容器安装使用维护说明.doc

Tianchen Chemical Engineering CO., LTDTurkey ETI Soda Project Contract No. BP-T13B03-EQU-15022Volume No. 01 of 02VENDOR DATA BOOKOFV2209c DemisterFORTURKEY ETI SODA PROCESS PROJECTCHINA TIANCHEN ENGINEERING CORPORATIONWUXI SHUANGXIONG GENERAL MACHINERY CO. LTD.CataloguePART 1:GENERAL DESCRIPTION OF THE EQUIPMENT 设备的总体说明 1.1. General description including Buyers specifications and data sheet总体说明包括买方的技术规格书和数据表。 1.2. List of equipment included in the supply 包括在供货范围内的设备表。PART 2:RECOMMENDATIONS FOR STORAGE, HANDLING AND LIFTING 储存，搬运和吊装的建议。2.1. Special precautions for handling prior to erection (1)安装前搬运的特殊防护措施。2.2. Recommendations for storage prior to and during erection安装前和安装期间储存建议。PART 3:ERECTION 安装3.1. List of components to be erected/installed on site现场安装/装配部件清单。 3.2. Detailed erection schedule including assumptions taken into account 设备安装详细进度和估计费用。 3.3. Equipment erection and installation procedures设备安装和装配程序3.4. List of connection points detailing location and dimensions连接点详细位置和尺寸清单。3.5. Electrical terminal wiring diagrams 电气端子接线图。3.6. Details of site assembly and field welds 现场总装和现场焊接细节。3.7. List of special tools for site erection and assembly现场安装和总装专用工具清单。3.8. Procedures for site assembly, level and welding现场总装，水准测量和焊接程序。3.9. Welding specifications for field welds现场焊接，焊接规格。3.10 List of checks and tests to be performed on site在现场完成的检查和测试清单。 3.11 Site testing and acceptance procedures 现场测试和验收程序3.12Procedures for preparation of equipment for commissioning (including calibration ofinstruments) 设备试车准备程序(包括仪表标准).3.13List of work to be performed on site instead of Vendors shop (when required) (如有需要)在现场完成的工作清单。PART 4:START-UP AND OPERATING INSTRUCTIONS 开车和操作说明4.1.General 概论4.2.Principle of Operation 操作原理4.3.Description of the equipment 设备描述4.4.Commissioning and Start-up Instructions 调试和开车说明4.5.Operating instructions 操作说明PART 5:MAINTENANCE INSTRUCTIONS 维修说明5.1.General 概论5.2.Safety instructions 安全说明5.3.Routine Maintenance Instruction 日常检修指导5.4.Plan Maintenance Instruction 定期检修指导5.5.Overhaul Instruction 大修指导5.6. Table of lubricants and equivalents 润滑油表和代用品5.7. Trouble shooting check lists and diagrams 故障点检查清单和图表PART 6:SPARE PARTS AND TOOLS 备品备件和专用工具6.1.Spare Parts List for erection, commissioning and start-up 安装，试车和开车备品备件清单。6.2.Special Tools List 专用工具清单6.3.Spare parts List for 2 years operation二年运转用的备品备件清单。6.4.Mandatory Spare Parts List (if required) 强制的备件清单(如需)。PART 7:MANUFACTURERS DRAWINGS 制造商图纸7.1.List of drawings 图纸清单7.2.Drawings 图纸7.3.Calculation notes 计算书7.4.Charts and technical data 曲线图和技术数据PART 8:PRODUCT QUALITY DOCUMENTS 产品质量文件8.1.Certificate of Quality 产品合格证8.2.Material certificates 材料证明书8.3.Inspection and test reports 检验和测试报告PART 1GENERAL DESCRIPTION OF THE EQUIPMENT TIANCHEN CHEMICAL ENGINEERING CO., LTDTianchen Chemical Engineering CO., LTDTurkey ETI Soda ProjectPART 1: GENERAL DESCRIPTION OF THE EQUIPMENT1.1 General description including Buyers specifications and data sheet Tag No.NameSpecificationQty.Design P. (MPa)Design T. ()Main MaterialWeight（Kg）V2209cDemisterVN=200 L310.5850S304082701.2 Equipment included in the supply According to sheet of 1.1. Tianchen Chemical Engineering CO., LTDTurkey ETI Soda ProjectPART 2RECOMMENDATIONS FOR STORAGE, HANDLINE AND LIFTINGPART2: RECOMMENDATIONS FOR STORAGE, HANDLINE AND LIFTING2.1 Special precautions for handling prior to erection 2.1.1 If the equipment is not being stored, inspect for shipping damage to all protective cover upon receipt at the jobsite. If damage is evident, inspect for possible contamination and replace protective covers as required. If damage is extensive, notify the carrier immediately.2.1.2 When installing, set the equipment level and square so that pipe connections can be made without forcing.2.1.3 Before piping up, inspect all openings in the equipment for foreign material. Remove all wooden plugs, bags of desiccation, and shipping covers immediately prior to installing. Do not expose internal passages of the equipment to the atmosphere since moisture or harmful contaminants may enter the unit and cause severe damage to the system due to freezing and/or corrosion.2.1.4 After piping is complete, if support cradles or feet are fixed to the equipment, loosen foundation bolts at one end of the equipment to allow free movement. Oversized holes in support cradles or feet are provided for this purpose.2.2 Recommendations for storage prior to and during erection2.2.1 Good storage practices are important, considering