上海石化90万吨_年乙烯装置工程静设备及其内件安装方案(双语)

SINOPEC TCC上海石化90万吨/年乙烯装置工程静设备及其内件安装方案目 录一工程概况2I. Engineering General二执行的标准、规范2II. Applied standards and specifications三服务内容3III. Service Contents四施工方法4IV. Construction methods五需求量计划34V. Material and Equipment Demand Plan六HSE控制计划38VI. HSE Control Plan七.附主要静设备安装明细表40VII. Attached Main Static Equipment Installation Break Down List八静设备安装施工质量控制点44.The quality control points of static equipment installation一 .工程概况I. Engineering General 上海赛科90万吨/年乙烯工程，标2中静设备共198台。其中，容器52台，最重容器（丙烯冷剂压缩机一段吸入罐）115.451吨；塔10台，最重塔也是最高的塔（丙烯精馏塔No.2 ） 1430.894吨，97m；反应器13台，最重反应器（乙炔转化器）106.934吨；换热器104台；冷箱1台120吨；干燥器3台；其它静设备15台。There are totally 198sets of static equipment in second tending section of Shanghai SECCO 900KT/Y ethylene project, which including 52 sets of vessels and the heaviest vessel 115.451t ( Stage one suction tank of propylene cool air compressor), 10 sets of towers and the heaviest and highest is 1430.894t and 97m (Propylene fractionating tower); 13 sets of reactors and the heaviest is 106.934t (Acetylene converter); 104 sets of exchangers, one set of 120t cold tank, 3 sets of dryers and 15 sets of other static equipment.二 .执行的标准、规范II. Applied standards and specifications1. 施工图及其它设计技术文件。Construction drawings and other design technical documents 2. 工程专题会议纪要。Engineering special topic meeting minutes3.中低压化工设备施工及验收规范 （HGJ209-83）。Construction and acceptance specification of middle and low pressure chemical industrial equipment （HGJ209-83）4.化工塔类设备施工及验收规范 （HGJ211-85）。 Construction and acceptance specification of chemical towers equipment （HGJ211-85）5.塔盘技术条件 （JB1205-80）。Technical requirements for trays （JB1205-80）6. 施工组织设计中对施工技术措施、施工方法所做出的规定。Construction technical methods and measures specified by Construction Execution Plan 7. 施工现场条件。Construction Site Conditions8. 机具装备条件。Machinery Equipment and tools conditions三 服务内容III. Service Contents 198台静设备及其中部分内件安装。设备开孔检查，图纸或甲方要求的试压，人孔封闭。同步提供安装记录、隐蔽记录、试压记录及竣工资料。To install 198 sets of static equipment and internal components, to open equipment hole for inspection, to carry out pressure tests required by drawings or by clients, to close out manholes and at the same time to provide installation records, covered works records, pressure tests records and work completion documents.四 施工方法IV. Construction methods 1 静设备安装施工方法Static equipment installation methods A 施工准备 Construction preparation a. 施工人员必须在施工前充分了解本工程的施工内容，明确设备结构特点及内件安装的特殊要求。 Constructors shall fully know about the construction contents of this works and understand the characteristics of equipment structures and special requirements of internal components installation. b. 核对设计总图上注明内容是否齐全；同时核对设备的规格、重量、型号、工艺位号，并核对基础与设备的方位、标高、几何尺寸。自审合格后，应与相关专业（工艺、仪表等）配合审查管口数量、规格、方位、标高是否与其他专业施工图纸相符。 Check and find out whether the notes on designed drawings is complete; meanwhile check the specifications, weights, models, location Nos. of equipment and review the foundation locations, elevations and geometry dimensions relevant to equipment. When self-inspection results are in accordance with requirements, to check pipe nozzles quantities, specifications, locations and elevations with other relevant disciplines (processing, instruments etc.) to make sure they are in accordance with other discipline construction drawings. c. 准备好安装用垫铁及其它一些安装辅助用料。 