一般静设备安装程序.doc

一般静设备安装程序CNOOC AND SHELLPETROCHEMICALS COMPANY LTD中海壳牌公司CSPC NANHAI PETROCHEMICALS PROJECT“LDPE PLANT”南海石化项目“LDPE 装置”LOCATION: HUIZHOU, PRC地址：中国.惠州METHOD STATEMENT FOR STATIC EQUIPMENT INSTALLATION静设备安装施工方案Project Procedure No: PR-8830-TEC1-0033项 目 文 件 编 号：PR-8830-TEC1-0033DISCIPLINE: MECHANICALRef. No. NH-LDPE-026REVDATEEASON FOR ISSUEPREPDCHKDAPRD0For Approval1For Approval CSPC NANHAI PETROCHEMICALS PROJECT LDPE PLANT NH LDPE 026FILE : METHOD STATEMENT FOR STATIC EQUIPMENT INSTALLATION Page: 19 of 21 CONTENTS目 录1. GENERAL31. 一般说明32. REFERENCE DOCUMENTS32. 参考文件33. PREPARATION43. 准备工作44. LINERS64. 垫铁65. SETTING AND ALIGNMENT95. 安装就位和找正96. GROUTING96. 灌浆97. CONCRETE MORTAL FINISHING AROUND GROUT117. 混凝土砂浆修整118. ALIGNMENT TOLERANCES118. 找正偏差119. WELDING139. 焊接1310. PLATFORMS AND LADDERS1310. 平台和梯子1311. INTERNALS FOR EQUIPMENT1311. 设备内件1312. REMOVAL OF LIFTING LUGS1312. 吊耳拆除1313. SCOPE OF INSPECTION/CHECK AT FIELD1413. 现场检验/检查范围1414. DO CUMENTATION1414. 文件1415. SAFETY MEASURES1515. 安全技术措施151. GENERAL1. 一般说明1.1 This procedure is provided to describe the instruction for general requirements of equipment installation such as reactors, columns, drums, heat exchangers, packaged equipment, equipment modules, miscellaneous equipment and miscellaneous machinery to be applied for CSPC NANHAI PETROCHEMICALS PROJECT LDPE Plant.该方案用于描述说明南海石化LDPE项目中的设备安装，像反应器、容器、塔、槽、换热器、组装设备、设备模块、 各种设备和机械的有关要求。1.2 This procedure shall be applied to static equipment installation work according to the codes and construction specifications described in paragraph2. In the case of any discrepancies between this Specification and Vendors instructions, the latter shall govern.依据第2部分中描述的规范和施工标准，该方案适用于一般静设备安装工作；如果在所列规范和供应商的随机文件之间有歧义， 后者占主导地位。2. REFERENCE DOCUMENTS2. 参考文件2.1 CODE2.1 标准 (1) GB50231-98 General code for construction and acceptance of mechanical equipment installation engineering (1) GB50231-98 机械设备安装工程施工与验收规范(2) GB50270-98: Code for construction and acceptance of continuous conveyer equipment installation engineering (2) GB50270-98: 连续输送设备安装工程施工与验收规范 2.2 D.E.P 2.2 业主文件 (1) 31.29.00.10-CSPC Installation of Rotating Equipment (1) 31.29.00.10-CSPC 传动设备安装 (2) 31.38.01.11-CSPC Piping-General requirements(2) 31.38.01.11-CSPC 管道总说明 (3) 70.10.80.11-CSPC Cleaning of equipment(3) 70.10.80.11-CSPC 设备清洗 (4) 31.38.01.29-CSPC Pipe Supports (4) 31.38.01.29-CSPC 管支架 (5) 61.10.08.11-CSPC Field inspection prior to commissioning of mechanical equipment(5) 61.10.08.11-CSPC 设备试车前的检查3. PREPARATION3. 准备工作3.1 Erection Equipment Procedure Flow Chat：Refer to block diagram followed施工流程图：见下图3.2 Prior to installation, open box inspection should be made by Employer, PMCcontractor, EPC contractor and subcontractor and the result shall be recorded, the inspection content is in accordance with the following items:现场安装前，开箱检查由业主、PMC、总承包商及下级承包商共同参加，开箱记录妥善保存。检查项目应依据下列项目进行： Box No. quantity and package condition 装箱号码、数量及包装情况 Equipment name, type and specification 设备名称、类型及相关文件 Packing list, technical document and special tool 装箱单、技术文件及专用工具 Equipment parts defective, missing, damage or rust 设备缺陷、缺失、损坏及污染情况 Other conditions which need to be recorded 其它需要记录的情况基础验收处理Foundation check & handling开箱验收open box inspection垫铁安装liner installation吊装、就位lifting and perch初步找正first alignment一次灌浆first grouting附件、附属设备及梯子平台安装adjunct Erection of &platform &ladder保温及表面涂装insulation and surface painting管道连接piping association清理封闭cleaning and sealing精找 final alignment二次灌浆second grouting3.3 Anchor bolt holes and the bottom of equipment bases only shall be cleaned and freeof laitance, loose particles, oil or grease. Any anchor bolt hole and foundation shall be rough chipped for removal of laitance. 