重油发电机组安装施工组织设计

1、1 机务部分施工方案Construction Scheme for the Machinery section 1.1 主厂房行车吊装 Main building bridge crane installation 1.1.1 吊装步骤The Lifting Process1) 将履带吊开至标识位置，松钩，挂钢丝绳。Rising the crawler crane up to the mark position, loosen the hook and suspension the steel wire ropes.2) 将钢丝绳按照标识位置将固定端的行车大梁绑扎好，确保起吊时大梁平稳，必要时

2、可利用链条葫芦调平。Making the steel wire ropes in accordance with the mark position and bidding crane runaway buckstay of the fixed ends.Then keeping the buckstay rise smoothly when hanging up the crawler crane. It necessary to use the chain block with steel structure adjust the balance.3) 利用吊车将该行车大梁吊至大跑车轨道上

3、，并用钢丝绳、枕木和垫块将大梁固定平稳。Using crane hang up the crane runaway buckstay to the track of bridge motor, at the same time, using steel wire ropes, sleeper and cushion block fix and keep the crane runaway buckstay stably.4) 用同样的方法吊装扩建端的大梁和两条大梁的连接件组合体，同样放置在大跑车轨道上。Using the same way lift the buckstay of extens

4、ion ends and the connection piece unit of two buckstays then put these onto the track of bridge motor5) 将两片大梁连接组合。Conntecting and composing the two buckstays6) 将小跑车吊到大梁轨道上就位。Lifting “the small racing bike” to the track of buckstay, and it will be positioned on this track7) 将驾驶室吊至行车下。Lifting the driv

5、ing room to underside of the buckstay8) 利用卷扬机将驾驶室吊至行车大梁端头下面，并与行车连接。Using the winding engine lift the driving room below the buckstay ends, and then connects with the crane runaway9) 将行车向里拖运至合适的位置并锁定。Pulling the crane runaway inner of the structure, then find the suitable place and shock it.10) 接电源，运

6、入试吊重物，进行行车试吊。Connecting the electrical power, and try to lift the heavy.1.2 柴油发电机组吊装Generator unit installation 1.2.1 发电设备安装Generator equipment installation 工艺流程：Construction flow基础检查划线拖运轨道制作安装柴油机安装发电机安装设备中心找正设备连接二次灌浆设备中心复查Inspection to the foundationsetting outmaking and installing the track used t

7、o haul equipmentinstall diesel engine install generatorAdjusting and positioning the equipmentequipment attachmentsecondary grouting reexamining the center of equipment1.2.1.1 柴油机安装 Install diesel engineØ 基础检查、清理并复核中心线；Examining foundation, cleaning and recheck the central lineØ 按照图纸文件要求打制

8、垫铁基础，配制、安装垫铁，垫铁与基础接触密实四角无翘动。The packing iron foundation should be forged according to the drawing and files and confected and installed the packing iron.The packing iron and the base foundation should touch close-grained. Ø 设备经检查无变形等重大缺陷； Inspecting the equipments and dont find serious defects&

9、#216; 采用行车将柴油机吊装就位；Using bridge crane to position the diesel engine Ø 使用水平仪、千斤顶等调整设备，直至设备纵横中心线及轴承水平标高符合设计图纸要求；Using gradienter, jack etc.to adjust the equipment, until the center and level elevation of the equipment meet the requirement of the drawing1.2.1.2 按照以上步骤将发电机安装就位；Follow the steps abov

10、e to position the generator :1.2.1.3 柴油机与发电机设备连接；Connect the diesel engine and generator 1.2.1.4 基础二次灌浆；The basa foundation secondary grouting1.2.1.5 设备中心线及水平标高复查；Reexamine the center line and level elevation of the equipment 1.2.1.6 弹性支座安装。 Install platform1.2.2 机械辅助系统安装Install auxiliary machinery

11、system1.2.2.1 机械辅助系统主要包括辅助模块、轻质燃油系统、重质燃油系统、压缩空气系统、冷却系统、充气系统、排气系统、混油水系统、水处理系统、机房附属消防系统、燃油加热蒸汽发电系统及其他辅助系统（具体安装方法可参考润滑油系统与燃油系统的安装）；Auxiliary machinery system include auxiliary modules, light fuel system, heavry fuel system, compress air system, cooling system, aeration system, exhaust system, mixing oi