Make preparation for sizing blocks and other auxiliary materials needed during installation B 静设备验收Acceptance of static equipment a. 到货的塔器、反应器、容器、换热器、冷箱及其附件，必须符合设计要求，并附有出厂合格证明书、竣工图等技术文件。 All delivered towers, reactors, vessels, heat exchangers, cold tanks and their components must be in accordance with design requirements and technical documents such as qualification certificates an completion drawings shall be attached with delivery. b. 检查清点时，应有各方人员同时参加，对照装箱单及图样进行核查、验收、交接，具体项目及要求如下： All parties shall be present in the inspection and acceptance and handing over procedures, which shall be done with packing lists and drawings. The detailed items and requirements are as following: 设备本体外形尺寸及管口方位是否正确。管孔、人孔等应封闭。To check equipment external dimensions and nozzle positions to be sure they are correct. Pipe holes and manholes shall be close outed. 设备上预焊件是否符合图纸要求。The pre-welded items on equipment shall be in accordance with drawing requirements. 设备内件及附件的规格、尺寸及数量是否齐全，验收后应分类由专人管理。易损件及零星部件应拆除，进行专门保管。The internal components specifications, dimensions and quantities shall be complete and they shall be categorized and managed by responsible person. Wearing parts and scattered parts shall be removed and kept specially. 表面损坏、变形及锈蚀状况是否超标。Surface damage, deformation and corrosive status shall not be over than specified scope. 立式设备上安装方位线、卧式设备安装找平基准线是否画上。Installation location reference lines of vertical equipment and levelness reference lines of horizontal equipment shall be marked. 检查、清点后应作好验收签证。Acceptance issue shall be made after inspection and quantities check. C 基础验收 Foundation acceptance 基础验收前，必须有基础施工单位提交的基础竣工技术资料。验收时， 由监理、安装、土建三方参加，验收标准如下：Foundation completion technical documents shall be handed over for acceptance. Three parties of CMC, installation and civil construction shall be present in acceptance inspection. a. 基础上应明显的画出标高基准线，纵横中心线，相应的建筑（构筑）物上应标有坐标轴线。Elevation reference line, horizontal and vertical center lines on foundation shall be marked out and coordination line on corresponding structures shall be marked out. b. 基础外观不得有裂纹、蜂窝、空洞及露筋等缺陷。 No defects such as cracks, honeycombs, air holes and bar exposed shall be found on foundation surface. c. 基础混凝土强度应达到设计要求，周围土方应回填、夯实、整平，预埋地脚螺栓的螺纹部分应无损坏，螺纹部分应涂少量油脂。Concrete strength of foundation shall reach to the design requirements. Ground around foundation shall be backfilled, tamped and leveled. The threads of embedded anchor bolts shall be undamaged and part of them shall be greased. d. 基础表面应修整，需灌浆抹面的基础表面要铲好麻面，基础表面不得有油垢及疏松层；放置垫铁处应铲平，铲平部位水平度允差为2 mm/米，预埋地脚螺栓孔内的杂物应清除干净。Foundation surface shall be finished. Foundation surface that grouting is required shall be preparation by shoveling and no oil dirty and loose layer shall be found on surface. Where prepared for sizing blocks shall be shoveled level with 2 mm/m allowable levelness tolerance. Inside hole of embedded bolts shall be cleaned. e. 地脚螺栓各部分的尺寸应符合图纸要求。The overall dimensions of anchor bolts shall be in accordance with drawing requirements. f. 钢梁基础或钢结构支座也要按设计要求验收。Steel beam foundation or steel structures supports shall be accepted according to design requirements. g. 基础各部尺寸及位置的偏差数值不得超过表一的规定。The deviation of foundation dimensions and locations shall not out of the scope specified by sheet I. 