VC-空冷凝汽器安装指导书-INSTRUCTION FOR THE ERECTION OF AIR COOLED CONDENSING SYSTEM.doc

空冷凝汽器安装指导书INSTRUCTION FOR THE ERECTION OF THE AIR COOLED CONDENSER空冷凝汽器安装指导书INSTRUCTION FOR THE ERECTIONOF THE AIR COOLED CONDENSER项 目 名 称PROJECT NAME印度维柯拉姆2X23MW热电厂EPC工程2x23MW TPP EPC PROJECT FOR VIKRAM CEMENT,INDIA合 同 号CONTRACT NO.CMEC-2006-C5-12-CT-EP-004主 合 同 号MAIN CONTRACT NO.CMEC-2005-C5-12-1业 主OWNER印度哥拉斯姆工业公司GRASIM INDUSTRIES LIMITED供 应 商 : 中国机械设备进出口总公司SUPPLIER: CHINA NATIONAL MACHINERY & EQUIPMENTIMPORT & EXPORT CORPORATION.制 造 厂 : 无锡东盛石化装备有限公司MANUFACTURER: WUXI DONGSHENG PETROCHEMICAL EQUIPMENT CO.,LTD.摘要 SUMMARY1. 介绍 INTRODUCTION1.1 概述 General1.2 适用的设计图纸清单Overall list of the applicable design drawings2. 空冷凝汽器安装指导 INSTRUCTIONS FOR THE ERECTION OF ACC2.1 概述 General2.2 安装作业程序 Sequences of erection work2.3 基础检验 Checking the foundation2.4 钢结构安装Structure erection2.5 轴流风机系统安装 Fan system erection2.6 管束吊装和焊接 Lifting and welding of bundles2.7 蒸汽分配管道和不凝汽出口汇集管安装和焊接Steam distribution pipe, Non-condensing steam outlet pipe erection and welding2.8冲洗装置安装 Cleaning system erection2.9 挡风墙安装 Wind wall erection1. 介绍 INTRODUCTION空冷凝汽器的主要设备有以下几个部分组成:ACC are composed of some main equipments, such as:-顺流管束/逆流管束 Condenser Bundle/Dephlegmator Bundle-轴流风机系统 Fan Systema) 风机 Fanb) 减速机 Fan Reducer(Gearbox)c) 电机 Motord) 导风筒 Fan Ringe) 风机桥 Fan Bridgef ) 鸟网 Bird Screen-钢结构 Steel Structurea) 基础预埋螺栓和预埋钢板 Foundation Bolt, Insert Plateb) A架 A-Framec) 挡风墙 Wind Walld) 平台,栏杆,梯子 Platform, Handrail, Ladder-蒸汽分配管道和不凝汽出口汇集管Steam Distribution Pipe, Non-condensing Steam Outlet Pipe-冲洗装置 Cleaning Systema) 冲洗水泵 Water Pumpb) 电机 Motorc) 冲洗装置 Cleaning SystemACC外形轮廓可参见下列图片:ACC Outline please see look at the photos below1.1 概述 General1.1.1 本文件是关于空冷凝汽器（以下简称ACC）的安装指导说明文件。This document explains the instructions relating to the erection of the air cooled condenser (ACC) equipment. 1.1.2 假如未遵循本指导书进行安装，随之而产生的问题，无锡东盛石化装备有限公司（以下简称无锡东盛）将不承担责任。Should these instructions about the erection not be complied with, this would imply that Wuxi Dongsheng Petrochemical Equipment Co.,Ltd. (WXDS) should not be held responsible for any subsequent problem.1.1.3 同样地，在设备现场安装和调试的过程中出现问题时，安装单位、买受人与或最终用户将得到无锡东盛服务部门或现场指导人员（当无锡东盛提供现场指导时）的书面答复。Likewise, should any specific point be a problem during the erection and the start-up of the equipment, the fitter, the prime contractor and/or user, according to the case, will get a written answer from the Service Department of WXDS or from the supervisor.（when WXDS provides a field supervision for these operations）1.1.4 现场安装作业应由有经验的人员来履行,安装人员的技术水平是保证由无锡东盛提供的装置得以正确安装和良好运行的主要因数。The erection operations will be performed by a skilled staff. The skill level of the staff in charge is a major parameter to ensure a proper assembly and a good operation of the unit delivered by WXDS.1.1.5 相反地,由于不正确的安装或任何随之而引起的相应的损坏,无锡东盛将不承担任何责任。