仪表施工方案方案

1、编号：15-06部-Stepan-SHF-601 The 50,000t/a polyester polyol project of Stepan (Nanjing) Chemical Co., Ltd. 斯泰潘（南京）斯泰潘（南京）5 万吨万吨/年聚酯多元醇项年聚酯多元醇项 目目 仪表施工方案仪表施工方案 Instrument Construction Plan 编制 Prepare by： 安全 Security by： 审核 Review by： 批准 Approve by： Nanjing Chemical Construction Co., Lid 南京南化建设有限公司 13. Ma

2、r. 2015 目目 录录 Contents 第一章工程概况第一章工程概况 GENERAL.3 第二章：编制依据第二章：编制依据 CHAPTER 2- REFERENCE.3 第三章：仪表实物工作量第三章：仪表实物工作量 CHAPTER 3- INSTRUMENTQUANTITY OF WORK.3 第四章：施工的主要程序第四章：施工的主要程序 CHAPTER 4-MAIN CONSTRUCTION PROCEDURE.4 第五章：主要施工方法和技术要求第五章：主要施工方法和技术要求 CHAPTER 5-CONSTRUCTION TECHNICAL REQUIRES AND QUALITY S

3、TANDARD.7 第六章：质量控制第六章：质量控制和检、试验计划和检、试验计划 CHAPTER 6-QUALITY CONTROL AND INSPECTION TEST PLAN.29 第七章：主要施工机具第七章：主要施工机具 CHAPTER 7- -MANPOWER.34 第八章：劳动力组织第八章：劳动力组织 CHAPTER 8-LABOR ORGANIZATION.34 第九章：施工进度计划第九章：施工进度计划 CHAPTER 9-CONSTRUCTION PROGRESS SCHEDULE.35 第十章：第十章：安全保证措施、安全保证措施、JHA 及文明施工及文明施工 CHAPTER

4、 FIVE SAFETY ASSURANCE SYSTEM, JHA AND HOUSEKEEPING .37 第一章：工程概况第一章：工程概况 Chapter 1-General 本工程为斯泰潘（南京）化学有限公司新建 5 万吨/年聚酯多元醇项目，工程范围主要 包括：行政办公和电控楼，空压站、门卫和称重，焚烧炉，冷却水系统，消防泵房，事故水 池，工艺装置区，仓储区等。 This is an expansion project of BASF-YPC Company Limited, the management team is IET, TAR work involved in area 1

5、 mainly includes existing instrument exchanges, remove, and resetting, new instrument installation, cable tray laying and cable pulling. 仪表种类主要有：控制阀、开关阀、流量计、差压变送器、压力变送器、温度变送器、 、分析仪表、气体检测仪等仪表。Various instruments covered like control valve, on-off valve, integrated flow meter, DP transmitter, pressure

6、 and temperature transmitter, fork liquid level switch and toxic gas detector. 第二章：编制依据第二章：编制依据 Chapter 2- Reference 招标文件 自动化仪表工程施工及质量验收规范GB50093-2013 Chinese instrument construction work code. 石油化工仪表工程施工技术规程SH3521-2007 Petrochemical instrument construction work code. 电气和仪表回路检验规范 GB/T25921-2010 自控安装

7、图册HG/T21581-2010 电气装置安装工程爆炸和火灾危险环境施工及验收规范GB50257-96 建筑工程施工现场供用电安全规范（GB50194-93）； Power Supply and Utility Safety Regulations on Construction Engineering Site GB50194-93 建设工程安全管理条例 第三章：仪表实物工作量第三章：仪表实物工作量 Chapter 3- Instrument quantity of work 名称单位数量名称单位数量 温度仪表台36调节阀台18 压力变送器台24过程开关台86 差压变送器台2分析仪表台5 差

8、压液位变送器台15有毒气体检测仪台2 液位仪表台16仪表电缆米39666 流量仪表台29桥架米2122 开关阀台51仪表管路米1147 施工前准备 preparation before construction 盘柜及底座制作安装cabinet fabricationandinstallation 第四章：施工的主要程序第四章：施工的主要程序 Chapter 4-Main construction procedure 1.主要施工程序流程图 预埋管、件安装 embedded pipe, fittings installation 电缆保护管安装 Cable protection pipe in

9、stallation 管线上仪表拆除、隔离阀关闭 Dismantle the pipeline Instrument, isolation valve closed 现场仪表二次安装 Secondary field instrumentation installation 配合单体试车 single commissioning 设计交底 design disclosure 电缆敷设 cable laying 系统联校 system joint calibration 导压管、气源管、伴热管安装Impulse control, air supply pipe, heating pipe inst