the high costs of repair or replacement, and the possible delays for items which require long lead times for manufacture. The following suggested practices are provided solely as a convenience to the user, who shall make his own decision on whether to use all or any of them.2.2.2 On receipt of the equipment, inspect for shipping damage to all protective covers. If damage is evident, inspect for possible contamination and replace protective covers as required. If damage is extensive, notify the carrier immediately.2.2.3 If the equipment is not to be placed in immediate service, take precautions to prevent rusting or contamination.2.2.4 The choice of preservation of interior surfaces during storage for other service applications depends upon your system requirements and economics. Only when included in the original purchase order specifications will specific preservation be incorporated prior to shipment from the factory.2.2.5 Remove any accumulations of dirt, water, ice or snow and wipe dry before moving exchangers into indoor storage. If unit was not filled with oil or other preservative, open drain plugs to remove any accumulated moisture, then reseal. Accumulation of moisture usually indicates rusting has already started and remedial action should be taken.2.2.6 Store under cover in a heated area, if possible. The ideal storage environment for equipments and accessories is indoors, above grade, in a dry, low-humidity atmosphere which is sealed to prevent entry of blowing dust, rain or snow. Maintain temperatures between 70F and 105F (wide temperature swings may cause condensation and “sweating” of steel parts). Cover windows to prevent temperature variations caused by sunlight. Provide thermometers and humidity indicators at several points, and maintain atmosphere at 40% relative humidity or lower. PART 3ERECTION INSTRUCTIONPART3: ERECTION INSTURCTION3.1 List of components to be erected/installed on siteThere is no any components to be erected/installed on site, only whole equipment will be installed on site.3.2 Detailed erection schedule including assumptions taken into account Not Applicable3.3 Equipment erection and installation procedures3.3.1 The equipment shall be installed in according with applicable requirements of local authorities. 3.3.2 The equipment shall be installed to the correct levels and vertical lines within the limits agreed by the owner/user. 3.3.3 Foundations shall be adequate to support the equipment and its maximum content.3.3.4 The equipment shall be installed with sufficient clearance from associated structures and equipment to provide safe efficient working by operators and to provide ready access for cleaning.3.3.5 Safety and control devices(if any), shall be located and installed so that they are readily accessible for operation, inspection, maintenance and removal.3.3.6 The equipment must be assembled complete with all its parts included blind flanges and internals(if any) fully assembled to the equipment. The assembly of equipment to its adjacent connections must be done by well trained personnel. The flanged connections must be ensured with gaskets and bolts indicated on the drawing if not already forecast on the supply. For the thread connections must be used special sealing to be chosen according to the operating temperature. It is strictly forbidden to change or modify the bolts of the gaskets or any other accessories supply with the equipment to join the connection. 3.4 List of connection points detailing location and dimensions The details are shown on the assembling drawing.3.5 Electrical terminal wiring diagrams Not Applicable3.6 Details of site assembly and field weldsNot Applicable3.7 List of special tools for site erection and assemblyNot Applicable3.8 Procedures for site assembly, leveling and welding Not Applicable 3.9 Welding specifications for field weldsNot Applicable 3.10 List of checks and tests to be performed on siteNot Applicable 3.11 Site testing and acceptance procedures Not Applicable 3.12 Procedures for preparation of equipment for commissioning (including calibration of instruments)Not Applicable 3.13 List of work to be performed on site instead of VENDOR s shop (when required)Not ApplicablePART 4START-UP OPERATION INSTRUCTIONSPART4: START-UP AND OPERATION INSTRUCTIONS4.1 GeneralThis section describes the brief instruction of the start-up and operating of the equipments supplied by WUXI SHUANGXIONG.4.2 Principle of OperationNot