In the contrary case, WXDS cant be held responsible for the problems which could arise from a erroneous assembly, or any related consequential damages.1.2 适用的设计图纸清单Overall list of the applicable design drawings相应的ACC现场安装所需的设计图纸清单如下，图纸上的要求须遵循。All the design drawings corresponding to the erection of ACC are listed as below, and must be comply with the requirements of drawings.无锡东盛石化装备有限公司Wuxi Dongsheng Petrochemical Equipment Co.,Ltd.图 纸 清 单DRAWING LIST序号SL.No.图 纸 名 称DRAWING NAME图 号DRWING No.1空冷凝汽器总体布置图GENERAL ARRANGEMENT OF AIR COOLED CONDENSERIND25.03.002空冷凝汽器柱脚载荷图AIR COOLED CONDENSER LOAD DATA-COLUMNIND25.03.013空冷凝汽器10.5m平台载荷分布图AIR COOLED CONDENSER LOAD DATA ON 10.5m FLOORIND25.03.024空冷凝汽器A架,挡风墙,风机桥与平台连接图INSERT DETAILS FOR A-FRAME,WIND WALL & FAN BRIDGEIND25.03.034.1A架地脚螺栓详图A-FRAME FOUNDATION BOLT DETAILIND25.03.03.014.2挡风墙地脚螺栓详图WIND WALL FOUNDATION BOLT DETAILIND25.03.03.024.3风机桥基础底板详图FAN BRIDGE INSERT PLATE DETAILIND25.03.03.034.4A架基础底板详图A-FRAME INSERT PLATE DETAILIND25.03.03.045空冷凝汽器风筒与平台连接图FAN RING & BIRD SCREEN FIXING ASSEMBLYIND25.03.045.1风筒与基础预埋件和连接螺栓详图INSERT PIPE & CONNECTION BOLT DETAIL OF FAN RINGIND25.03.04.016顺流管束总装配图CONDENSER BUNDLE GENERAL ASSEMBLYIND25.C3.007逆流管束总装配图DEPHLEGMATOR BUNDLE GENERAL ASSEMBLYIND25.D3.008.1A架装配图柱脚AA-FRAME FILE AIND25.A3.11118.2A架装配图柱脚BA-FRAME FILE BIND25.A3.11128.3A架装配图柱脚CA-FRAME FILE CIND25.A3.11138.4A架装配图柱脚DA-FRAME FILE DIND25.A3.11148.5A架装配图柱脚ABSECONDARY A FRAME BETWEEN A&BIND25.A3.11158.6A架装配图柱脚BDSECONDARY A FRAME BETWEEN B&DIND25.A3.11168.7A架装配图侧面图A-FRAME ASSEMBLY-SIDE VIEWIND25.A3.11179.1风机桥总装配图（两侧）FAN BRIDGE GENERAL ASSEMBLY（SIDE）IND25.B3.00s9.2风机桥总装配图（中间）FAN BRIDGE GENERAL ASSEMBLY（MIDDLE）IND25.B3.00m10.1蒸汽分配管装配图STEAM DISTRIBUTION PIPE GENERAL ASSEMBLYIND25.P3.0010.2不凝气出口汇集管NONCONDENSING STEAM OUTLET PIPE DETAILIND25.P3.0111.1检修平台梯子总装配图PLATFORM & HANDRAIL & LADDER 1IND25.M3.113011.2检修平台梯子总装配图PLATFORM & HANDRAIL & LADDER 2IND25.M3.113112.1挡风墙装配图近柱脚AWIND WALL NEAR TO FILE AIND25.W3.124012.2挡风墙装配图近柱脚DWIND WALL NEAR TO FILE DIND25.W3.124112.3挡风墙装配图近柱脚5WIND WALL NEAR TO GRID 5IND25.W3.124212.4挡风墙装配图近柱脚3WIND WALL NEAR TO GRID 3IND25.W3.124313冲洗装置总布置图CLEANING SYSTEM GENERAL ARRANGEMENTIND25.L3.0014冲洗装置电气控制图CLEANING SYSTEM CONTROL BOXIND25.L3.0115冲洗装置水泵基础及外形图CLEANING SYSTEM PUMP GENERAL ARRANGEMENTIND25.L3.0215.1冲洗装置地脚螺栓详图CLEANING SYSTEM PUMP FOUNDATION BOLT DETAILIND25.L3.02.0116风机防护网总装配图FAN BIRD SCREEN GENERAL ASSEBMLYIND25.S3.0017风机总装配图FAN ASSEMBLY18风筒总装配图FAN RING ASSEMBLY19减速机总装配图FAN REDUCER ASSEMBLY2. 空冷凝汽器安装指导 INSTRUCTIONS FOR THE ERECTION OF ACC2.1 概述 General2.1.1钢结构的安装、验收应符合GB50205-95钢结构工程施工及验收规范、图样技术要求及本文件的规定。