设备管理_某公司工业乙醇项目设备安装方案

文件类型文件页数版次修订说明受控编号GH671版首次 设备安装方案Equipment installation plan02012年8月7日版次Edition日期Date 编制Formation审核examine批准approval中国化学工程第十三建设有限公司The 13 th construction company of CNCEC目 录SB.1.1 概述Overview3SB.1.2 编制依据Basis5SB.1.3 设备安装准备工作Equipment installation preparation6SB.1.3.1技术准备工作Technique preparation work7SB.1.3.2基础验收 Base acceptanceSB.1.3.3 设备卸车Unload equipment10SB.1.3.4开箱验收OPI12SB.1.3.5设备就位安排Equipment arrangement13SB.1.4 静设备安装Static equipment installation14SB.1.4.1一般安装施工程序Process flow for installation14SB.1.4.2一般安装要求General installation requirements15SB.1.4.3塔、容器类静止设备安装示意图18SB.1.4.4换热器安装Heat exchanger installation19SB.1.5 泵类设备安装Pump installation of equipment39 SB.1.5.1泵类设备安装施工工序Pump equipment installation construction process. SB.1.5.2基础处理Foundation treatment.SB.1.5.3泵设备找平Equipment leveling requirements.SB.1.5.4设备灌浆Equipment grouting.SB.1.5.5拆检Overhauling41SB.1.5.6管道应力检查Pipe stress inspection41SB.1.5.7最终对中Final centring42SB.1.5.8泵类设备的防护Pump equipments protection42SB.1.5.9试运行Commissioning43 SB.1.6 质量管理Quality management51SB.1.6.1 质量保证体系quality guarantee system51SB.1.6.2 质量保证措施Quality guarantee measures52SB.1.6.3动设备安装质量控制计划(ITP)54SB.1.6.4静设备安装质量控制计划（ITP）58SB.1.6.5起重吊装质量控制计划(ITP)61SB.1.7 安全管理Safety management63SB.1.7.1 安全保证体系Safety guarantee system63SB.1.7.2 安全保证措施计划Safetyntee guarranteeMeasures64SB.1.7.3文明施工Civilized Construction66 SB.1.8 工作危险源分析评估及预防Hazard analysis evaluation and prevention.61 SB.1.1 概述Overview本项目为塞拉尼斯（南京）八期China Fsat项目，我方负责安装的设备主要包括：设备类别现场制作储罐泵容器储罐余热回收火炬系统其它数量（台）413611若干我方负责安装的设备特点是：设备数量不多，主要为容器储罐、泵类、火炬及废热锅炉（锅炉设备包里面包含风机和储罐、泵类等），火炬及废热锅炉考虑到整体安装，有供货厂家现场技术指导的将按照指导意见安装。 The engineering characteristics of t火炬和he equipment is: equipment quantity is not much, but the great weight of tower equipment, long length; In addition the need to install in the steel structure of the devices on the platform is in the majority. This scheme pump, the torch and waste heat boiler to the whole installation consideration, there is supply technical guidance of the manufacturer will be in accordance with the instruction opinion installation. 本方案为一般设备的安装方案，对于本工程中整体安装的系统，按业主要求另行编制设备的专项吊装方案。This scheme for general equipment installation scheme, for the project medium-large equipment such as T-778 / T-780, for weight is heavy, the field is limited, according to clients requirement of special equipment shall be separately the lifting scheme. 现场制作储罐将另行编制制作安装方案The production will be made of storage tank installation plan SB.1.2 编制依据Basis机械设备安装工程施工验收通用规范 GB50231-2009General code for machinery installation engineering construction and acceptance GB50231-2009压缩机、风机、泵安装工程施工及验收规范 GB50275-2010Code for construction and acceptance of compressor, fan and pump installation GB50275-2010化学工业塔类设备施工及验收规范HGJ211-85 Code for construction and acceptance of chemical tower 化工工程建设起重施工规范HGJ201-83 crane construction standard for Chemical engineering construction HGJ201-83乙烯裂解炉和制氢转化炉施工技术规程 SH/T3511-2007工业锅炉安装工程施工及验收规范GB50273-2009“The construction & acceptance specifications of industrial boiler installation engineering”GB50273-98石油化工施工安全技术规程SH3505-1999 Technical code for construction safety in petrochemical engineering SH3505-1999机械设备安装和安装设计建议惯例API STD 686 Recommended practices for machinery installation and installation designAPI STD 686SB.1.3 设备安装准备工作Equipment installation preparation资料1. 图纸、说明书2. 装箱清单、平面图3. 随机文件（副本）基础1. 