仪表施工方案方案

1、编号：15-06 部-Stepan-SHF-601The 50,000t/a po lyester polyol p roject of Stepan (Nanjing) Chemical Co、丄td、 斯泰潘(南京)5万吨/年聚酯多元醇项目 仪表施工方案In strume nt Con structi on Plan编制Prepareby:安全Securityby :审核Reviewby:批准App rove by :、3Nanjing Chemical Construction Co、, Lid南京南化建设有限公司13、 Mar、2015目录 Contents第一章工程概况GENERAL

2、第二章：编制依据 CHA PTER 2-、3REFERENCE、第三章：仪表实物工作量 CHA PTER 3- INSTRUMENTQUANTITYOFWORK、第四章：施工得主要程序 CHAPTER 4-MAIN CONSTRUCTIONPROCEDURE 、4第五章：主要施工方法与技术要求 CHAPTER 5-CONSTRUCTIONTECHNICAL REQUIRES AND QUALITYSTANDARD 、7第六章：质量控制与检、试验计划 CHAPTER 6-QUALITYCONTROL AND INSPECTION TEST、29PLAN 、第七章：主要施工机具 CHAPTER 7

3、-MANPOWER 、34第八章：劳动力组织 CHAPTER 8-LABOR ORGANIZATION34第九章：施工进度计划 CHAPTER 9-CONSTRUCTION PROGRESSSCHEDULE35第十章：安全保证措施、 JHA 及文明施工 CHAPTER FIVE SAFETYASSURANCE SYSTEM, JHA AND、37HOUSEKEEPING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：行政办公与电控楼，空压站、门卫与称重，焚烧炉，冷却水系统，消防泵房，事故水池,工艺装置区，

4、仓储区等。This is an expansion pr oject of BASF-YPC Company Limited, the man ageme nt team is lET,TAR work involved in area 1 mainly includes existing instrument exchanges, remove, and resett ing, new in strume nt in stallati on, cable tray lay ing and cable p ulli ng、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

5、器、分析仪表、气体检测仪等仪表。Various in strume nts covered like control valve, on-off valve,integrated flow meter, DP transmitter, pressure and temperature transmitter, fork liquid level switch and toxic gas detector 、第二章：编制依据 Cha pter 2- Refere neeGB50093-2013 Chin ese in strume nt招标文件自动化仪表工程施工及质量验收规范con struct

6、 ion work code 、石油化工仪表工程施工技术规程SH3521-2007 Petrochemical in strume ntcon struct ion work code 、电气与仪表回路检验规范GB/T25921-2010GB50257-96自控安装图册HG/T21581-2010电气装置安装工程爆炸与火灾危险环境施工及验收规范建筑工程施工现场供用电安全规范(GB50194-93)；Po wer Supply and Utility Safety Regulati ons on Con struct ion Engin eeri ng Site GB50194-93建设工程安全

7、管理条例第三章：仪表实物工作量Cha pter 3- I nstrume nt qua ntity 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第四章：施工得主要程序 Chapter 4-Main construction procedure1、主要施工程序流程图施工前准I备preparatior before construct ion图纸会审 joi nt review of draw

8、ings设计交底 desig ndisclosure领检设备材料 receive,checeq uipm ent and materials-预埋管、件安装embedded pipe 支托架立柱预制安装Support bracketsolumhnstallati on of p refabricatedfitt ings in stallati on仪表单校In strume ntsing e calibrati on盘柜及底座I作安装cabi netfabricati onandin stallatio桥架就地盘柜接线箱安装tray, cab in ewiri ng box on site

9、in stallati on配合工艺一次部件安装th the in stallati on p rocess once电缆保护管安装able p rotection part pipeinstallation电缆敷设cable layi ng导压管、气源管、伴热管安装pulse con trol, air supplyipe, heat ingoipe现场仪表安装 site instrument in stallati on管线上仪表拆除、隔离阀关闭Disma ntithe pip eli nel nstrume nt, isolati on valve closed仪表导压管试压In str

10、ume nt guide p ressure pipe p ressuretest试压、试漏Pressure testi ng, leak testi ng校、接线calibration, wiring现场仪表二次安装系统联校system joint ca ibration配合单体试车sin gle commissi oningSec on dary field in strume ntati on交工验收acce ptance2、准备工作 Preparation1）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得问题，从而为施工阶段争取时间。 Organize tech

11、nical clarification and DWG review, problems existing in DWGs shall be quickly solved to gain more time for TAR2）根据设计图与有关资料编制好设备材料表与有关施工资料，熟悉设计得规范、标准、设计图纸以及有关得操作说明等资料。Prepare material list andrelated constructiondocuments as per designed DWG and relative documents 、 Befamiliar with codes,standards,