The erection and acceptance of the steel structure shall meet with GB50205-95 “Code for Construction and Acceptance of Steel Structural Engineering” and technical requirements in the drawings and specifications in the Instructions.2.1.2安装前，应按照图纸中构件明细表、箱件清单和装箱单核对进场的构件。凡有标记或编号的构件在现场组装时应按标记或编号进行。Prior to the erection, the components delivery to the site shall be checked according to the detailed table in the drawings, General Packing Lists and Packing Lists. Any components with marks or numbers shall be assembled according to the marks or numbers in the field assembly.2.1.3钢结构安装前，应对各独立构件进行检查，对偏差（因运输及吊装等引起的）超过图样或有关标准规定的构件应予以矫正。Prior to the erection of steel structure, each independent components shall be checked and any components whose deviation is more than what is specified in the drawings or by the relevant standards (resulting from transportation and lifting) shall be corrected.2.1.4构件的安装程序，应根据图样技术要求及本文件的规定进行，必须确保结构的稳定性和不导致永久性的变形；构件安装宜采用扩大拼装法和综合安装法进行，尽量在地面预先焊接或拼装好。The erection procedures of steel structure shall be carried out in accordance with the technical specifications in the drawings and specifications in the Instructions. The steadiness in steel structure shall be ensured in the erection and the steel structure shall be prevented from permanent deforming. The step-by-step and comprehensive procedures are preferably adopted in steel structure erection and the components shall be welded and jointed in advance before erection to the maximum extent.2.1.5在现场组装、焊接等的质量要求均应符合GB50205-95及本文件的规定。The quality regarding field assembly, welding, etc. of the components shall meet the requirements in GB50205-95 and specifications in the Instruction.2.1.6钢结构在运输和安装过程中损坏的涂层部分以及现场安装连接处，应在构架安装完毕后补涂环氧富锌防锈底漆二度和银粉面漆一度(油漆等不属无锡东盛提供范围）。The damaged coated part of the components in the course of the transportation and erection, and the joints in field assembly shall be coated with grey epoxy zinc rich primer paint twice and aluminum finish paint once after the erection of the steel structure (the paints shall not be supplied by WXDS).2.2 安装作业程序 Sequences of erection work正常的安装作业程序如下：The normal sequence of erection work is as below:2.2.1基础检验 Checking the foundation2.2.2安装作业程序 Sequences of erection worka)风机桥安装。Installation of Fan Bridge.b)导风筒和鸟网在水平地面上组装。Fan Ring and Bird Screen assembled at ground.c)A形部件在水平地面上组装。A-Shape parts assembled at ground.d)导风筒和鸟网吊装和安装。Fan Ring and Bird Screen lifting and installation.e)A形部件吊装和安装。A-Shape parts lifting and installation. f)A架其它部件的安装。Installation another parts of A-Frame erection.g)风机,减速机,电机的安装。Fan, Fan Reducer (Gearbox), Motor assembly.h)A架间平台的安装。Installation of Platform between A-Frame.i)管束的吊装和管板间，联箱间焊接。Lifting and welding bundles-Installation of the tube bundle on A-Frame, welding of tube sheets and Catchment Head.j)蒸汽分配管和不凝汽出口汇集管的安装和焊接。Installation and welding of the Steam Distribution Pipe and Non-condensing Steam Outlet Pipe.k)平台,栏杆,梯子的安装。