12、l and water system, water treatment system, fire extinguisher system and other auxiliary system (specific installantion method please consult lubricating oil system and fuel system installation )1.2.2.2 充气及排气模块、冷却水箱、油过滤器及进油管宜与烟道同步安装，连接对口过程中严禁强拉或附加外力，避免设备变形和移位；Inflatable and exhaust modules, cooling

13、water tank, oil filters etc. should be installed synchronization with tewel. Connecting the equipment should not pull seriously so as to avoid shifting and metamorphosing of the equipment.其他辅助系统可根据设备到货及土建施工情况分散安装。Other auxiliary system will be installed separately according to actual situation.1.3 烟

14、道制作安装及烟囱吊装 Gas duct fabrication and installation, chimney lifting1.3.1 烟道制作Gas duct fabrication 作业前应做的准备工作和必须具备的条件 Preparative Work and Essential QualificationsØ 设计施工图纸满足现场施工并已会审，单线图已标注焊缝编号；并根据施工图纸和技术要求编制材料需用计划。 Drawing meets the requirement of construction and be approved; Draw out material pl

15、an according to the drawing and technical requirement.Ø 制定详细的管道安装工序和工序控制点（见证点“W”，停工待检点“H”）。Establish detailed piping installation procedure and control post of the working procedure (witness point “W”, stop work to wait examining “H”)Ø 施工方案经批准并已作技术安全交底, 施工组织健全，施工人员熟悉本专业的施工工艺程序、质量标准和安全作业措施。

16、 Construction scheme has be approved and do technical clarifications before construction, construction organization is integrate，workers are familiar with construction sequence、quality standard and safe measure.Ø 管子、管件、管道附件及密封紧固件应符合国家现行有关标准，具有出厂合格证。Pipe, pipe component, sealing component and re

17、lated equipment meet national current standard and possess certification.Ø 施工机具准备：链条葫芦2t/1t各4只，尼龙吊带2条，25t汽车吊1台，焊机3台，10t千斤顶4个，割炬、砂轮机、水平尺、线锤、榔头、卷尺、对口钳若干，空压机1台，卷管机1台，焊条烘箱1个。Prepare construction tools and machinery: cutting torch, grinding machine, leveling instrument, wrench, hammer, tape, several

18、 pincers, a air compressor, a pipe roller, a welding rod oven. 1.3.1.1 施工方法及步骤Construction method and pocessØ 烟道制作所采用的钢材，应具有质量证明书，并应符合设计的要求。当对钢材的质量有疑问时，应按国家现行有关标准的规定进行抽样检验。The rolled steel used to make gas duct should possess certification and meet the design requirement. If doubt about the rol

19、led steel quality, it will do sampling inspection according to related national rule.Ø 施工前应对钢材表面质量进行检查，除应符合国家现行有关标准的规定外，尚应符合下列规定：当钢材表面有锈蚀、麻点或划痕等缺陷时，其深度不得大于该钢材厚度负偏差值的1/2；Inspect the surface of the rolled steel before construction, tally with national current related standard, and also conform to

20、 de follow stipulation: when the rooled steel surface has defect just like rustiness, scratch as so on, the defect depth should not greater than than the1/2 D-value of the rolled steel.Ø 在烟道制作前，放样和号料应根据工艺要求预留制作和安装时的焊接收缩余量及切割等加工余量。 In pre-production, setting out the flue and feed should be set a

21、side under the technological requirements of the manufacture and installation of welding contraction allowance and cutting machining allowance. Ø 下料切割前应将钢材切割区域表面的铁锈、污物等清除干净，气割后应清除熔渣和飞溅物；切割时根据卷管的弧度方向和焊接方向将钢板对应边开出单边坡口，坡口加工宜采用机械方法，也可采用氧乙炔焰等加工方法，在采用氧乙炔焰加工坡口或切割后，必须除去坡口表面的氧化皮，熔渣及影响接头质量的表面层，并将凹凸不平处打磨平

22、整；The steel material under the cutting area before cutting the surface rust, dirt and other clean, gas cutting shall be removed after the slag and flying material; cutting paper tube according to the arc direction and the direction of the steel plate welded out single slope corresponding port side ,

23、 groove mechanical methods should be adopted, it can be used and other processing methods oxyacetylene flame, using oxyacetylene flame in the processing or cutting groove, the groove surface to remove oxide, slag and impact of joint quality of the surface layer, Department polished smooth and rugged