12、DWGs and guidelines3 ）熟悉施工有关得资料及图纸， 了解现有仪表得原理及接线柜位置。Be acknowledgeablewith construction related documents and DWGs , be clear withexisting instrumentphilosophy and junction box location4）对施工班、组进行全面系统得技术交底，上岗人员能熟悉图纸，明确施工任务与施工要点，规范及特殊要求。 Technical clarification to construction team shall be complete a

13、ndsystematic, make sure construction personnel are familiar wit DWGs, work content andrequirements 、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得装箱单、技术资料，会同业主、监理单位开箱检验，核实仪表设备材料得规格，型号及数量就是否符合设计要求，并做好记录，并在干燥清洁得条件下妥善保管。Be clear with material and equipmentstatus, open-box inspection jointly with IET and BYC as per p

14、acking list and technical documents provided 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）准备好干燥清洁得房间，作为调校室，环境应符合要求。班组要检查机具就是否完好，、 Machines and tools检验期就是否有效， 校验仪表得等级就是否符合要

15、求。 A clean room will be prepared to be as calibration room which shall comply with environmental requirements shall be checked with completeness and expires by the group and instrument shall be checked with its grades（1）根据图纸及工作量准备各种施工工具；7) 施工机具得准备。 Preparation on construction machines and toolsPrepa

16、re various construction machines and tools 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 图准备同规格得套筒、 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

17、 isometrics2施工前期1）仪表安装受装置作业、工艺设备、工艺管道、土建等专业得现场条件限制，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 constructionof TAR instrument erection considering plant operation, process equipment & piping , civil, however, some installation can be finished at pre-TAR or partially finished(1)仪表单体调校，阀门强度

18、试验。 Instrument unit calibration, valve strength test(2) 桥架支架预制。 Cable tray support fabrication(3) 部分主桥架安装。 Partial main cable tray erection(D477i piperack replacement,D472i piperack partial cable tray erection, D473i piperack cable tray)(4) 变送器支架预制。 Transmitter support fabrication(5)盘柜基础预制 Cabinet f

19、oundation fabrication(6) 接线箱支架预制。 Junction box support fabrication(7) 接线箱、气源分配器安装。 Erection of junction box and air distributor3 、 施工中期 Middle stage of TAR在工艺设备、管道安装陆续完成，整个工作已初步明朗，仪表安装进入施工高潮，这段 时间工期紧， 任务重，且多种工种交叉作业， 应妥善安排施工计划。 At this time, most process equipment and piping erection has been finishe

20、d, instrument erection enters into climax;tight time, heavy task and multi-trades crossing requires a detailed and strict schedule。Branch cable tray施工高潮主要工作如下： Main works for this time1） 分支桥架（接线箱至仪表） 、气源管线敷设 （气源分配器至气动阀门）laying (from junction box to instrument), air distributor wire pulling(from air

21、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 installation4) 安装仪表、 校接线。 New and dismantled instrument installation, pressure test, leakage test, wiring calibration5) 回路测试。 Loop test4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

22、定 ”与系统联校、仪表投运工作，此项工作必须会同业主与监理等有关人员，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 installationworkfinished, work out punch list and clean all items remained, then conduct system calibrationand instrument commissioning jointly with IET and BYC related personnel 、A fullinspection is require

23、d 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, acceptance work will be performed第 五 章 ： 主 要 施 工 方 法 与 技 术 要 求 Chapter 5-Constructiontechnical requires and quality standard1、 仪表盘柜得安装 Dash

24、board cabinet installation1) 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 times2) 设备开箱时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，对于明显得设备缺陷，作好记录并报有关人员。When the equipment is installed out of the box near the location of

25、 the box, not to the diskas a fulcrum when using a crowbar, so as not to damage the disk enclosure 、ThereKuguan, manufacturers, and supervision and other related personnel present duringtheunpacking of equipment for obvious defects, make records and report to the relevantpersonnel 、3) 盘柜在开箱时， 由技术员按安

26、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。不允许剧烈振动与撞击。盘到位后，还要仔细核对其型号就是否正确，零部件、缺件、损坏件核对后做好记录。Enclosure at thebox by pressing the Setup icon technician good out of the box the order, shipped to thebase after the unpacking process to ensure that equipment and personal safetyDue toheavy plate bod