10、allation 试压、试漏 Pressure testing, leak testing 现场仪表安装 site instrument installation 校、接线 calibration, wiring 桥架、就地盘柜接线箱安装tray, cabinet wiring box on site installation 配合工艺一次部件安装 With the installation process once part 支托架立柱预制安装 Support bracket column installation of prefabricated 交工 验 收 acceptance 仪表单

11、校 Instrumentsingl e calibration 领、检设备材料 receive, check equipment and materials 仪表导压管试压 Instrument guide pressure pipe pressure test 图纸会审 joint review of drawings 2.准备工作 Preparation 1）组织施工有关人员进行交底，充分做好施工图会审工作，及时解决图纸中发现的问题， 从而为施工阶段争取时间。Organize technical clarification and DWG review, problems existing

12、 in DWGs shall be quickly solved to gain more time for TAR. 2）根据设计图和有关资料编制好设备材料表和有关施工资料，熟悉设计的规范、标准、 设计图纸以及有关的操作说明等资料。Prepare material list and related construction documents as per designed DWG and relative documents. Be familiar with codes, standards, DWGs and guidelines. 3）熟悉施工有关的资料及图纸，了解现有仪表的原理及接

13、线柜位置。Be acknowledgeable with construction related documents and DWGs , be clear with existing instrument philosophy and junction box location. 4）对施工班、组进行全面系统的技术交底，上岗人员能熟悉图纸，明确施工任务和施工 要点，规范及特殊要求。Technical clarification to construction team shall be complete and systematic, make sure construction pers

14、onnel are familiar wit DWGs, work content and requirements. 5）及时了解设备、材料到货情况，设备到货时，一定要根据厂家提供的装箱单、技术资 料，会同业主、监理单位开箱检验，核实仪表设备材料的规格，型号及数量是否符合设计要 求，并做好记录，并在干燥清洁的条件下妥善保管。Be clear with material and equipment status, open-box inspection jointly with IET and BYC as per packing list and technical documents pr

15、ovided by manufacturer, check if equipment and material specification, type and quantity are satisfied, and record made, all equipments and materials received shall be well kept. 6）准备好干燥清洁的房间，作为调校室，环境应符合要求。班组要检查机具是否完好， 检验期是否有效，校验仪表的等级是否符合要求。A clean room will be prepared to be as calibration room whi

16、ch shall comply with environmental requirements. Machines and tools shall be checked with completeness and expires by the group and instrument shall be checked with its grades. 7) 施工机具的准备。Preparation on construction machines and tools (1)根据图纸及工作量准备各种施工工具；Prepare various construction machines and too

17、ls as per DWG and work quantity. (2)现场严禁使用活动扳手，需要按照仪表规格书、安装图、管道 ISOMETRICS 图准备 同规格的套筒、梅花、开口扳手等。Movable wrench is not allowed to be used on site, sleeves and open-end wrench shall be prepared as per the specification provided in specification, hook-ups, and pipe isometrics. 2施工前期 1）仪表安装受装置作业、工艺设备、工艺管

18、道、土建等专业的现场条件限制，不宜提前 进行，但一些安装可在前期完成或部分完成。如：Site conditions limit advance construction of TAR instrument erection considering plant operation, process equipment tight time, heavy task and multi-trades crossing requires a detailed and strict schedule. 施工高潮主要工作如下：Main works for this time 1) 分支桥架（接线箱至仪表）

19、 、气源管线敷设（气源分配器至气动阀门） 。Branch cable tray laying (from junction box to instrument), air distributor wire pulling(from air distributor to pneumatic valve ) 2) 电缆敷设。Branch cable pulling(from junction box to instrument) 3) 导压管安装。Pressure pipe installation 4) 安装仪表、校接线。New and dismantled instrument install

20、ation, pressure test, leakage test, wiring calibration. 5) 回路测试。Loop test 4施工后期 Late stage of TAR 在所有安装工作结束后，要对整个安装工程进行“三查四定”和系统联校、仪表投运工作， 此项工作必须会同业主和监理等有关人员，根据施工验收规范要求，对整个仪表施工全面检 查，记下不合格点，并逐个给予解决，最终办理交付验收工作。When all installation work finished, work out punch list and clean all items remained, then

21、conduct system calibration and instrument commissioning jointly with IET and BYC related personnel. A full inspection is required to find out non-conformances and solve one by one. IET, BYC, MAV1 and supervision unit shall be involved in system loop calibration and make decisions, finally, acceptanc