24、;Ø 下料完毕后在卷管时，应逐渐轧小钢板的弧度，不可一次将钢板弧度变化过大，卷管将完成时应随时测量管道的椭圆度，对超标的地方及时进行处理和修正，将烟道椭圆度控制在规范要求的范围内。After the feeding tube in volume, should gradually rolling small plate in radians, not once to plate radians changes too large, the volume should be completed at any time the ovality measurement pipeline,

25、on the local time for processing and the flue ellipse control requirements in the specification range. Ø 烟道卷制完成并测量确认无误后，即可进行烟道的焊接。焊接质量的好坏，将直接影响到以后的运行安全及使用寿命，故焊条型号的选用应严格遵守设计文件的要求，进货的焊条应具备制造厂的质量证明书（合格证）及质保书。为保证焊接质量，焊条在施焊前必须按照焊条质量管理规程的规定进行烘烤，烘烤时严格遵照规定的时间和温度。Roll to complete and measure the flue ch

26、ecked and verified, can be welded to the flue. The quality of the welding quality, will directly affect the safe operation of the future, and life, so the choice of electrode type should strictly comply with the requirements of design documents, purchase the welding rod should have the manufacturer&

27、#39;s quality certificate (qualifying certificate) and warranty book . To ensure the welding quality, welding electrode in the facilities must follow before the "rod of quality management procedures" provisions of baking, baking in strict accordance with the stipulated time and temperature

28、.Ø 焊接时应将坡口及其内、外侧表面不小于15mm范围内的油垢、铁锈、毛刺及其它杂物等清除干净，并不得有裂纹、夹层等缺陷。Welding when Groove and medial and lateral surface is not less than the 15mm range of oily dirt, rust, Burr and other incidentals, clean, and no defects such as cracks, sandwich. Ø 焊接检验按照DL5007-92电力建设施工及验收技术规范（火力发电厂焊接篇）要求，采用1超声检验

29、，若有不合格应对相应的地方立即进行返修，返修后重新进行超声检验直至合格。 Welding inspection in accordance with DL5007-92 the electricity construction specifications for construction and acceptance (part 1) thermal power plant welding requirements, with 1% ultrasonic examination, if they have not qualified to deal with the appropriate

30、place to rework immediately, refurbished ultrasound examination upon until qualified. 1.3.2 烟道安装Gas duct installation 1.3.2.1 安装条件要求Installation requirement Ø 烟道已制作完成，并经验收合格。Gas duct has been fabricated and be acceptance check Ø 发电机组设备已吊装就位。Generator unit has been installed Ø 烟囱已吊装就位。

31、Chimney has been installed 1.3.2.2 安装原则Installation principle Ø 根据现场设备到货及安装情况，烟道安装方法可采用从烟囱中间向两侧安装，也可以从一侧向另一侧安装； According to the on-site equipment arrival and installation status, the flue installation method can be used from the middle to install on both sides of the chimney, or from one side

32、to the other side of the installation; Ø 组合件组合后应对整体组件的尺寸进行检查(复核边长、对角线、焊接焊缝以及变形数据等)；Assemblies are combined to deal with the size of the overall component checks (diagonal length, review, welding, and transform data, etc.); Ø 组合件完成后，应清除组合件内部杂物，组合件应有适当的刚度，做好临时加固，焊接吊装吊耳等，并经验收认可；Assembly is co

33、mpleted, you should clear the Assembly internal debris, the Assembly should have appropriate stiffness, stopgap reinforcement, welding hoisting etc, and experience your authorized; Ø 焊口应平整光滑，严密不漏，焊渣、药皮应清除干净，安装焊口应预留在便于施工及安装的地方；Assembly is completed, you should clear the Assembly internal debris,

34、 the Assembly should have appropriate stiffness, stopgap reinforcement, welding hoisting etc, and experience your authorized; Ø 缩节安装前进行密封性检查，风门档板及暖风器等附件组合安装前必须经过严格检查；Expansion joint seal before installation inspection, damper and baffle combination of air heater and other accessories must go th

35、rough strict inspection before installation;Ø 存放件安装对口时，应从柴油发电机组侧开始对起；Placed pieces of installation counterparts, the diesel generator should start from the side;Ø 为预防焊接变形，施焊时按对角施焊、先分段焊后全焊的原则进行；To prevent deformation, welding by diagonal welding, first of all-welded sections after welding o