27、y, to force a smooth and consistentDo not allow excessive vibration andshock 、 After the disc in place, but also carefully check the model is correct, parts, missingparts, damaged parts after checking make a record4) 盘柜找平、找正时，先精确得找好第一块，再以第一块为基准，将其它依次调整找平、找正。 Enclosure leveling, alignment, first the

28、first one to find a good accurate, then the firstone as a reference, the other in order to adjust the leveling, alignment5) 同一系列规格相邻两盘、柜、台得顶部高度允许偏差为 2mmm;In the same seriesspecifications of two adjacent plates, cabinets, table top height tolerance for 2mmm6) 当同一系列规格盘、 柜、台间得连接处超过 2处时，顶部高度允许偏差为 5mm ；W

29、hen the junction of the same series specifications cubicle, desk between more than two, top height tolerance of 5mm;7) 相邻两盘、 柜、台接缝处正面得平面度允许偏差为1mm ；Two adjacent plates, cabinets,front desk seams flatness tolerance of 1mm;8) 当盘、柜、台问得连接处超过 5处时，正面得平面度允许偏差为 5mm ； When the disc, connection cabinets, desk

30、and asked the more than 5, the front of the flatness tolerance of 5mm;9) 相邻两盘、柜、台之间得接缝得间隙，不大于2mm 。 Two adjacent cubicle, the gapbetween the seams of the station, no more than 2mm、2、 接线箱安装 Mounting of junction boxes1) 接线箱应安装在水平面或平台上， 接线箱得安装位置应便于操作与维护。 Junction boxesshall be installed at grade or on t

31、he platform 、 Location of junction boxes will generally bedecided by considering operability, ease of maintenance2) 接线箱应根据施工图进行安装。 Junction boxes shall be installed in accordance withconstruction drawings a nd/ or instruction by BYC s superv、isor3) 当不在接线箱内工作时，所有得接线箱盖板必须完全关闭。3、 仪表支架 instrument suppor

32、t1)仪表立柱与其它支架应根据已批准得图纸进行制作安装。Stanchions and other supportsshall be fabricated and installed in accordance with approved drawings2) 在制作完成后，立柱与支架应立即进行表面处理并刷底漆。Surface preparation andprimer coating shall be applied for all stanchions and supports immediately after completionof fabrication 、3)在钢结构进行防火处理前

33、，应将支架安装到结构件上。When a support is attached to astructural member, the work shall be carried out before fireproofing of the member4) 仪表立柱为 2 寸镀锌钢管。 The instrument stanchions shall be of 2 inch steel pipe as arule 、4、 基础槽钢得安装 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

34、应平直并固定良好。基础得尺寸应与设备底座一致。其水平度得允许误差为1 mm/m 。当基础底座得长度大于 5m 时，全长允许误差为 5mm。Prior to installation of equipment, the channel base shall be fastened to the floor horizontally 、 The profiled steels of the foundations should be straight and wellfixed 、 Their sizes should comply with equipment bases 、 The allow

35、able error for linearityshall be 1 mm/mIn case the length of the bottom seat of sectional steel is 5m, theallowable error in full length shall be 5mm5、 现场仪表安装 Field instrument installation1) 总括： General(1) 仪表得中心距操作地面得高度宜为1、2m-1 、5m 之间；the elevation of the center of instrument should be 1、2m(2) 显示仪表应

36、安装在便于观察示值得位置；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、温度变化剧烈与有腐蚀性气体得位置；instrument should not be installed in positions of vibration, humidity, easy be damaged bymachine, strong magnetic disturbance, high temperature, sharp temperature change andcorrosion g

37、as 、(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、管道或构件得连接及固定部位应受力均匀，不应承受非正常得外力。No knocking and vibrating instrument during installationInstalled instrument should befirm and even 、 The stress at the connection joints and fixed position between instrumentand equipment, pipe and structure should be symmertric

38、al, no abnormal stress fromoutside 、(5) 仪表设备得安装位置、连接型式、方向、标高原则上按照施工图进行, 安装得细节与使用方法按照说明书得要求进行。Principally, the installation position, connection type, orientation and elevation of instrumentshould be in accordance with construction drawing, details and usage methods referring tospecifications 、(6) 在满

39、足了测量精度与控制灵敏得条件下 ,应考虑安装在操作、 维修、 观察方便得地方 ,不宜安装在震动、潮湿、高温、宜受机械损伤、强磁场干扰、腐蚀性强得地方。Instrument, up to the requirements of measurement precision and control sensitivity, shouldbe installed in location convenient for operation, maintenance and observation、 They shallnot be installed in a position of variation,