Installation of Platform, Handrail and Ladder.l)冲洗装置的安装。Installation of Cleaning System m)挡风墙的安装。Installation of Wind Wall.2.3基础检验 Checking the foundation2.3.1空冷凝汽器的基础由买受人提供，并应与用户一并对尺寸予以检验。The foundation (civil works) are to be supplied by the purchaser, a dimensional checking will be performed jointly with the client.2.3.2基础的尺寸应遵从经买受人批准的无锡东盛的图纸。They are to be in compliance with the dimension shown on the WXDS drawings as approved by the purchaser.2.3.3基础柱脚/平台的上平面必须水平，其最大允差为+0 mm / -15 mm。地脚螺栓和预埋底板须根据图纸上的尺寸排布，且应是非常精确的。The top surface of foundation footings/slabs shall be leveled within maximum tolerance of +0 mm / -15 mm. Foundation bolts and insert plate must be arranged according to the drawings and must be very accurate.2.3.4安装前，特别要对基础作进一步复核并予以记录。Prior to the erection，should be recheck the foundation again and the results should be record.a)检查10.5米平台水平度。Check the level of 10.5m foundation floor.b)A架和挡风墙柱脚预埋底板的标高、水平度和预埋底板间的相对位置尺寸。The elevation, level of insert plates and relative location between the insert plates of A-Frame and Wind Wall.c)风机桥预埋底板的标高、水平度和预埋底板间的相对位置尺寸。The elevation, level of insert plates and relative location between the insert plates of Fan Bridge.d)A架和挡风墙的地脚螺栓位置尺寸。The foundation bolt relative location of A-Frame and Wind Wall.e)导风筒的连接孔位置尺寸。The connective holes relative location of Fan Ring.重要提示: IMPORTANT NOTE安装公司在承接安装任务前，必须保证基础的上平面是水平和平整的，并且须配备设备就位所需要的任何薄的垫板。The erector must prior to undertaking erection work-ensure that the top surface of foundation is true leveled and flat, and he shall provide for any shims required to obtain a true seating plan.2.4 钢结构安装Structure erection2.4.1钢结构部件的储存和装配区域应位于安装区域（在起重机下）。这个区域最好为薄的水泥地面便于卡车和起重机移动。The storage and assembling area of structural parts shall be located near erection area (under the lifting device of crane).This area must be grouted for trucks and crane movement.2.4.2安装前，应认真参阅钢结构的图纸，钢结构件须整理出并且按设备要求用螺栓连接并检查。Before undertaking erection work, the structural steel drawing should be consulted, the structural part should be picked and bolting checked in accordance with devices.2.4.3组装的钢结构件要与起重设备的能力相一致。The erection structural steel should be made in accordance with lifting devices.2.4.4首先，将钢结构零部件，诸如立柱、横梁、支撑等在地面上装配成较大部件，然后将之吊装到基础上。First, assemble at ground the lower part of the steel structure, such as column, beans, bracings, and so on; then erect these assembled parts on the civil work.2.4.5立柱底板下应垫薄的垫板以使个主要的尺寸，如位置尺寸、标高、角度等符号图纸的要求。The column shall be erected with shims under base plates so as to have their main dimension such as location, elevation, angle, etc. exactly in accordance with the general drawing.2.4.6安装其他钢结构件，包括A架间的平台、栏杆、梯子等。Installation the another structural part , include platform, handrail and ladder between A-Frame.2.5 轴流风机系统安装 Fan system erection2.5.1风机桥须先于A架安装前吊装到基础平台上。