36、f principles; Ø 所有烟道尺寸均为内壁尺寸；All flue dimensions are wall dimensions; Ø 伸缩节安装时应按图留出足够的膨胀距离，密封面应光滑，垫料应均匀饱满；Expansion joints should be installed in accordance with figure leaving sufficient expansion distance, seal the surface should be smooth, full of uniform; Ø 烟道与设备连接时，严禁强力对接，以免机械设备产

37、生位移； Flue and device connection, no strong connection to avoid mechanical equipment generates displacement;1.3.3 烟囱安装烟囱安装工艺流程如下：钢架安装（预留吊装口）消音器吊装烟道部件存放拼装焊接膨胀节安装预留口安装爬梯栏杆安装1.4 管道安装Chimney installed1.4.1 主要安装工序Main Installation Procedure：1) 管段吊装：吊装前需确定管子的方位、流向、管子所处位置，测算所吊管段重量，钢丝绳、吊耳是否相适应，吊装管段时应注意顺序。Pip

38、e lifting; the orientation of the piping, flowing and the position of the piping should be confirmed before lifting piping, and measure the weight of the piping, the steel rope and hanger whether or not adapt,but pay attention to the gradation when the piping lifting2) 管内清洁：在管段吊装前应清理管内的杂物、锈斑、焊渣等，并用压

39、缩空气吹扫，确保管内干净、无杂物。The inside pipe cleaning: the inside of piping should have not sundries, rust and weld deposit before lifting piping, and using the compressed air purge it3) 支架配装：按设计图配齐支吊架构件并按图安装，位置应准确、根部应固定牢固。Support installing: the lifting support frame components will be installed according to t

40、he drawing, the position must be correct and the root should be fixed firmly4) 装配：管段吊装就位后，应按施工图的设计尺寸进行核对，如设计有冷拉的应将冷拉值考虑在内，确保尺寸的误差值在允许范围内；阀门、节流孔板、流量计的方向、法兰的紧固、伸缩节等的安装应按相关要求进行施工。Assembling: after the piping has been positioned, and check the design dimension according to the construction drawing. If t

41、here is cold-drawn on design and should think about it, then keep the error data of the dimension on the allowable extension. The Valves, throttle hole board, flowmeter, direction, flange tightening and extension burl should be installed according to the correlative requests5) 焊接：由持有有效合格证的焊工按相关工艺要求施

42、焊，确保焊口施工质量。Welding: it should be welded by the eligibility welder, then assure the quality of the welding6) 焊口无损检查：焊接完成后应按有关要求进行焊缝热处理及无损检测。Lossless examining: the welding line and lossless examining should be done after welding has been finished according to the correlative requests.7) 管线检查：管线安装后应进行

43、自检，检查管线的支、吊架及管道的坡度等是否符合图纸设计要求，做好有关记录。Pipe line checking: after the piping has been installed, we should check it ourselves, then check the support of the piping, lifting frame and the grade of the piping whether or not according to the design request and write the notes down8) 压力试验：管线自检完毕后，经确认具备压力试验

44、应按设计要求进行压力试验。Pressure test: after the checking has been finished, we can do the pressure test according to the design requests.9) 管线保养：压力试验验收合格后，应按设计要求进行管线保养工作。Pipe line maintain: we should do the work of the piping maintain after the pressure test has been passed10) 管线保温：管线经压力试验合格后方可进行保温工序。Pipe lin

45、e heat preservation: we should do the work of Piping heat preservation after the pressure test has been passed11) 管线验收：前面有关工序完成后，应及时通知有关部门、单位对系统管线进行验收并做好有关签证记录。以便下一道工序施工。The pipe line acceptance: the system of the piping should be checked and accepted after all of the working procedures have been fi

46、nished.1.4.2 阀门检验、研磨、标识Examining, Grinding and Marking of the Valves电厂阀门数量多，种类、规格多种多样，其在机组运行中起着重要作用。为确保机组设备的经济运行，对阀门实施施工全过程控制，建立阀门档案，对其进货、存放、检验、标识、领用和安装等过程进行有效管理，保证阀门的追溯性。同时在现场设立阀门检验班，负责阀门安装前的检验、研磨、标识工作。The power station has the so many valves and the valves have so many kinds and specification, and

47、 they are very important on the unit circulate. All of the valves should be controlled on the whole process and build the archives to manage the stocking, saving, examining, marking and installing effectly. While seting up the checking class on the locale ground and take charge for the checking, gri