外观及位置2. 标高3. 预留孔清洗开箱1. 开箱2. 清点3. 外观检查机具进场吊车进场垫铁1. 打磨2. 在基础上找平表面处理1. 打麻面2. 垫铁位置打平Document 1. Drawing, instruction2. Packing list, the plan3. Attached document（copy）Foundation 1. Visually and position2. Elevation 3. Performed hole for cleaningBox open1. Open box2. counting3. Visual inspectionMachine&tools mobilizationCrane mobilizationSizing block1. Grinding 2. Leveling Surface treatment1. Rough the surface2. Ground leveling for sizing blockSB.1.3.1技术准备工作Technique preparation work内 容供应方1. 交付安装的设备、机器、附件等合格证、安装说明书应提供施工方。业主方/管理方2. 设备安装施工图、设备图、设备基础图、设计说明书提供施工方。业主方/管理方3. 装箱单、随机文件提供给施工方管理方协调4. 基础中间交接记录进行施工方5. 业主审定本工程应执行的技术规范，标准及质量验收标准。施工方6. 编制正式的施工方案报请业主批准施工方Content Supplier 1. Certificate, installation instruction of the equipment, machine and accessories shall be provided to the contractor.Owner 2. Equipment installation drawing, equipment drawing, equipment foundation drawing, design specification shall be provided to the contractor.Owner 3. Packing list and attached documents shall be provided to the contractor.With Owners assistance 4. Foundation handover shall be finished prior to equipment installation.Contractor 5. Technical specification, standard and quality acceptance of this project shall be reviewed by the Owner.Contractor 6. Compile formal execution plan to submit to the Owner for approval.Contractor 1、图纸会审：包括施工图纸、设备本体图、说明书以及有关工艺操作规程等.认真会审施工图纸,理解设计意图,视察现场,核对图纸。The construction drawings should be reviewed by all staffs,include construction drawings,equipment body drawings,specification ,manual and operation specification .2、了解现场及图纸（包括图纸会审的澄清），编制施工方案,做好施工现场各项准备工作。Make a joint checkup on drawings, know site situation(the clearance of problems), Formate construction plan and preparation work . 3、技术交底：开工之前对现场施工人员进行技术交底，使施工人员了解工程概况、工程内容、工期、质量要求、施工重点、难点、要点，明确自己在施工过程中所承担任务的工作责任。要求参加施工的人员认真阅读图纸，领会设计意图。Technical clarificaiton:before technical clarificaiton construction ,staff should know the requirement of drawing, code standard, construction sequence, technique, quality requirements,key point, difficulties,and individual responsibilities and so on 4、在进场施工之前，对所有施工人员一次全面系统的教育，使施工人员对工程有较深的认识，加强施工人员的质量、安全、文明施工的意识。了解施工现场实际情况，本次施工中需要注意的特殊要求。Before construction,all construction personnel should participate comprehensive education system, make deep understanding of engineering, strengthen construction personnel quality, safety and civilized construction consciousness. Understand actual situation and pay attention on the special requirements in the constructionSB.1.3.2基础验收 Base acceptance 设备的基础按国家标准及Celanese、WPC的技术文件、图纸要求进行验收，基础上应有明显的标高基础线、纵横向中心线，基础外观不得有裂纹、蜂窝、空洞和露筋现象。并做好交接验收记录。The equipment foundation should be checked according to the national standards and technical documents of Celanese, WPC documents. Obvious elevation,vertical and horizontal line should be marked on the centerline of the foundation without crack, cellular, empty hole and existed rebar, acceptance record shall be prepared.机器、设备基础尺寸及位置的允许偏差（mm）：The allowable deviation size and location for machine,equipment foundation 项次No项 目 名 称Item 允许偏差(mm) allowable deviation1基础坐标位置(纵横轴线)Basis coordinate position 202基础各不同平面的标高The elevation of the different plane +0、-203基础上平面外形尺寸Plane shape dimension of foundation 凸台上平面外形尺寸Plane shape dimension of up point凹穴尺寸Recesses size20+0、-20+20、-04基础上平面的水平度(包括地坪上需安装设备的部分)levelness on the foundation(include terrace part which need to install equipment ) 每米meter全长overal length5105竖向偏差vertical deviation ：每米meter 全高overrall height 5206预埋地脚螺栓：Preinstall Foundation bolt标高（顶端）Elevation (peak)中心距center distance（在根部和顶部两处测量）+20、-0 27预留地脚螺栓孔:preinstall foundation bolt hole中心位置central position :深 度:deepth孔壁的铅垂度verticality of hole(全深deepth )10+20、-010SB.1.3.3 设备卸车Unload equipment 安装场地、施工场地内 容实 施 人1. 