Fan bridge must be lifted on the foundation floor prior to the erection of A-Frame.2.5.2将导风筒和鸟网在相应安装位置底下的平地上组装好使之形成一个圆形体。Assemble the fan rings and bird screen on the ground in order to obtain a cylinder, in this case, the fan rings and bird screen are assembled in their erection position on the ground.2.5.3调整导风筒的圆度，把紧螺栓和螺母，再次检查导风筒的圆度达到规定的要求。Adjust the roundness of the fan ring, tightened the bolts and nuts, recheck the roundness of the fan ring again till it meet with the requirements.2.5.4调整导风筒的圆度时，可以用薄的橡胶垫片。When adjust the roundness of the fan ring, the thinness rubber is available.2.5.5起吊导风筒和鸟网用螺栓固定在基础平台上。调整导风筒的中心使之与基础的中心一致，把紧螺栓和螺母并对风筒的中心进一步检查直至符合规定的要求。Lift up the fan ring and bird screen and bolt on the foundation floor. Adjust the center of fan ring so as to meet with the center of the foundation, tightened the bolts and nuts, recheck the center of fan ring till it meet with the requirements.2.5.6调整风机桥的中心使之与基础和导风筒的中心一致。Adjust the center of fan bridge so as to exactly in accordance with the center of foundation and fan ring.2.5.7将减速机安装到风机桥的基础地板上。Assemble the gearbox to the base plate of fan bridge.2.5.8安装风机，详细见风机安装指导书。Assembly the fan, details please see the document about fan installation.2.5.9人工旋转风机叶片一周以上，检查叶片叶尖与导风筒的间隙是否均匀，如不符合要求则需调整风机及风机桥的中心。Rotate the fan blade more than one circuit manually, check if the gap between the fan blade and fan ring is well-proportioned, if it is not meet with the requirements, must adjust the center of fan or fan bridge.2.5.10将风机桥与基础底板焊接牢固。Weld the fan bridge to the insert plate stability.2.5.11将电机安装在减速机的顶部，调整电机和减速机。Place the motor on the top of gearbox, adjust the motor with gearbox.2.5.12紧固风机系统的所有连接螺栓。Tighten the all connection bolts of fan system.2.6 管束吊装和焊接 Lifting and welding of bundles2.6.1管束吊装时需用四个或六个由无锡东盛配备的吊耳。The tube bundle shall be lift using the four or six lifting lug provided by WXDS. 2.6.2假如用四个吊耳安装，联箱端的两个吊耳需配备手拉葫芦，葫芦要根据管束的重量来配置。用四根钢丝绳在水平位置起吊管束，然后通过手拉葫芦将联箱端缓慢下降直至管束与A架梁的角度相一致。If use four lifting lug, the two lifting lugs on the side of “catchment head” shall be fitted with chain hoist which will be chosen in accordance with the bundle weight. Lift the bundle with four leg slings in horizontal position then descend the catchment head side with the assistance of chain hoist up to the angular of A cross beam.2.6.3假如用六个吊耳安装，管束两端的四个吊耳需配备手拉葫芦，葫芦要根据管束的重量来配置。用六根钢丝绳在水平位置起吊管束，然后通过手拉葫芦将联箱端缓慢下降同时将另一端缓慢上升直至管束与A架梁的角度相一致。If use six lifting lug, the four lifting lugs at both side of bundle shall be fitted with chain hoist which will be chosen in accordance with the bundle weight. Lift the bundle with six leg slings in horizontal position then descend the catchment head side and increase another side with the assistance of chain hoist up to the angular of A cross beam.2.6.4将管束吊装到A架上并用定位螺栓定位。