48、nding and marking before the valves installing1.4.2.1 阀门检验Valves Examining1) 外观检查；铸造阀门外观无明显制造缺陷；填料密封处的阀杆有无腐蚀；开关是否灵活，指示是否正确。Appearance examining: foundry valves appearance has not the making bug clearly and the valves stick of padding sealing has not cautery; the switch whether or not agility, the di

49、rection whether or not correct2) 密封性试验：以检查阀座与阀芯、阀盖及填料室各接合面的严密性。阀门严密性试验一般应宜1.25倍的铭牌压力水压进行。低压阀门按规定比例抽查进行严密性试验，高压阀门应逐个进行严密性试验。Sealing test: the valves and the valves core, the valves cover and the strictness of the entire connective surface should be examined. The strictness testing of the valves shoul

50、d be carried on the 1.25 times nameplat pressure hydraulic pressure. The low pressure valves should do the strictness testing according to proportion and the high pressure should do then strictness testing one by one.1.4.2.2 阀门解体、研磨The Disassembly and Grinding of the Valves1) 阀门解体检查：用于设计温度大于或等于450的阀

51、门，合同另有规定除外；安全阀、节流阀(合同另有规定除外)；严密性试验不合格的阀门。阀门的解体应有专业熟练技术人员进行操作。解体时，应依照制造厂规定的拆装顺序解体，解体各部件分项做好记录和记号，以便正确复装。The disassembly of the valves examination: do the examining for the valves of the design temperature higher or equal to 450 and expect additional regulation on the bargain, safety valves, throttle

52、valves (expecting additional regulation on the bargain); the disqualification valves of the strictness testing.The disassembly of valves should be operated by the masters. The valves should be knocked down according to the knocked-down order which the manufactory prescribed, and then all of disassem

53、bly parts should be marked2) 检查项目：Examining ItemsØ 检查外部介质流动方向指示是否与实际相符；Examining the indication of outer medium flowing direction whether or not according with the fact;Ø 合金钢阀门的内部零件应进行光谱复查，并应将检查结果做出记录；The inside accessorys of the alloy steel valves should do spectrum rechecking and write d

54、owm the notes;Ø 阀座与阀壳结合是否牢固，有无松动现象；The valves support connects with the valves hull whether or not firmly and has not loosened phenomenon;Ø 阀芯与阀座的结合面是否吻合，结合面有无缺陷；The connective surface between the valves core and the valves support whether or not inosculate and the connective surface has n

55、ot disfigurement;Ø 阀杆与阀芯的连接是否灵活可靠；The valves stick and the valves core are connecting whether or not neatly and reliably;Ø 阀杆有无弯曲、腐蚀，阀杆与填料压盖互相配合松紧是否合适，以及阀杆上螺纹有无断丝等缺陷；The valves stick should have not bend and canker, while the cooperation of the valves stick and filling cover whether or not

56、 suitable and the upside whorl of the valves stick should have not disfigurement;Ø 阀盖法兰面的结合情况。The connective condition of the valves cover flange surface3) 研磨；阀芯与阀座的结合面不吻合有缺陷时，应对阀芯和阀座进行研磨修复，可采用手工或阀门研磨机作业。Grinding: the valves core and the valves support should be repaired and grinded when they c

57、an not inosculate, and we can use the handcraft and the valves grinder4) 缺陷消除后，应依顺序复装阀门，复装后阀门应达到规定的质量要求，并做严密性试验。The valves should be installed again according to the order after the disfigurement has been removed.And these valves should reach the quality request and do the strictness testing.1.4.2.3

58、 阀门标识、存放Remarking and Preservation the Valves1) 阀门标识：对已检验合格的阀门，根据现场标识程序，在阀壳外表面显眼地方做出标记，并给每一阀门临时挂牌，以保证阀门正确领用。Remarking the valves: the eligibility valves should be remarked on the stare place of the valves hull surface, and every valve will be hanged the temporarily then assure using of the valves co

59、rrectly2) 阀门存放：根据阀门检验状态分区存放管理，分待检区、检验区(含严密性试验、解体检查、光谱分析、研磨等)、已检验合格区、不合格区，有利于阀门管理。Preservation the valves: the valves will be preserved in different areas according to the examining state, the areas contained for check area, checking area (including strictness testing, disassembly examining, spectroscopic analysis and gr