设备运输、吊车进退场道路应畅通WPC、施工配合2. 设备堆放点已平整WPC、施工配合3. 施工临时用电已接至现场WPC、施工配合4. 安装、吊装技术措施已完成，场地已加固WPC、施工配合5. 设备已按清单开箱清点WPC、监理、施工配合1. 首先由设备的到货单得知设备的重量大小，根据图纸要求的设备安装位置及现场施工情况，合理选择设备的暂时放置点。并对放置点进行平整。2. 其次派交通指挥员按照celanece;WPC管理公司规定的大门引导运输设备车辆按照指定的行车路线将运输车辆运至指定的待吊装位置。First the traffic commander should be sent according to provisions of celanece and WPC management company to guide equipment transportation to the designated hoisting position in accordance with specified route for vehicle 3. 然后核对吊装所用的机索具是否具有齐全的合法合格证及相关质量证明记录文件，例定期检验报告，行驶证保险正本等，核实吊装重量是否与其匹配，禁止过载吊装。 Second check the machine rigging whether it has the complete legal certificate and relevant quality certificate recording documents,regular inspection report and the original insurance such as vehicle license to verify whether weight lifting is matching,it is forbidden to lift overload.4. 核实实际吊装作业回转半径及吊装角度。设置警戒线及警戒区域，悬挂吊装标识牌，禁止无关作业人员进入。检查吊耳，吊环是否受损，并在卸车指定位置放置好设备支座。Verify turning radius and lifting Angle of actual lifting . Set the cordon and warning area, hang hoisting sign to ban personnel who do not involved in this type of work to enter . Check whether the lug and rings are damaged, and place equipment supporter in the specified position.5. 由经验丰富的施工作业人员按照安全操作规定拆除运输车辆固定设备的绳索。悬挂吊索。 The fixed rope of the equipment on transport vehicles shall be demolished by experienced construction personnel in accordance with safety operation regulation . Suspension sling.6. 由专业经验丰富的起重指挥卸车。吊装设备应平稳缓慢的进行吊装，当设备吊至200mm的位置时，检查所有索具情况，吊车负荷情况，地基变化情况，平衡梁负荷情况.Experienced personnel shall be provided to give special command. Lifting equipment should be smooth slowly in hoisting.Check all rigging, crane load conditions, the foundation changes and load balance beam at 200 mm position of equipment crane 7. 发现问题，应及时将设备放回原处，针对问题进行整改，直至合格，经celanece，WPC管理公司确认一切正常后，方可正式吊装卸车。If we find problem, we should place equipment in place, and rectify and reform until the qualified in view of the problems ,After confirmed from the celanece and WPC management company,we shall officially lifting unloading8. 对于机泵类小型容器，设备在卸车时采用吊装带进行卸车，吊装卸车时应平稳缓慢进行吊装卸车，卸车后，对机泵类设备要运至仓库进行保存，确保设备不受损害。对于小型容器类设备，卸至指定位置，采取保护措施。防止容器类设备受到损害。For pumps type small vessel, lifting belt shall be used in the unloading equipment , lifting unloading shall be smoothed slowly in areas.After unloading, machine pumps equipment shall be shipped to the warehouse to be saved to ensure equipment is not demaged. For small vessels category equipment, unloaded to the designated position, take protective measures. Prevent containers such equipment to be damaged.9. 大型设备的卸车详见设备卸车方案SB.1.3.4开箱验收OPI1. 设备开箱应由施工单位组织、业主/WPC、监理、供货单位代表参加，在开箱验收过程中发现的问题由施工方作好记录，三方代表签字，发现问题及时确定处理方案。OPI would be done by relevant personnel from construction company together with specialists from OWNER ,WPC,supervisor company and manufacturer,Found problem shall be reported by construction company ,and the reporte shall be signed by 3 parties representatives, treatment plan shall be decided timely.设备开箱验收应依据施工图设计、机器安装说明书、机器到货装箱清单。