Applicable4.3 Description of the equipment Not Applicable 4.4 Commissioning and Start-up Instructions 4.4.1 Before operating, Qualified personnel should check at least: * Correct position of the equipment; * No material has been left during assembling in the internal of the equipment; * Cleanness of the internal according to the drawing; * All the connections are fully and correct assembled; * All the bolts are correct closed; * The foundation bolts are all in place and correct closed; * All the safety instruments are in place and correct assembled; * No evidence of damage to any parts of the equipment; * Safety devices and alarms are connected on the whole of the equipment.4.4.2 Starting the operating of the equipment must be done according to the plant engineering procedure of the owner.4.4.3 At least at half of the operating pressure a step must be done in order to check the following point by a qualified personnel: Lacks; Correct fasting; Distortion or damage; Safety accessories are well visible and readable.4.4.4 Operating the equipment to proper design date indicated on the nameplate must always be done by a qualified personnel.5 Operating instructions4.3.1 Open vent connections before starting up.4.3.2 Start operating gradually.4.3.3 After the system is completely filled with the operating fluids and all air has been vented, close all manual vent connections.4.3.4 Re-tighten bolting on all gasket or packed joints after the equipment has reached operating temperatures to prevent leaks and gasket failures. Standard published torque values do not apply to packed end joints. 4.3.5 Do not operate the equipment under pressure and temperature conditions in excess of those specified on the nameplate. 4.3.6 To guard against water hammer, drain condensate from steam equipments and similar apparatus both when starting up and shutting down. 4.3.7 Drain all fluids when shutting down to eliminate possible freezing and corroding. 4.3.8 In all installations there should be no pulsation of fluids, since this causes vibration and will result in reduced operating life. 4.3.9 Under no circumstances is the equipment to be operated at a flow rate greater than that shown on the design specifications. Excessive flows can cause vibration and severely damage the equipment tube bundle.4.3.10 Equipments that are out of service for extended periods of time should be protected against corrosion as described in the storage requirements for new equipments. Equipments that are out of service for short periods and use water as the flowing medium should be thoroughly drained and blown dry with warm air, if possible. If this is not practical, the water should be circulated through the equipment on a daily basis to prevent stagnant water conditions that can ultimately precipitate corrosion.PART 5Maintenance InstructionsPART5: Maintenance Instructions5.1 General5.1.1 The maintenance of the equipment shall always be done by the qualified personnel.5.1.2 Do not remove all the covers or bonnet until pressure in the equipment has been relieved complete.5.1.3 Since many of the remove component of the equipment, particularly in the equipment sizes, are too heavy for people to handle, care must be used to take this weight with proper rigging to avoid injury. Wear hard hats and safety shoes as require.5.1.4 When the equipment is cleaned, it is possible that full characteristics of the fouling material and the clearing agent be known and care exercised in handing them according to instruction. Use eye protection to prevent damage to your eyes. Wear a respirator when required.5.1.5 Do not blow out equipment with air when the normal process fluids or the clearing fluids being handled are inflammable.5.2 Safety instructionsSee 5.1 5.3 Routine maintenance instructionThe maintenance personnel shall do the patrol inspection according to inspect regulation, take actions to eliminate the equipment faults. If the faults can not be eliminated, the personnel shall report it to the director.5.4 Plan Maintenance instruction5.4.1 The periodic inspection shall be done according with the inspection interval.5.4.2 Decide whether to repair or not according to the inspection results.5.4.3 If the equipment is needed to be repaired, a reasonable scheme shall be generated and executed by the experienced personnel.5.4.4 The re-inspection shall be done after maintenance to assess the security situation of the equipment.5.5 Overhaul Instruction See 5.4 5.6 Tabl