Put the bundle on A-Frame and bolt the upper screws.2.6.5所有管束吊装好后，调整所有管板使之在同一水平线上。After erection of all bundles in the same bank, adjust all tube sheets in the same level. 2.6.6将管板间焊接。在焊接前，应将所有管口塞住避免垃圾和其他东西进入管束。Welding all tube sheets together. Before starting the weld operation, all tubes shall be plugged to avoid the penetration of dust and other matter inside the bundles.2.6.7将联箱焊接起来。Welding all catchment heads together.2.6.8管板间或联箱间的焊接应按照焊接工艺规程进行，焊接后应做无损探伤。Proceed at the welding of tube sheets or catchment head in accordance with welding specification and Non Destructive Test for field assembly.2.7 蒸汽分配管道和不凝汽出口汇集管安装和焊接Steam distribution pipe, Non-condensing steam outlet pipe erection and welding2.7.1在地面上准备蒸汽分配管道和不凝汽出口汇集管，清理需要焊接的部位。Prepare the steam distribution pipe and non-condensing steam outlet pipe on the ground. Cleaning the parts where should be welding.2.7.2蒸汽分配管道检修平台在地面上安装就位，装配栏杆，然后焊接。The platform will be placed on the section on floor; equipped with handrail, then welding.2.7.3将随蒸汽分配管道发运的封板焊接到管板上。Weld the sealing strips which delivery with the steam distribution pipe to the tube sheets.2.7.4针对蒸汽分配管道安装的所有操作，应在管板的两侧以蒸汽分配管道的全长搭建脚手架，以使工作人员行走并保护翅片。For all the operations concerning the fitting of steam distribution pipe sections, scaffolding will be positioned on both sides of tube sheets, on all length of steam distribution to allow the circulation of staff and the protection of fins of tubes.2.7.5吊装蒸汽分配管道到管板上，进行调整和对准，此时蒸汽分配管道应一直被起重机吊住。Place steam distribution pipe on tube sheets, do the adjustment and the aiming of part always hold by the hoist crane.2.7.6吊装不凝汽出口汇集管到逆流管束上，进行调整和对准。Place non-condensing steam outlet pipe on dephlegmator bundles, do the adjustment and aiming.2.7.7焊接蒸汽分配管道和不凝汽出口汇集管。Weld steam distribution pipe and non-condensing steam outlet pipe.2.7.8在焊接以及调整和对准蒸汽分配管道到管板时，应将所有管口塞住避免垃圾和其他东西进入管束。Before welding and aiming of steam distribution pipe sections with the tube sheets, all tubes shall be plugged to avoid the penetration of dust and other matter inside the bundles.2.7.9蒸汽分配管道和不凝汽出口汇集管的焊接应按照焊接工艺规程进行，焊接后应做无损探伤。The welding of steam distribution pipe and non-condensing steam outlet pipe should be in accordance with welding specification and Non Destructive Test for field assembly.2.7.10在对焊接试验后，应对蒸汽分配管道进行彻底的清理，在移去脚手架前对蒸汽分配管的外部进行油漆。After positive test of welding, proceed to a perfect cleaning of steam distribution pipe and external paints before removal of outside scaffoldings.2.7.11对蒸汽分配管道的内部进行彻底的清理，临时关闭人孔。Cleaning the internal of steam distribution pipe and temporarily closing of manholes.2.7.12安装基础平台至蒸汽分配管道平台间的梯子。Installation the ladder, which is from foundation floor up to the platform locate at steam distribution pipe.2.7.13当整个空冷凝汽器安装完成后，蒸汽分配管道，不凝汽出口汇集管和管束须以0.313MPa的表压进行水