首先，依据施工图设计和装箱清单核对机器到货的规格、型号是否相符。开箱之前应检查各个包装是否完好；然后逐个开箱，按照装相清单对照实物进行清点；在清点的过程中对各零部件外观质量进行认真检查，发现有锈蚀损坏现象要求责任方及时处理。依据机器安装说明书检查机器到货的零部件是否齐全、规格型号是否相符，发现问题及时处理。OPI would be done inside warehouse, or outdoor with bad weather protection measures.To make sure machine and parts wouldnt be damaged during OPI with special tools.Check equipment against name, type, and specification with design data. Check the case No., case quantity and packages outside integrality.Check the packing list against documents, certificates, parts and their defects, special tools .Check the apparent of the main parts of machine if there are crack, corrosion, knocked defects, etc. Recover the water-proof, moisture-proof packages, if any, after check. 在确认无误后，将可安装的设备运至现场并做好设备保护，暂时不便安装的设备放置在仓库，如需放置在室外，需做好防雨防晒措After OPI , equipment would be stored inside warehouse, or outdoor with bad weather protection measures.SB.1.3.5设备就位安排Equipment arrangement1 设备就位先后顺序的一般原则Equipment the principle of ordera.先大型设备，后小型设备；large equipment,then small equipment b.先关键设备，后一般设备；,key equipment,then general equipment c.先静止设备，后传动设备；tatic equipment first ,then transmission equipmentd.具体根据业主实际到货日期按实调整。Adjust according to the equipemt delivery schdulee. 因本标段仅包含机电仪安装，在现场设备安装时与其他承包商负责的钢结构安装存在空间交叉作业，在其他承包商安装二层及以上的钢结构时，需及时经业主/WPC协调将部分钢结构预留，以便我方进行设备安装。届时将提供详细的暂留作业计划。2 设备就位的方法The method of equipment in place根据设备重量，设备安装高度，设备位置，一般利用汽车起重机使设备就位。Cranes shall be used to make equipment in place according to the weight of the equipment, the installation of height equipment and the equipment position, use that equipment.各大型设备另编制吊装施工方案。The other hoisting construction plan shall be made for large equipment .SB.1.4 静设备安装Static equipment installation 此工程静设备包含塔、换热器、反应器、容器类、过滤器等。The static equipment in project includes tower, heat exchanger, reactor, vessels category, filters and so on.操作平台及扶梯安装内件拆洗安装(合同要求) 外部附件安装设备总体检查确认设备找正测量交工验收灌浆设备吊装就位垫铁或支座敷设施工准备SB.1.4.1一般安装施工程序设备本体检查Process flow for installationOperation platform and installation escalator Preparation for construction In a (contract) installed unpick and washEquipment ontology check External attachment installed Mat iron or bearing installation The overall equipment check Equipment hoisting in place Find are measuring equipment Acceptance date grouting SB.1.4.2一般安装要求General installation requirements1、地脚螺栓上的油脂和污垢应清除干净，但螺纹外露部分应涂油脂。Oil and dirt on the anchor bolts shall be cleaned up, but thread exposed portion should be coated with grease protection;2、在工作温度下经受膨胀或收缩的卧式设备，其滑动侧的地脚螺栓应先紧固，当设备安装和管线连接后，再松动螺母留下0.51毫米的间隙，然后将锁紧螺母再次紧固以保持这一间隙。当采用滑动底板时，设备支座的滑动面应进行清理，并涂上润滑剂。The horizontal equipment which subjected to expansion or contraction in operating temperature its slide anchor bolts should be tighten first, after the equipment installation and pipeline connectedr, nut shall be loosed to leave 0.5-1 mm gap , then nut will tighted again to ensure keepthis gap. When adopting the sliding floor, sliding surface of equipment supporter should be cleaned and coated with lubricant.3、与震动的机械相连接的设备，其地脚螺栓的紧固应按图样或技术文件要求进行。The equipment which connected with vibrated mechanical ,its anchor bolts shall complied with the design drawing or technical documentation requirements4、直接承受负荷的垫铁组，其位置和数量应符合下列要求：每个地脚螺栓近旁至少应有一组垫铁，垫铁组应尽量靠近地脚螺栓。有加强筋的设备底座，垫铁应垫在加强筋下。