地脚螺栓孔和设备底座底部要清理干净， 不得有混凝土浮浆、 松动颗粒、油或油脂。 有地脚螺栓孔和基础要铲平将浮浆除掉。3.4 Anchor bolts shall also be cleaned. 地脚螺栓也要清理干净。3.5 Marking on foundations used for alignment shall be checked. 要检查基础上用于找正的标识。3.6 Padding using liners and grout shall be performed in accordance with the methods specified in Para.4 and Para.6 in this specification. 要依据本规范中Para.4 和 Para.6中确定的方法来完成使用垫铁和灌浆的垫层。3.7 Equipment and tools for transport, lifting, and the assembly of equipment should have get ready. The plan and calculations books About lifting should have been completed.用于运输和起吊的工具、设备应准备好。有关于吊装的布置图、计算书等技术工作完成。3.8 The equipment or their components have been transported to the site, near to the foundations, so as to lifting work can be carried out. 设备及其附件已经运抵现场，并靠近基础以便于吊装。4. LINERS4. 垫铁4.1 Materials 材料 Materials of liners shall be Q235 or equivalent. 垫铁材料要为Q235或同类产品4.2 Position and Number Required 位置和所需数量。4.2.1 Liners shall be provided on both sides of anchor bolts. 垫铁通常要放置在地脚螺栓的两侧。4.2.2 In general, the interval between liners shall not exceed 800mm. If the interval is more than 800mm, an additional liner shall be added between the liners.一般来说，垫铁之间的间隔不得超过800mm。如果间隔超过800 mm，在这两组垫铁之间还要加一组垫铁。4.2.3 Not withstanding the general guidance as set out in Para 4.2.2, the load to be supported by liners shall be max.30 kg/cm2. If the supported load is to exceed 30 kg/cm2, either the width or number of liners or both shall be increased.依据Para 4.2.2中提出的一般指导说明，垫铁需要承载的载荷最大要为30 kg/cm2。 如果支撑载荷要超过30 kg/cm2，或者垫铁的宽度或数量或两者都要增加。The load to be supported shall be calculated in accordance with the equation shown below.要支撑的载荷要依据下面所示的方程进行计算:L: Load supported by liner （kg/cm2）L: 垫铁支撑的载荷（kg/cm2）W: Lifting load of equipment（kg）W: 设备吊装载荷（kg）N: Number of linersN: 垫铁数量A: Width of base plate for equipment （cm）A: 设备底板的宽度（cm）B: Width of liner （cm）B: 垫铁的宽度（cm）4.2.4 However, in case of horizontal equipment, only one piece of straight liner shall be used for every one set as a standard. 对于卧式设备，作为一种标准，只使用一块平垫铁。4.3 Shape 形状4.3.1 The width of liners shall be as shown in Table below.垫铁的宽度要按下表所示4.3.2 The lengths of liners shall be 20 to 30 mm longer than the width of the equipment bases, and shall be over the center of the adjacent anchor bolts. 垫铁的长度要超出底座宽度20-30mm，并要超过邻近地脚螺栓的中心。4.3.3 The thickness of both taper and straight liners shall be at least 10 mm and the minimum thickness of the tapered ends shall be 2 mm.斜垫铁和平垫铁的厚度至少为10mm，并且倾斜端的最小厚度为2mm。Adjustment allowance shall be 4 to 6 mm.调整允差为4-6mm。4.3.4 The gradient of taper liners shall be 1/50 in general but at least within the range of 1/30 to 1/70. 斜垫铁的坡度一般来说为1/50，但至少要在1/30-1/70的范围内。4.4 Finishing修整 Tapered faces shall be machined to a normal finish. If other portions are under formed and smooth, they need not be finished. Edges, however, shall be beveled to prevent injury to personnel. 倾斜表面要加工到要求的光洁度，如果其他部分修整成型，光滑，这些部分就不需要修整。 可是边缘部分要打磨，以防止对作业人员造成损伤。4.5 Setting of Liners 垫铁安装4.5.1 Prior to the installation of liners and equipment, the liners and grouting portions of foundations shall be chipped and all concrete laitance shall be removed from grouted portions.