40、 humidity, high temperature, easy to bemechanically damaged, strong magnetic field disturbance and strong causticity(7) 仪表设备得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 fromentering into connection joint(8) 直接安装在工艺管道间得控制阀、流量计、一次元件等，应在工艺管道

41、吹扫完毕后进行安装。 Field thermometer, pressure meter and testing instrument will be installed as perstandard DWG 、 Control valves, flow meters and inline instruments installed directly in theprocess 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得保护，防止因其它施工引起仪表及附件受 到 可

42、 能 得 损 害 或 污 染 。 Immediately after installation, the instruments and theiraccessories shall be suitably protected by a bag, weatherproof or fire-resistant sheeting,etc、 against possible damage or contamination caused by other construction works2 ) 温度检测仪表得主要安装要求：Installation requirements of temperatu

43、re measure instrument:(1) 接触式温度检测仪表得测温元件应安装在能准确反映被测对象温度得地方。The temperature device of touch temperature measure instrument should be installed inthe location where can accurately reflect the temperature of object(2) 温度仪表安装在保温得设备或管道上时， 一直到温度计套管得螺纹连接件处都要进行保温。In case of installing to heat insulated equi

44、pment or piping, insulation shall be providedup to the thread portion of thermowell3 )压力检测仪表安装得主要要求： Installation of Pressure Gauge(1)对于测量潮湿气体、水平敷设得较长得导压管，安装坡度应大于1/10 ，并应敷设在无振动得位置。 Long horizontal tubing for wetted gas service shall have gradient more than1/10 、 And select the good position without

45、vibration(2)如果压力表远离取样点，应确认取样点与压力计之间得差压。Difference of pressurebetween tapping point and pressure gauge 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、 氧压表与禁油压力表之间得区别。 Careful attentionmay be required for the difference of the gauge for general, for ammonia, for oxyg

46、en andfor 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 takenwhen the target 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 )差压变送器得安装 Installation of differential type transmitter(1)如果测量介质为蒸汽， 应使

47、用冷凝罐， 冷凝罐应安装在同一高度。 If measured fluid issteam, seal pot should be providedThe seal pot shall be at the same elevation(2) 导压管应尽可能短。测量液位或压力得变送器得安装位置应尽可能靠近取压管嘴，避Pressure lead tubing shall be免因为产品本身特性而产生不必要得聚合与结晶得危险。provided as short as possible 、 Transmitters for level or pressure should be installed as

48、 close as possible to the nozzle in order to avoid unnecessary risk of polymerization or crystallization, depending on the product(3) 正负压得导压管应尽可能得平行安装，并应安装在环境温度相同得地方，固定支架得间距应小于 2m 。 Pressure lead tubing is installed in parallel as much as possible and shall have the same environmental temperature 、

49、Support shall be fixed to supporting structure less than 2 meters span5 ) 流量检测仪表得主要安装要求：Installation requirements of flow measure instrument:(1) 节流件得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，孔板得入口边缘应无毛刺、圆角与可见损伤；Surface check prior to installation, no b

50、urr, round angle and visible damage in the exit of spray mouth and entrance of orifice plate节流件必须在管道吹扫后安装；Install throttle piece after piping blowing 节流件得安装方向，必须使流体从节流件得上游端面流向节流件下游端面。孔板得锐边或喷嘴得曲面侧应迎着被测流体得流向；the installation orientation of throttle must ensure liquid flow from the upstream of throttle

51、 to the downstream 、 The curve surface of shape margin or spray mouth should face the flowroute of objected liquid节流件得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 1在水平与倾斜得管道上安装得孔板或喷嘴，若有排泄孔时，排泄孔得位置为：当流体为液体时应在管道得正上方，当流体为气体或蒸汽时应在管道得正下方。For orifi

52、ce plate or spray mouth installed on level or declining piping, its drainage hole, 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得管道上， 其中心线与铅垂线间得夹角不应超过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

53、 flow meter should be installed on non-vibrating piping, with the angle between itscenterline and plumb line no more than 20The direction of objective flow must be fromthe 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

54、用屏蔽线，上、下游直管段得长度应符合设计要求，放大器与流量计分开安装时，两者得间得距离不应超过20M；The signal line of 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

55、20M(4) 电磁流量计得安装应符合下列规定：The installation of electromagnetic flow meter should meet the following requirements:流量计外壳、被测流体与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在垂直得管道上安装时，被测流体得流向应自下而上，在水平得管道上安装时，两个测量电极不应在管道得正下方与正上方位置；should flow down to up, while installedWhen installed on vertical piping, the object liquid on horizontal piping,