表一 基础各部尺寸及位置的偏差数值表： Sheet I Allowable tolerance of foundation overall dimensions and locations 项目Item偏差名称Description允许偏差值（mm）Allowable tolerance (mm)1基础坐标位置（纵、横轴线）Foundation coordination ( Vertical and horizontal axis line)202基础各不同平面的标高Elevations of various foundation levels 0- 203基础上平面的水平度： Foundation surface levelness: 每米 per meter 全长 Full length 5104竖向偏差： Longitudinal tolerance每米 Per meter全长 Full length 5205预埋地脚螺栓： Embedded anchor bolts:顶端标高Top elevation在根部和顶部两处测量中心距Center distances measures at both top and root0+2026预埋地脚螺栓孔:Embedded anchor bolt hole： 中心位置Center location深度 Depth孔壁垂直度Verticality of hole wall100+2010 D 设备吊装就位准备 Preparation for equipment lifting a. 核实管口方位，找出有代表性的管口作为安装就位时的方位标记。 Review orientation of nozzles, find a representational nozzle as an orientation reference for installation. b. 地脚螺栓上的油脂和污垢应清除干净。Grease and dirt on anchor bolts shall be cleaned. c. 在验收合格的基础上按要求预置垫铁组，它的放置应符合下列要求：Place sizing block groups on acceptance basis, which shall be in accordance with the following requirements: 每个地脚螺栓两侧至少有一组垫铁，且应尽量靠近地脚螺栓。 At least one group of sizing blocks shall be placed on both sides of each anchor bolts as near to anchor bolts as possible . 有加强筋的底座，垫铁应垫在加强筋下面。 As for bottom support with reinforcement, sizing blocks shall be placed under reinforcement . 每组垫铁均应放置整齐平稳，接触良好。Each sizing blocks shall be placed stable and smoothly contacted. 保证各垫铁组的上表面基本上在一个水平面上。To make sure that all top surfaces of each group sizing blocks shall be in the same level. 垫铁表面的油污等应清除干净。Grease on surface of sizing blocks shall be cleaned.d. 如果是预留地脚螺栓孔，应检查孔内不得有异物和积水。 Water and things in spared anchor bolt hole shall be cleaned. E 设备就位 Lifting equipment in position a. 设备就位时，各工种应密切配合，慢吊轻放，注意保护地脚螺栓丝扣。All workers shall corporate with each other to lift equipment, which shall be done slowly and stably. Pay attention that anchor bolts threads shall not be damaged. b. 吊装时设备的接管或附属结构不得因绳索的压力或拉力而受到损伤。 Pipe joints or accessories of equipment shall not be damaged by stress of slings while lifting equipment. c. 就位后应注意保证设备的稳定性。 Equipment stability shall be assured when they are lifted in position. F 设备找正、找平Equipment spotting, centering and leveling a. 静设备找正与找平的测点宜在下列部位选择:It is suitable to select the measurement points of equipment spotting, centering and leveling from the following positioin: 主法兰口、水平或铅垂的轮廓面。Main flange opening, horizontal or vertical contour surfaces 其他指定的基准面或加工面。Other specified datum level or machined surfaces. b. 静设备找正、找平应符合下列规定:Static equipment spotting, centering and leveling shall be in accordance with the following specifications: 设备地脚螺栓预留孔灌桨的，混凝土强度达到设计强度75%以上时，方能进行设备最终找正或找平及紧固地脚螺栓的工作。For the spared anchor bolt holes with grouting required, only when the concrete strength is higher than 75% of design strength, can the finally equipment spotting, centering and leveling work be done. 找正找平应在同一平面内互成直角的两或两个以上方向进行。Spotting, centering and leveling shall be done along two or more than two directions being vertical to each other in the same plane. 高度超过20m的立式设备，为避免气象条件影响，其铅垂度的调整和测量工作应避免在一侧受阳光照射及风力大于4级的条件下进行。For vertical equipment with height over than 20m, its verticality adjustment and measurement shall not be done under conditions with sun burning at one side and wind over than grade 4 静设备找正找平时，应根据要求用垫铁（或其他专用调整体）调整，不应用紧固或放松地脚螺栓及局部加压等方法进行调整。