Mat iron group which directly bear heavy load, the position and number shall meet the following requirements: at least one group iron mat shall near every anchor bolt, mat iron group should be closed to the anchor bolts as close as possible. mat iron shall be filled under strong rebar for reinforced equipment base .5、设备的找正、找平应按基础上的安装基准线（中心标记、水平标记）对应设备上的基准测点进行调整和测量。立式设备的铅垂度应以设备两端部的测点为基准；卧式设备的水平度一般以设备的中心划线为基准。找正与找平应在同一平面内互成直角的两个或两个以上的方向进行；设备找平时，应根据要求用垫铁（或其它专用工具调整件）调整精度，不应用紧固地脚螺栓及局部加压等方法进行调整。 Level and alignment for equipment shall be measured and adjusted on the basis of installation baseline (center mark, levels mark) of corresponding equipment .The verticality of vertical equipment of shall be measured with benchmark on both ends of equipment ; levelness of horizontal equipment shall be standarded by the centerline . level and alignment shall be carried out at two plumb lines (90from and to each other)in the same plane s with two direction; During equipment leveling, we shall adjust precision according to require a mat iron (or other special tools ,shall not tighten the anchor bolts or application local pressure adjustment methods.检查项目允 许 偏 差（mm）一般设备与机械设备衔接设备立式卧式立式卧式中心线位置D2000 5D2000 10533标高 elevation55相对标高 3 relative elevation相对标高 3 relative elevation水平度horizontalityL/10002D/1000轴向0.6L/1000 Radical direction径向D/1000 Radical direction铅垂度verticalityh/1000h/1000方位Direction 沿底座环圆周测量D2000 10 D2000 15 measure along the round shape basement沿底座环圆周测量 5 measure along the round shape basement注：D设备外径OD of equipmentL卧式设备两支座间距离 The distance between the two basement of horizontal equipment h立式设备两端部测点间距离the distance between two observation point on vertical equipment6、设备基础二次灌浆Backup grouting灌浆前基础应具备以下条件：Before the grouting basement should have the following conditions:麻面已凿、表面清洁及表面充分湿润；The out surface of the back grouting should be flatten and good-shaped The surface should be wetting for enough time灌浆前应检查垫铁：与基础表面充分接触；Before the grouting mat iron should be checked: should fully contact with the surface of foundation;放置位置、数量符合规范要求；Placed position and number should be corresponded specification;外露长度不大于20mm；Exposed length not more than 20 mm;每组块数不超过4块；The pieces of each group should not more than 4 piece;垫铁间点焊完毕；welding shall be accomplished between each mat iron;灌浆时应支模；Formwork should be made in Grouting ;操作时不能碰歪地脚螺栓；Operation cant touch the anchor bolts;灌浆后要有养护措施；After grouting maintenance measures should be adopted;灌浆采用环氧灌浆料，灌浆料标号应比基础混凝土标号高一个等级。The fine particle concrete for grouting has the strength one grade higher than the foundation7、人孔封闭Manhole sealing静设备人孔封闭在装置系统气密试验前进行；Static equipment manhole sealing will be done before the air-test of device system ;人孔封闭前设备内件安装完毕，强度试验已进行；Internal installation and strength test shall be done before static equipment mahole sealing封闭时，由上往下逐层扫清内部杂物，达到设计要求的清洁度；Clean internal sundry from the top to down cleared to meet the design requirements of cleanness in sealing process;封闭时，逐层检查并确认设备内部所有内件的安装质量符合要求；Monitor all inside equipment step by step to meet installation quality requirements,达到上述条件后，进行填料装填（按业主需求）；After achieving the above conditions, loading packing will be carried on最终进行人孔封闭。Finally the manhole will be sealedSB.1.4.3塔、容器类静止设备安装示意图 1、容器类设备安装过程：Vessels category equipment installation process:a 先制作平衡梁，利用设备原有吊耳，吊起设备就位。first shoulder pole shall be fabricated, using equipment original lug to lift the equipment in place.b 设备找平，找正 Level and alignment for equipment c 该类设备安装过程图：The equipmen