垫铁和设备安装前，垫铁和设备基础需要灌浆的部分要铲毛； 灌浆部分的所有混凝土浮浆要除掉。4.5.2 Flat liners shall be installed at the level and positions as described in Para.4.2. The non shrink grout maintaining should be done according to seller. 设备安装前， 平垫铁要安装在Para.4.2中描述的水平和位置处，无收缩灌浆垫层的养护工作要依据厂家要求而做。 5. SETTING AND ALIGNMENT5. 安装就位和找正5.1 Equipment shall be set and aligned at the proper position, elevation, levelness and perpendicularity in accordance with the drawing. 设备要依据图纸进行安装就位，标高,水平度和垂直度要正确适当。5.2 The equipment proper shall not be lifted by its nozzle but by its lifting lugs or shell parts. Shell parts shall be protected by wooden blocks, rubber or other material from damage caused by sling wire. 设备吊装位置不得在接口处，而是在吊耳或壳体处。 壳体部分要用木块， 胶皮或其他材料保护，以免于被吊索损坏。5.3 With regard to horizontal type equipment requiring allowance for thermal expansion, full attention shall be paid to the positional relation between the anchor bolt holes of the base place and the anchor bolts themselves.关于需要热膨胀允差的卧式设备， 一定要注意设备底板地脚螺栓孔和地脚螺栓自身的位置关系。5.4 Upon completion of alignment, the liners shall be welded level by level. Liners which project more than 15mm from the base plates shall be cut. 一完成找正工作，垫铁要层层点焊，伸出长度超过底板15mm的垫铁要割掉。6. GROUTING6. 灌浆6.1 Materials6.1 材料a) Grout material may be wither: cement-based non-shrink grout or epoxy grout.灌浆料要采用以下两者之一：无收缩混凝土或环氧砂浆。b) Fine aggregate（sand） shall conform to GB 50231-98 or equivalent.细骨料（砂）要符合GB 50231-98或同类产品。c) Water for mixing grout materials shall be fresh and clean, and free from injurious amount of oil, acid, alkali, salt or organic materials.混合灌浆材料用水要新鲜, 干净, 没有损害性油, 酸, 碱, 盐或无机材料。6.2 Mixing6.2 混合The mixing should be done according to the requirements of seller.混合要根据卖方要求而做。6.3 Application6.3 应用(1) After cleaning, the foundation top shall be saturated with fresh water for at least 24 hours prior to grouting. And padding or grouting shall be done in a moisture condition, there shall be no free water on the foundation top during grouting. Remaining puddles shall be removed before padding or grouting.清理干净后， 基础顶部要在灌浆前24小时浇水（仅限于无收缩水泥）， 灌浆或垫层工作要在湿润条件下进行，且灌浆时基础表面不应有剩余水分； 垫层或灌浆前，残留的浮浆要除掉。(2) Grouting of one continuous area shall be completed without interruption.一个连续区域的灌浆工作进行期间不得有间隔。(3) Grouting shall be applied not only under the equipment bases and anchor holes but also the ejected portion of the liner so that such portion can be perfectly covered by grouting （the ejected portion to be covered may be around 30 to 40 mm）.灌浆部位不仅在设备底座和地脚孔处,而且还包括垫铁的伸出部分， 以便使得这些部分都能被完全灌上（需要覆盖的伸出部分可能为30-40mm）。(4) The mounting space of grout shall be in general at arrange of 25 to 50 mm.灌浆的高度一般为25-50mm高。(5) Mortar shall be carefully placed in between the base plate and the foundation top, and rammed in and tamped sufficiently with an iron bar or the like to eliminate and air pockets.小心地将砂浆放在设备底板和基础顶端之间，用铁板或同类物质夯实，以消除“气囊”现象。(6) Upon completion of padding or grouting, mortar shall be properly cured for three days or longer by covering it with mats or sprinkling it with water according to the weather conditions.垫层或灌浆工作完成后， 砂浆要盖上垫子进行三天或更长时间的养生期， 或根据天气条件往上面浇水。(7) No load shall be applied fro at least 3 days after padding or grouting.垫层或灌浆层浇注后至少三天内，上面不得放任何载荷。(8) Drain pipe shall be installed along the drain ditch and fixed by grouting.排污管要沿着排污沟安装，并用灌浆料固定。(9) The surface of grouting shall be finished so as to be smooth by using a steel trowel, etc.