平度偏差不超过2D/1000（L轴向两测点间距，mm；D筒体外径，mm）；horizontal equipment shall be leveled with a U type plastic tube: 5.1.11 设备找正找平后，拧紧地脚螺栓，浇二次灌浆。After leveling and alignment of equipment, the anchor bolts shall be fastened then secondary grouted.5.2 砼基础预埋螺栓设备安装。Installation of equipment of embedded anchor bolts in concrete foundation5.2.1 预埋螺栓连接的设备，找正、找平同上。 The leveling and alignment work of equipment connected with embedded anchor bolts shall be conducted as above.5.2.2 设备的安装标高以基础上的标高基准线为基准，其允差为5mm，对有安装斜度要求的卧式设备应按设计图样要求进行施工。The installation elevation of equipment shall base on the elevation datum line of the foundation. And the allowable deviation is 5mm. The horizontal equipment requiring installing inclination shall be installed according to the specified drawings.5.2.3 立式设备的垂直度允差为H/1000而且不超过25，H为两测点间距。The allowable verticality deviation of vertical equipment shall be H/1000 and not exceed 25, H is the distance between two measured points.5.2.4 设备找正找平后，拧紧地脚螺栓，浇二次灌浆。After leveling and alignment of equipment, the anchor bolts shall be fastened then secondary grouted.5.3 带滑动端的砼基础卧式设备安装 installation of horizontal equipment with sliding end on concrete foundation. 5.3.1 对有滑动要求的设备基础，首先参照设备图和工艺设备布置图找准滑动端；For equipment foundation requiring gliding, sliding end position shall be found out according to the equipment drawings and layout of equipment.5.3.2 滑板厚1520mm，其长度比设备支座底板长度每边长10mm，宽度每边长20mm。The thickness of slide plates is 1520mm. It shall be 10mm longer and 20mm wider than bearing plate of equipment. 5.3.3 根据设备支座长圆孔确定滑动板的开孔位置，且滑动板上的开孔对应设备支座长圆孔中心偏向滑动方向。The holes on the slide plate shall be opened according to the long-round hole on equipment bearer. 5.3.4 将滑动板套在地脚螺栓上，找准设备基础面标高后，与地脚螺栓焊接固定，顶部要磨平，并且在滑动端和设备底座之间涂抹黄油，然后将地脚螺栓埋入设备基础中预留孔内，再次找准滑动板的基础标高，二次灌浆抹面固定，滑动端的螺栓应松23个丝扣，使设备达到滑动要求。5.3.5 设备找平及找正要求同上。The leveling and alignment work of equipment shall be conducted as above. 5.4 静设备安装允许偏差见附表4 Allowable installation deviations of static equipment pls see table 4附表4 table 4检查项目 item静设备安装允许偏差（mm）allowable installation deviations of satic equipment(mm)一般设备 commom equipment与机械设备衔接设备 equipment linking with machine立式 vertical 卧式 horizontal 立式vertical卧式horizontal中心线位置 positon of centerlineD2000，5D2000，10533标 高elevation55相对标高3 relative elevation相对标高3 relative elevation水 平 度 levelness轴向，L/1000 axial direction径向，2D/1000Radial direction轴向，0.6L/1000 axial direction径向，D/1000 Radial direction铅 垂 度 verticality H/1000且30H/1000方 位zimuth沿底座环圆周测量measuring around the baseplate circleD2000，10D2000，15沿底座环圆周测量5measuring around the baseplate circle6 设备的二次灌浆 secondary grouting of equipment6.1设备经初步找平与找正后，进行地脚螺栓预留孔的灌浆。地脚螺栓孔灌浆料如图纸上有特殊要求的按图纸要求施工，无要求的灌浆用细石混凝土，标号应比基础砼高一级，且一次灌浆至基础毛面高度，不得分次灌浆，并捣固密实，不得使地脚螺栓歪斜。After primary leveling and aligning of equipment, pre-set holes of anchor bolts shall be grouted. Grout material shall be in accordance with drawings if there is special requirement and fine aggregate concrete if without requirement. Its concrete grade shall be one class higher than that of foundation. The grouting shall be performed continuously to the position of foundation surface without pause. Then the cement shall be tamped and filled to every corner without anchor bolts deflecting. 6.2混凝土强度达到设计强度75%以上时，方能进行设备的最终找正、找平及紧固地脚螺栓，设备安装精度经检查合格，填写隐蔽工程记录进行二次灌浆。