22、e work will be performed. 第五章：主要施工方法和技术要求第五章：主要施工方法和技术要求 Chapter 5-Construction technical requires and quality standard. 1. 仪表盘柜的安装 Dashboard cabinet installation 1) 盘柜到现场后，为避免设备损坏，要尽量减少搬运次数。Cabinet arrives at the scene, in order to avoid damage to the equipment, to minimize handling times. 2) 设备开箱时

23、在安装地点附近开箱，使用撬棍时不得以盘面为支点，以免损伤盘柜。拆 箱时有库管、厂家、及监理等相关人员在场，对于明显的设备缺陷，作好记录并报有关人员。 When the equipment is installed out of the box near the location of the box, not to the disk as a fulcrum when using a crowbar, so as not to damage the disk enclosure. There Kuguan, manufacturers, and supervision and other re

24、lated personnel present during the unpacking of equipment for obvious defects, make records and report to the relevant personnel. 3) 盘柜在开箱时，由技术员按安装图标好开箱先后顺序，在开箱后运至基础过程中要保 证设备及人身安全。由于盘体较重，要用力平稳、一致。不允许剧烈振动和撞击。盘到位后， 还要仔细核对其型号是否正确，零部件、缺件、损坏件核对后做好记录。Enclosure at the box by pressing the Setup icon technic

25、ian good out of the box the order, shipped to the base after the unpacking process to ensure that equipment and personal safety. Due to heavy plate body, to force a smooth and consistent. Do not allow excessive vibration and shock. After the disc in place, but also carefully check the model is corre

26、ct, parts, missing parts, damaged parts after checking make a record. 4) 盘柜找平、找正时，先精确的找好第一块，再以第一块为基准，将其它依次调整找平、 找正。Enclosure leveling, alignment, first the first one to find a good accurate, then the first one as a reference, the other in order to adjust the leveling, alignment. 5) 同一系列规格相邻两盘、柜、台的顶部

27、高度允许偏差为2mmm; In the same series specifications of two adjacent plates, cabinets, table top height tolerance for 2mmm 6) 当同一系列规格盘、柜、台间的连接处超过2处时，顶部高度允许偏差为5mm；When the junction of the same series specifications cubicle, desk between more than two, top height tolerance of 5mm; 7) 相邻两盘、柜、台接缝处正面的平面度允许偏差为1

28、mm；Two adjacent plates, cabinets, front desk seams flatness tolerance of 1mm; 8) 当盘、柜、台问的连接处超过5处时，正面的平面度允许偏差为5mm；When the disc, connection cabinets, desk and asked the more than 5, the front of the flatness tolerance of 5mm; 9) 相邻两盘、柜、台之间的接缝的间隙，不大于2mm。Two adjacent cubicle, the gap between the seams

29、of the station, no more than 2mm. 2. 接线箱安装 Mounting of junction boxes 1) 接线箱应安装在水平面或平台上，接线箱的安装位置应便于操作和维护。Junction boxes shall be installed at grade or on the platform. Location of junction boxes will generally be decided by considering operability, ease of maintenance. 2) 接线箱应根据施工图进行安装。Junction boxe

30、s shall be installed in accordance with construction drawings and/ or instruction by BYCs supervisor. 3) 当不在接线箱内工作时，所有的接线箱盖板必须完全关闭。 3. 仪表支架 instrument support 1)仪表立柱和其它支架应根据已批准的图纸进行制作安装。Stanchions and other supports shall be fabricated and installed in accordance with approved drawings. 2)在制作完成后，立柱和

31、支架应立即进行表面处理并刷底漆。Surface preparation and primer coating shall be applied for all stanchions and supports immediately after completion of fabrication. 3)在钢结构进行防火处理前，应将支架安装到结构件上。When a support is attached to a structural member, the work shall be carried out before fireproofing of the member 4)仪表立柱为 2

32、寸镀锌钢管。The instrument stanchions shall be of 2 inch steel pipe as a rule. 4. 基础槽钢的安装 foundation channel steel fabrication and installation 在设备安装前，基础槽钢应水平地固定到地面上。基础型钢应平直并固定良好。基础的 尺寸应与设备底座一致。其水平度的允许误差为 1 mm/m。当基础底座的长度大于 5m 时， 全长允许误差为 5mm。Prior to installation of equipment, the channel base shall be fas

