51 Equipment installation and construction process设备安装施工工艺.docx
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51 Equipment installation and construction process设备安装施工工艺.docx
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51Equipmentinstallationandconstructionprocess设备安装施工工艺
5.1Equipmentinstallationandconstructionprocess设备安装施工工艺
5.1Equipmentinstallationandconstructionprocess设备安装施工工艺
5.1.1General概述
5.1.2Thebasisforpreparing编制依据
5.1.3Staticequipmentinstallation静设备安装
5.1.4Rotatingequipmentinstallation动设备安装
5.1.Equipmentinstallationandconstructionprocess设备安装施工工艺
5.1.1.General概述
5.1.1.1.TheconstructionprocesspreparedforBMSCPCSExpansionLine200ktProject–DPCMEPInstallationWorks
本施工工艺为拜耳材料科技(中国)有限公司,拜耳材料科技中国20万吨/年聚碳酸酯扩建项目DPC项目机电设备安装工程而编制
5.1.1.2.Theprojectequipmenttotaling181units,rotatingequipmentabout20units,singlemaximumweightof135tonsofphosgenereactor,monomerisgreaterthan20tonsofequipment8.
该工程项目设备共计181台,动设备约20台,单台最大重量135吨的光气反应器1台,单体大于20吨设备8台。
5.1.2.Thebasisforpreparing编制依据
5.1.2.1.BayerDPCexpansionprojecttenderdocuments
拜耳DPC扩建项目招标文件
5.1.2.2.Codeforqualityacceptanceofstaticequipmentinstallationinpetrochemicalengineering
石油化工静设备安装工程施工质量验收规范GB50461-2008
5.1.2.3.Technicalprocedureforconstructionofstaticequipmentinstallationinpetrochemicalindustry
石油化工静设备安装工程施工技术规程SH/T3542-2007
5.1.2.4.Generalcodeforconstructionandacceptanceofmechanicalequipmentinstallationengineering
机械设备安装工程施工及验收通用规范GB50231-2009
5.1.2.5.Codeforconstructionandacceptanceofconveyorequipmentinstallationengineering
连续输送设备安装工程施工及验收规范GB50270-2010
5.1.2.6.Codeforconstructionandacceptanceoffan,compressorandpumpinstallation
压缩机、风机、泵安装工程施工及验收规范GB50275-2010
5.1.2.7.Codeforconstructionandacceptanceofcraneinstallationengineering
起重设备安装工程施工及验收规范GB50278-2010
5.1.2.8.GeneralSpecificationforconstructionandacceptanceofmechanicalequipmentinstallationinpetrochemicalindustry
石油化工机器设备安装工程施工及验收通用规范SH/T3538-2005
5.1.2.9.Specificationforconstructionandacceptanceofpumpunitinstallationinpetrochemicalindustry
石油化工泵组施工及验收规范SH/T3541-2007
5.1.3.Staticequipmentinstallation静设备安装
5.1.3.1.Preparationbeforeconstruction施工前准备
¯Technicalpreparations技术准备
⏹Drawupconstructionplan,theliftingoperationswhichisequipmentweighttooheavy,installationlocationtoohighorthehoistingpositionshoulddrawupspecialconstructionplanaccordingtotherequirementsofBayerandaskforBayerapplication;
施工方案,对于设备重量大,安装位置高或吊装位置受局限等吊装作业,按拜耳要求编写吊装专项方案,报拜耳批准;
⏹Recordandgivetechnicalteststotheconstructionworkers
对施工人员进行技术交底并记录
⏹Onthebasisoftheprojectschedule,detailedthescheduleofeachdeviceinstallation;
在项目进度计划基础上,细化进度计划到每台设备的安装;
⏹Trackthesituationoftheactualarrivaloftheequipment,adjusttheconstructionsequenceintimewhenthesituationisinconsistentwiththeplan.