Sizing blocks (or other special auxiliary materials) shall be used for static equipment spotting, centering and leveling according to requirements. It is forbidden to adjust by screwing anchor bolts and adding stress on local parts. d. 采用垫铁找正或找平时，应符合下列规定：The following regulations shall be followed when sizing blocks are adopted for adjustment. 垫铁组应使用成对斜垫铁，搭接长度应不小于全长的3/4，斜垫铁下面应有平垫铁。Sizing blocks shall be used by pairs with connection length not less than 3/4 of total length, flat sizing blocks shall be used under inclined ones. 应尽量减少每组垫铁的块数，一般不超过四块，并应少用薄垫铁，放置平垫铁时，最厚的放在下面，最薄的放在中间。To reduce numbers of each group sizing blocks as can as possible, generally it shall be not over than four blocks and thin sizing blocks shall not be used as possible. To place flat sizing blocks, the thickest shall be placed on bottom and the thinnest shall be placed on middle layer. e. 设备找正或找平后，应满足下列要求：Equipment shall be in accordance with the following requirements after they are spotted, centered and leveled. 平垫铁应露出支座底板外缘10至20mm，垫铁组伸入长应超过地脚螺栓，且应保证支座受力均衡，各组垫铁均应被压紧。每组垫铁各块垫铁之间互相点焊牢固。Flat sizing blocks shall be extended out of bottom plate edge for 1020mm, the extension length shall be over than length of anchor bolts and sizing blocks shall be under even stress. Each of them shall be pressed tightly and spot welded reliably. 螺母与垫圈，垫圈与设备底座间的接触应良好，螺母上端螺纹部分应露出2个螺距。Contacting between nuts and gaskets, gaskets and equipment base shall be fine. Two screw pitches shall be exposed out on top of nuts. 地脚螺栓上一般应配二个螺母和一个垫圈，地脚螺栓的紧固应均匀对称。紧固地脚螺栓后，静设备安装的主要偏差见表二。Two nuts and one gasket shall be matched for one anchor bolts. Screwing of anchor bolts shall be even and symmetry. With anchor bolts screwed, main installation tolerance of static equipment see sheet II. 表二 静设备安装的主要偏差表： Sheet II Main Installation Tolerance of Static Equipment 检查项目Inspected items允 许 偏 差(mm)Allowable tolerance (mm)立 式Vertical type卧 式Horizontal type中心线位置Location of center line105标 高Elevation55水平度Levelness-轴向L/1000Axial L/1000径向2D/1000Radial 2D/1000铅垂度VerticalityH/1000但不超过30H/1000 but not over than 30-方 位Orientation沿底座环圆周测量Measure circling equipment base- G 二次灌浆Second groutinga. 二次灌浆前应满足下列条件：The following requirements shall be met before second grouting 设备安装精度经检查合格。Equipment installation accuracy is inspected and accepted. 隐蔽工程记录完备。Records of covered works are complete. 环境温度低于0C时，应有防冻措施。Ambient temperature shall be lower than 0C and precaution measures shall be taken. 灌浆前，灌奖处应用水清洗洁净并润透，积水应吹净。Before grouting, the place shall be cleaned and fully wetted with water, deposit water shall be blasted off. 灌浆前，宜安设外模板。It is suitable to set outer module plates before grouting.b. 二次灌浆注意事项：Pay attention to the following items for second grouting: 灌浆混凝土标号应比基础混凝土标号高一级。Grouting concrete tab shall be higher than foundation concrete tab for one grade. 灌浆时，应捣固密实。Concrete shall be tamped to dense during grouting. 混凝土养护期间，当环境温度低于5C时，应有防冻措施If the ambient temperature is lower than 5C during concrete curing period, weatherproof measures shall be taken. H 换热器试压Pressure tests heat exchangers 换热器试压与否按业主要求，如果试压，其试验压力、介质应按设计要求而定；由于设备在制造厂里已经作过强度试验，施工现场不宜反复试验，一般仅作严密性试验，严密性试验可采用气密，具体按业主要求。Pressure tests heat exchangers shall be done according to clients requirement. If it is required, the testing medium shall be selected according to design requirements. Considering that strength tests of equipment has been carried out in workshop, it is not suitable to re-test. Generally, only airproof test is required and gas shall be adopted as medium, which shall be defined by requirement of client. I 设备清洗与封闭 Equipment cleaning and close outing 静设备安装内件、安装填料或封闭前均应进行清扫、冲洗或吹扫工作。