When the concrete reach 75% of specified strength, the final leveling and aligning work shall be conducted and the anchor bolts shall be fixed. Hidden construction shall be recorded and secondary grouting shall be performed after installation passes examination. 6.3 基础二次灌浆前，表面应用水润透，基础表面的积水应用棉布浸干。浆应一次完成捣实，不容许有空洞等缺陷。灌浆应符合现行国家标准钢筋混凝土工程施工及验收规范的规定。Before secondary grouting, the surface shall be wetted with water, the accumulated water shall be dried with cotton fabric. Cement shall be one-step tamped and filled to all the voids. Grouting job shall comply with recent national standard (construction and acceptance specification of reinforced concrete engineering)6.4 图纸上有特殊要求的灌浆料，浇注时要按其说明书的要求执行。For the grout material specified in drawing, it shall be performed as per instruction when grouting.7 附属构件与内件的安装 installation of attached and internal parts 7.1 填料塔、分离器上的填充物的支承件应牢固平整、支承圈在300mm弦长上的表面局部不平度不得超过1mm。The bearers for filler on packing tower and separator shall be reliable and level. The inclination of bearer shall not exceed 1mm against 300mm chord.7.2 内件安装前，应清点零件的数量，清除其表面上的油污、铁锈、泥沙及其它污物，并标注序号。After internal parts installing, accessories shall be counted clearly, then cleaned of oil, rust, soil and other dirt on the surface.7.3 填料应在设备清洗、试压完毕后装填，填充应均匀，高度应符合设计要求，填料在装填前，应清洗干净，并吹干。Filler shall be filled evenly after cleanout and pressure test of equipment. The height shall meet the specification. 7.4 对拆卸检查的设备，其垫片密封面应采取保护措施，以防损坏，密封面应保持光洁，无机械损伤，无径向划痕，无锈蚀和焦油残迹等缺陷。受压法兰重新安装时，需更换新垫片。The sealing surface of plates shall be well kept from damage when checking and disassembling the equipment. The sealing surface shall be smooth and clean and free of mechanism injury, radial nick, corrosion, tar residue and other defect. The plates shall be replaced by new one when pressure flange is rebuilt.8 安全质量技术措施及文明施工 HSE assurance measures and civilized construction项目经理 project manager8.1 施工全过程建立质量保证体系，保证吊装施工优质、高速、安全。项目质量保证体系如下图：Quality standards shall be complied during the whole construction to guarantee quality, speed and security of lifting construction. Quality standard system is as below: 项目总工 general project manager质量工程师 quality engineer安全部 safety department工程部 project department各施工队 construction group材料组 material department电焊组 welder技术组 technical personnel起重组 rigger钳工组 fitter 铆工组 riveting 项目经理 project manager项目安全保证体系如下图：project security guarantee system is as below:项目总工程师 general construction managerHSE经理 HSE manager施工经理 construction manager项目部各职能部室负责人 project principal of function department施工队长 construction captain专业技术员 specialized technician专职安全员 specialized safety supervisor作业班组 construction group8.2 现场的每一道工序，都要有书面记录保留下来。Writing record shall be kept for every on-site procedure.8.3 采用A、B、C三级控制点形式，使每一道工序按规范标准执行。A、B、C三级分别得到相应的认可。ABC three-class control system shall be applied to make procedures performed according to specification. A、三方共检 joint check of three parties B、双方共检 joint check of two partiesC、自检 self-check8.4 对上一工序引起的超差，在本工序得到纠正，不许带到下一工序。The deviation caused by last procedure shall be corrected in recent procedure and cannot be left to next one.8.5 每个测量器具都在周检范围之内。Every measuring instrument is in its overhaul cycle. 10 安全保证措施HSE Assurance Measures 总体执行本工程“施工组织设计/质量计划”中“HSE保证措施”中相关措施。本方案特别强调和时细化以下几点。The relevant measures specified in “HSE Assurance Measures” of “Construction Organization Design/Quality Plan” of this