33、tened to the floor horizontally. The profiled steels of the foundations should be straight and well fixed. Their sizes should comply with equipment bases. The allowable error for linearity shall be 1 mm/m. In case the length of the bottom seat of sectional steel is 5m, the allowable error in full le

34、ngth shall be 5mm. 5. 现场仪表安装 Field instrument installation 1) 总括：General (1) 仪表的中心距操作地面的高度宜为 1.2m-1.5m 之间； the elevation of the center of instrument should be 1.2m (2) 显示仪表应安装在便于观察示值的位置； install indicative meter at position easy to read. (3) 仪表不应安装在有振动、潮湿、易受机械损伤、有强电磁场干扰、高温、温度变化 剧烈和有腐蚀性气体的位置； instrum

35、ent should not be installed in positions of vibration, humidity, easy be damaged by machine, strong magnetic disturbance, high temperature, sharp temperature change and corrosion gas. (4) 安装过程中不应敲击、震动仪表。仪表安装后应牢固、平正。仪表与设备、管道或 构件的连接及固定部位应受力均匀，不应承受非正常的外力。 No knocking and vibrating instrument during ins

36、tallation. Installed instrument should be firm and even. The stress at the connection joints and fixed position between instrument and equipment, pipe and structure should be symmertrical, no abnormal stress from outside. (5) 仪表设备的安装位置、连接型式、方向、标高原则上按照施工图进行,安装的细节和 使用方法按照说明书的要求进行。 Principally, the ins

37、tallation position, connection type, orientation and elevation of instrument should be in accordance with construction drawing, details and usage methods referring to specifications. (6) 在满足了测量精度和控制灵敏的条件下,应考虑安装在操作、维修、观察方便的地方,不 宜安装在震动、潮湿、高温、宜受机械损伤、强磁场干扰、腐蚀性强的地方。 Instrument, up to the requirements of

38、measurement precision and control sensitivity, should be installed in location convenient for operation, maintenance and observation. They shall not be installed in a position of variation, humidity, high temperature, easy to be mechanically damaged, strong magnetic field disturbance and strong caus

39、ticity. (7) 仪表设备的进线引入孔不应朝上,以避免油水、灰尘进入接线端处。 The intake hole of instrument should not be upward to avoid oil, water and dust from entering into connection joint. (8) 直接安装在工艺管道间的控制阀、流量计、一次元件等，应在工艺管道吹扫完毕后 进行安装。Field thermometer, pressure meter and testing instrument will be installed as per standard DWG

40、. Control valves, flow meters and inline instruments installed directly in the process piping shall only be installed after piping blowing and flushing. (9) 在安装完成后，仪表及其附件应进行适当的保护，防止因其它施工引起仪表及附件 受到可能的损害或污染。Immediately after installation, the instruments and their accessories shall be suitably protect

41、ed by a bag, weatherproof or fire-resistant sheeting, etc. against possible damage or contamination caused by other construction works. 2） 温度检测仪表的主要安装要求： Installation requirements of temperature measure instrument: (1) 接触式温度检测仪表的测温元件应安装在能准确反映被测对象温度的地方。 The temperature device of touch temperature mea

42、sure instrument should be installed in the location where can accurately reflect the temperature of object. (2)温度仪表安装在保温的设备或管道上时，一直到温度计套管的螺纹连接件处都要进 行保温。In case of installing to heat insulated equipment or piping, insulation shall be provided up to the thread portion of thermowell. 3）压力检测仪表安装的主要要求：In

43、stallation of Pressure Gauge (1)对于测量潮湿气体、水平敷设的较长的导压管，安装坡度应大于 1/10，并应敷设在 无振动的位置。Long horizontal tubing for wetted gas service shall have gradient more than 1/10. And select the good position without vibration. (2)如果压力表远离取样点，应确认取样点和压力计之间的差压。Difference of pressure between tapping point and pressure gau

44、ge shall be confirmed if the location is far from tapping point. (3)应特别关注普通压力表、氨压表、氧压表和禁油压力表之间的区别。Careful attention may be required for the difference of the gauge for general, for ammonia, for oxygen and for oil prohibited. (4)当被测介质压力波动较大时，应采取缓冲措施。Buffering measures should be taken when the target

45、media are subject to major pressure fluctuation. (5)在安装完成后，应关紧切断阀。After installation, take-off valves shall be closed tightly. 4）差压变送器的安装 Installation of differential type transmitter (1)如果测量介质为蒸汽，应使用冷凝罐，冷凝罐应安装在同一高度。If measured fluid is steam, seal pot should be provided. The seal pot shall be at th