灌浆料表面要进行修整，以便用钢抹子等将表面抹平。7. CONCRETE MORTAL FINISHING AROUND GROUT7. 混凝土砂浆修整After grouting work completed, surrounding mortal finish shall be carried out with a slope for water drainage.完成灌浆工作后，砂浆周围的修整要形成一个坡度，以便于排水。8. ALIGNMENT TOLERANCES8. 找正偏差Equipment shall be aligned within the following tolerances and the results shall be recorded:设备找正要在以下偏差范围内，结果要记录。8.1 Position8.1 位置 The center line of the foundation shall be in alignment with that of the equipment in every direction within the tolerances of 3 mm.设备的找中工作，设备各方向相对基础的中心线，偏差要求在3 mm范围内。8.2 Elevation8.2 标高 At least, one point on the base plate shall be aligned within the tolerances of 3 mm. 设备底板上至少一点的标高调整在3 mm.的偏差范围内。8.3 Perpendicularity8.3 垂直度 The center (basic line) of the equipment shall be in alignment with the vertical line within the tolerances of 6 mm for every 10m length of the equipment, in principle, provided that such tolerance for 20m and longer equipment shall not exceed 12 mm. 所有设备的中心线(基准线)要同垂直线相一致， 设备每10米长偏差在6mm范围内；原则上，对于设备长度为20 m或更长的设备，其偏差不应超过12 mm的范围。 8.4 Levelness8.4 水平度 The center line （ basic line） of the equipment shall be in alignment with the horizontal line within the tolerances of 1 mm for every 1 m length（1/1000）. 设备的中心线（基准线）要同水平线相一致， 设备每1米长偏差在1mm（即1/1000坡度）范围内。 *（This tolerance is applicable to horizontal equipment） *（此偏差适用于卧式设备）8.5 In the case where an item of equipment is cured and the center line （ basin line ）therefore is not within the specified tolerance, the center line shall be measured at any point close to the base line of the vessel （ tangential） where it is possible to measure it . 在一台设备进行修整的情况下，设备中心线（基准线）因此不在规定的偏差范围内，在靠近容器（相切、切向）基准线的任意一点处,可能测量中心线的地方,测量中心线。8.6 If there is any interference from other objects in measuring the center line (basic line ) of an item of equipment, measurement shall be taken on both side of the equipment proper from two directions 90 apart and the average value shall be adopted.如果在测量一台设备的中心线时，有其他物体干扰，测量要在设备距离90的两个方向进行， 采用平均值。9. WELDING9. 焊接Welding technical requirement and construction method statement shall be prepared in term of specific equipment. 焊接的技术要求和施工方法应按照设备随机文件中的内容准备。10. PLATFORMS AND LADDERS10. 平台和梯子10.1 Installation of platforms and ladders which are attached directly to equipment shall beperformed in accordance with relevant specifications and drawings.附着在设备上的梯子平台要依据有关规范和图纸来完成。11. INTERNALS FOR EQUIPMENT11. 设备内件11.1 Assembly of internals for equipment shall be performed in accordance with relevantspecifications and drawings. 设备内件装配要依据有关规范和图纸来完成。12. REMOVAL OF LIFTING LUGS12. 吊耳拆除12.1 Lifting lugs and tailing lugs may be left welded to equipment unless removal is required in the relevant specification/drawing or removal is requested by Company due to the field conditions.吊耳和尾端支耳可留到设备上，除非相关图纸/规范要求拆除或由于现场条件，业主要求拆除。12.2 In case cutting of lugs is required a minimum 30 mm length of the lug from the equipment surface shall be left to avoid damage to the equipment material. The cut surface shall be ground smooth.万一要求割掉吊耳，距离设备表面最小30mm长要保留， 以避免对设备造成损害。 切割表面要磨平。13. SCOPE OF INSPECTION/CHECK AT FIELD13. 现场检验/检查范围Item No.序号Description描 述TISA泰克尼蒙特JCC中油化建(1)Direction of Expansion caused sliding movement向膨胀方向滑动的趋势FW/RPFW/RP(2)Plumbness and levelness垂直度和水平度FW/RRFW/RP(3)Check of internals before closing man-holes人孔封闭前的内部检查工作FW/RRFW/RP FW： Full Witness. FW： 现场见证 SW： Spot Witness. SW： 抽检 RP： Report / Record to be p