跟踪设备的实际到货情况,出现和计划不一致时及时调整施工顺序。
¯Equipmentacceptanceandcustody设备验收和保管
Equipmentacceptance,inventory,inspectionandstorageshouldmeetthefollowingrequirement:
设备的验收、清点、检查及保管,应符合以下规定:
⏹Deliverinstalledequipmentandaccessoriesshouldmeetdesignrequirements,attachtechnicaldocumentssuchasqualifiedcertificateandinstructionforinstallation;
交付安装的设备及附件,必须符合设计要求,并附有出厂合格证明书及安装说明书等技术文件;
⏹Opentheequipmentshouldbeontheconditionoftherelevantpersonnelatthescene,contrastthepackinglistanddrawings,checkaccordingtothefollowingitemsandcount,fillin《EquipmentAcceptanceandInventoryRecords》:
设备开箱应在有关人员参加下,对照装箱单及图样,按下列项目检查与清点,并填写《设备验收、清点记录》:
ØTheboxnumber,thenumberofboxesandpackaging;
箱号、箱数及包装情况;
ØEquipmentname,type,modelandspecifications;
设备名称、类别、型号及规格;
ØEquipmentoveralldimensionandnozzlelocation;
设备外形尺寸及管口方位;
ØThespecification,sizeandquantityoftheinnerpartsandaccessories;
设备内件及附件的规格、尺寸及数量;
ØSurfacedamage,deformationandcorrosionconditions;表面损坏、变形及锈蚀状况;
⏹Beforeequipmentinstallationshouldconsiderthefollowingconditionsinordertodeterminethelocationandmethodofthestorageandcustody:
设备安装之前应考虑下列条件,以确定存放、保管的地点和方法:
ØThemodelofequipmentandinnerparts、thepropertiesofmaterialsandthedegreeofsmoothandcleanonthesurface,non-ferrousmetalequipment,liningequipment、enamelandotherequipmentthateasytodamageshouldavoidmixedstackingwithsteelequipment,thesiteshouldkeepflat,clean,etc;
设备、内件及附件的型式,材料的性能及表面光洁程度,色金属设备、衬里设备、搪瓷及其他易损设备应避免与钢制设备混杂堆放,场地应保持平整、清洁等;
ØStorageperiodandweatherconditions;
贮存时期和气象条件;
ØEnvironmentconditionssuchassediment,corrosivegasandsoon;
环境条件,如有无泥沙、腐蚀性气体等;
ØTakenecessaryprotectivemeasuresaccordingtothedifferentequipmentstorage.
据不同的设备存放,做必要的防护措施。
¯Handovercivilfoundation土建基础交接
⏹Beforeinstallationconstruction,theequipmentfoundation(includingotherprecast)shouldpasstheacceptance.Basicconstructionunitshouldofferqualitycertification、measurementrecordsandothertechnicalconstructioninformation;
安装施工前,设备基础(包括其他预制构件)须经交接验收。
基础施工单位应提交质量合格证明书、测量记录及其他施工技术资料;
⏹Shoulddrawelevationofbaseline,verticalandhorizontalcenterlineobviouslyonthefoundation,markthecoordinateaxisonthecorrespondingbuildings(structures);thedesignrequirementsforsettlementobservationequipmentfoundationshouldsettlementobservationlevelpoint;
基础上应明显的画出标高基准线、纵横中心线,相应的建筑(构筑)物上应标有坐标轴线;设计要求作沉降观测的设备基础应有沉降观测水准点;
⏹Strengthoffoundationconcreteshouldmeetthedesignrequirements.Surroundingearthworkneedbackfilling,compaction,leveling.thethreadedportionoftheanchorboltsshouldbenodamageandnorust
基础混凝土强度应达到设计要求,周围土方应回填、夯实、整平,地脚螺栓的螺纹部分应无损坏和不生锈;
⏹Foundationappearancecannothavedefectssuchascrack,cellular,cavityanduncoverrebar
基础外观不得有裂纹、蜂窝、空洞及露筋等缺陷;
⏹foundationcanbecheckedaccordingtotherequirementlistedintablebelow,eachsizeandpositiondeviationvalueshallnotbemorethantheprovisionsofthetable
具体可按下表规定对基础进行检查,基础各部尺寸及位置的偏差数值不得超过表的规定;
Item
项次
CheckItem检查项目
Allowabledeviationvalue(Millimeter)
允许偏差值(毫米)
1
coordinatepositionoffoundation(Vertical,horizontalaxis)
基础坐标位置(纵、横轴线)
±20
2
Theelevationofthedifferentplanesofthefoundation
基础各不同平面的标高
0,-20
3
Planedimensionoffoundation基础上平面外形尺寸
Planedimensionofboss凸台上平面外形尺寸
PlanedimensionofPockets凹穴尺寸
±20
0,-20
+20,0
4
Unlevelnessonthefoundationplane(Includingthegroundneedtoinstalltheequipmentparts),Permeter
基础上平面的不水平度(包括地坪上需要安装设备的部分),每米
Unlevelnessonthefoundationplane(Includingthegroundneedtoinstalltheequipmentparts),Totallength
基础上平面的不水平度(包括地坪上需要安装设备的部分),全长
5
10
5
Verticaldeviationoffoundation,Permeter
基础竖向偏差,每米
Verticaldeviationoffoundation,Totalheight
基础竖向偏差,全高
5
10
6
Embeddedanchorbolts,Elevation(top)
预埋地脚螺栓,标高(顶端)
Embeddedanchorbolts,Centercirclediameter
预埋地脚螺栓,中心圆直径
Embeddedanchorbolts,Centerdistance(Measuringatfoot&top)
预埋地脚螺栓,中心距(在根部和顶部两处测量)
Verticality
垂直度
+10,0
±5
±2
2
7
Reservedbolthole,Centrallocation
预留地脚螺栓孔的,中心位置
Reservedbolthole,Depth
预留地脚螺栓孔的,深度
Reservedbolthole,HolewallverticalityPermeter
预留地脚螺栓孔的,孔壁铅垂度(每米)
±10
0,+20
10
8
Embeddedplate,Theelevation(plane)
预埋件,标高(平面)
Embeddedplate,Centerline
预埋件,中心线位置
Embeddedplate,Levelness
预埋件,水平度
0,+5
10
10
¯Sitepreparation现场准备
⏹Pre-installationshouldsettheinstalledbaselineandpositioningreferencemarkaccordingtothedesigndrawingsortechnicaldocumentsrequirement;
Devicesareaffiliatedorcohesioneachothermustidentifycommonreferenceaccordingtoconnectionrequirement.