奥氏体不锈钢静设备用水进行冲洗后，应将水渍去除干净，当无法达到这一要求时，则应控制用水的氯离子含量不超过25PPm。Static equipment shall be cleaned by blasting or washing. As for static equipment made by austenite stainless steel, water shall be completely cleaned off after washing. If it is impossible to meet this requirement, the content of chloride ion shall not over than 25PPm.a. 吹扫要求：Requirement for blasting 吹扫介质可用空气或蒸汽。吹扫用的气体应清洁，忌油设备的清扫气体不得含油。对因热膨胀可能影响安装精度或损坏构件的静设备不得用蒸汽吹扫。Air or steam shall be used for blasting and it shall be clean. Blasting air used on oil- avoiding equipment shall be free of oil. If the installation accuracy of static equipment will be affected by heat expanding, steam shall not be used for blasting. 吹扫气体进口压力不得高于静设备工作压力，进出口压力表不得超过设计图样或技术文件的规定值。Inlet pressure of blasting air shall not over than working pressure of static equipment. Inlet and outlet pressure values shown on pressure gauges shall not over than specified values on design or technical documents. 设计图样或技术文件规定不能进行吹扫的部位不应吹扫。If it is required by design or technical documents that blasting shall not be applied on some parts of equipment, it shall be followed. 吹扫时，在距离气体出口150-200mm处，放置白滤纸或白布检查，如纸或布上无油点、灰尘、污物等即为合格。White filter paper or white cloth shall be put on 150-200mm away from air exit, if no oil dot, dust or dirt on paper or cloth is found, it is proved to be qualified.b. 封闭要求：Requirements for closing of equipment 经单体试验合格，表面处理，脱脂、吹洗、清理合格后或原已封闭但又经启封的，均应进行封闭。After testing, surface treatment, degreasing, blasting and cleaning up, equipment shall be closed. If the original closing is opened, it shall be closed again. 有内件安装要求的，内件安装合格后方能进行设备最终封闭。If internal components installation is required, equipment shall be closed after internal components are installed. 每次封闭时必须由施工、检查及监督人员共同检查，确认无问题后，方可封闭。It shall be reviewed and inspected by constructors, inspectors and supervisors together before closing, which shall be done with confirmation. 填写“设备清理、检查、封闭记录”。Fill out Equipment Cleaning, Inspection and Closing Records” 2 静设备安装施工流程见图一：Static Equipment Installation Flow Chart see Chart I:设备找正Equipment spotting and centering 内件安装Internal Components Installation 二次灌浆Second grouting清洗吹扫Washing, blasting检查封闭Inspect and close 图纸会审Drawing review施工机具准备Construction tools preparation 基础验收Foundation Acceptance 设备验收Equipment Acceptance交工验收Hand over for acceptance 图一 静设备安装施工流程图Chart I: Static Equipment Installation Flow Chart3 . 塔盘安装施工方法Tray installation methods A 塔盘安装准备 Preparation for tray installation a. 熟悉塔内件装配图，了解每层塔盘特点、按塔盘不同规格分类，给 每种规格塔盘列一件号表。 Get familiar with the tower internal components assembly drawing and know about the characteristics of each floor trays. Classify trays according to different specifications and make a part No. list for each specified tray.b. 准备工具。Installation tools preparation B 塔内件验收及在安装现场的保管: Acceptance of tower internal components and keeping on installation site a. 制造商交予安装的塔内件必须符合设计要求并附有质量合格证及安装说明书。 The tower internal components delivered by manufacturer shall be in accordance with design requirements and attached with qualification certificate and installation manual. b. 检查内件