46、e same elevation. (2)导压管应尽可能短。测量液位或压力的变送器的安装位置应尽可能靠近取压管嘴， 避免因为产品本身特性而产生不必要的聚合和结晶的危险。Pressure lead tubing shall be provided as short as possible. Transmitters for level or pressure should be installed as close as possible to the nozzle in order to avoid unnecessary risk of polymerization or crystalli

47、zation, depending on the product. (3)正负压的导压管应尽可能的平行安装，并应安装在环境温度相同的地方，固定支架 的间距应小于 2m。Pressure lead tubing is installed in parallel as much as possible and shall have the same environmental temperature. Support shall be fixed to supporting structure less than 2 meters span. 5） 流量检测仪表的主要安装要求： Installat

48、ion requirements of flow measure instrument: (1)节流件的安装应符合下列要求： Installation of throttle piece should meet the following requirements. 安装前应进行外观检查，孔板的入口边缘应无毛刺、圆角和可见损伤； Surface check prior to installation, no burr, round angle and visible damage in the exit of spray mouth and entrance of orifice plate.

49、 节流件必须在管道吹扫后安装； Install throttle piece after piping blowing 节流件的安装方向，必须使流体从节流件的上游端面流向节流件下游端面。孔板的锐 边或喷嘴的曲面侧应迎着被测流体的流向； the installation orientation of throttle must ensure liquid flow from the upstream of throttle to the downstream. The curve surface of shape margin or spray mouth should face the flo

50、w route of objected liquid 节流件的端面应垂直于管道轴线，其允许偏差为 10； The surface of throttle should plumb with piping axis, with allowable deviation of 10 在水平和倾斜的管道上安装的孔板或喷嘴，若有排泄孔时，排泄孔的位置为：当流体 为液体时应在管道的正上方，当流体为气体或蒸汽时应在管道的正下方。 For orifice plate or spray mouth installed on level or declining piping, its drainage hole

51、, if have, should be positioned as: the opposite upside of piping if the flow is liquid, and the opposite downside if the flow is gas or steam. (2)转子流量计应安装在无振动的管道上，其中心线与铅垂线间的夹角不应超过 20，被 测流体流向必须自下而上，上游直管段长度不宜小于 5 倍管直径； Rotor flow meter should be installed on non-vibrating piping, with the angle betwe

52、en its centerline and plumb line no more than 20 . The direction of objective flow must be from the upper to down. And the length of straight piping at the upstream should be no less than 5 times of piping diameter. (3)涡街流量计信号线应使用屏蔽线，上、下游直管段的长度应符合设计要求，放大器 与流量计分开安装时，两者的间的距离不应超过 20M； The signal line o

53、f turbine flow meter should be screen line, and the length of straight piping at upstream and downstream should meet design requirement. The distance between amplifier and flow meter, if installed separated, should be no more than 20M. (4)电磁流量计的安装应符合下列规定： The installation of electromagnetic flow met

54、er should meet the following requirements: 流量计外壳、被测流体和管道连接法兰三者之间应做等电位连接，并应接地； The outer shell of flow meter, object flow and connective flange of piping should connect with potential voltage and grounding. 在垂直的管道上安装时，被测流体的流向应自下而上，在水平的管道上安装时，两个 测量电极不应在管道的正下方和正上方位置； When installed on vertical piping,

55、the object liquid should flow down to up, while installed on horizontal piping, two measure electrodes should not be located at the opposite down and up piping. 流量计上游直管段长度和安装支撑方式应符合设计要求。 The length of straight piping at the upstream of flow and the type of installation and support should meet design

56、 requirement. (5)椭圆齿轮流量计的刻度盘面应处于垂直平面内。椭圆齿轮流量计和腰轮流量计在垂 直管道上安装时，管道内流体流向应自下而上； The gear flow meter should be in vertical plane. When installing gear flow meter and waist flow meter on vertical piping, liquid inside piping should flow up to down (6)超声波流量计上、下游直管段应符合设计要求，对于水平管道，换能器的位置应在 与水平直径成 450夹角的范围内。被

57、测管道内壁不应有影响测量精度的结垢层或涂层； Straight piping at the upstream and downstream of ultrasonic flow meter should meet design requirement. For horizontal piping, the location of energy exchanger should be in the scope of angle of 450 . No filthy or coat inside object piping that impacts measure precision. (7)质量流量计应根据制造厂的安装指导进行安装，矩形流量管、U 型流量管应处于垂 直平面内。工艺介质为气体时，流量管应