⏹安装前应按设计图样或技术文件要求画定安装基准线及定位基准标记;对相互间有关联或衔接的设备,还应按关联或衔接的要求确定共同的基准;
⏹Foundationsurfaceshouldbetrimmedbeforeequipmentinstallation.groutingsurfaceneedtoshovelpockmarkedface;foundationsurfaceshallnothavegreaseorlooselayer;placedshim(toaround50mm)shouldbeleveled,levelnessofleveledpartsbealloweddeviationof2mm/m,Reservefootboltholedebrisshouldbecleaned
⏹基础表面在设备安装前应进行修整。
需灌浆抹面时要铲好麻面;基础表面不得有油垢或疏松层;放置垫铁处(至周边50毫米)应铲平,铲平部位水平度允许偏差为2mm/m,预留地脚螺栓孔内的杂物应清除干净。
⏹Beforetheinstallationofequipment,accessoriesandanchorboltsmustbecheckedwithoutdamageandcorrosion;andtheorientationofthedevicemark,thecenterofgravitymarkandhangingpointsalsobechecked,thosedonotmeettheinstallationrequirementsshouldbeadded
⏹安装前应对设备、附件及地脚螺栓进行检查,不得有损坏及锈蚀;要检查设备的方位标记、重心标记及吊挂点,对不符合安装要求者,应予补充;
¯Theaccuracyofmeasurement,inspectioninstrumentsandgaugesinstallationmustcomplywiththeaccuracystandardsbytheNationalBureauofWeightsandMeasures,Andshouldbetestedonschedule
安装时所使用的测量及检查用仪器与量具的精度均需符合国家计量局规定的精度标准,并应按期检验合格。
5.1.3.2.On-siteinstallation现场安装
¯Equipmentinplace设备就位
⏹Equipmentinplacegenerallyusethecranehoisting,liftingbefore,basedontheweightoftheequipment,liftingheight,liftingradius,choosesuitablecranes,preparetheliftingprocedures;
设备就位一般采用吊车吊装就位的方式,吊装前,根据设备的重量,吊装高度、吊装半径,选择合适的吊车,编写吊装程序;
⏹Structurewithintheframeworkcannotplacethedevice,onceliftingwithacrane,thefirstliftingequipmenttotheedgeoftheframe,placedincarerafts,astheleveloftractionchainguide,horizontalshiftofthedevicenexttotheequipmentfoundation,thentheverticalliftingofthechainguidetothefoundationinplace,horizontalshiftattentiontothestructure'sload-bearingandprotection;
对于结构框架内无法用吊车一次吊装就位的设备,先将设备吊装至框架边缘,放置在托排上,采用导链作水平牵引,将设备水平移位至设备基础旁,再用导链垂直吊装到基础上就位.水平移位时注意结构的承重及保护;
¯Alignmentandmakelevel找正与找平
⏹Equipmentalignmentandlevelingshouldbebasedontheinstallationofbaseline(centermarklevelmark),correspondingreferencemeasuringpointonthedeviceforadjustingandmeasuring;adjustmentandmeasurementreferenceprovidesasfollows:
设备的找正与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;调整和测量的基准规定如下:
Theelevationoftheundersideofthedevicesupport(skirttypesupport,earbearing,brackets,etc.),shouldbebasedontheelevationofthebaselineasarefe
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