30000立方米罐施工技术措施英

1、jj中国石油工程建设（集团）公司喀土穆炼油厂扩建项目经理部第六工程处The Sixth Construction of CPECCKhartoum Refinery Expansion Project Management Office1 Project Outline1.1 Project brief introductionThe project belongs to one of the expansion project of Khartoum Refinery.The crude oil came from oil pipeline outside the plant to be s

2、tored in the34 x 30000m tank after measuring and transported directly by feeding pump tothe Delay Coking Unit as raw oil.1.2 Characteristics of the project1.2.1 The project has large workload of welding from the preparation of welding such as WPS, welders examination and training to welding on site

3、and non-destructive tests all the work need to be strictly managed.1.2.2 The workload from construction preparation, procedure control to final inspection is large and difficult thereby all the staff including workers and administrator should take the full responsibility of their work and witness.1.

4、3 Compiling basis1.3.1 The construction processing and experience the Company gets from thesi milar project.1.3.2 The construction drawings and bidding documents1.3.3 The practical construction and acceptance specifications of China and petroleum industry1.3.3.1 SY/T4059-93«Construction And Acc

5、eptance Specification For CoatingAnd Insulation Work Of Steel Vesssles »1.3.3.2 GBJ128-90« Construction And Acceptance Specification For VerticalDrum Selding Steel Oil Tanks »1.3.3.3 GB50236-1998«Construction AndAcceptance Specification For WeldingWork On Site Of Equipment And In

6、dustry Piping »1.3.3.4 GB50205-2001« Construction Quality And Acceptance SpecificationFor Steel Structures Work »1.4 The main construction means1.4.1 The tanks to be welded by hand arc welding and the shells to be fabricated by large plate roller.1.4.2 The tanks are to be installed by

7、 the method of water-fill to ensur security and good shape.1.4.3 When water-fill and test the tanks, the water is to be transfer fromone tank to another by a centrifugal pumpto save water and speed up the work.1.4.4 The bottoms leakage tests should be carried out by a Japanese leakagetest box to inc

8、rease the precision and speed up the work.2 Construction working prucedureWorking prucedure is showed in the following formItemsNo.DescriptionWorking contents1AcceptanceoffoundationsCheck the intermediate acceptance certificates; Check the foundationsfor proper center coordinate,elevationand roughne

9、ss; check the surface ofpitch-sand layer for proper level andcompactness andfreeing of protrusion, sag and pronging cracks; check the foundation of circular beam for proper levelness.2Prefabrication of oil tank1、 Prefabrication of bottoms (including bottom plates, annular plates and bedplates)2、Pref

10、abrication of shells3、Prefabrication of floating roof (including supports, internal and external side plates, casings, frames, trusses, clapboards and fire fighting baffles)4、Prefabrication of spiral stairway5、Prefabrication of stiffen ring6、Prefabrication of wind girder7、Prefabrication of horizonta

11、l projection8、Prefabrication of turning floating ladder and guiding rail9、Prefabrication of seal of roof10、Prefabrication of heat exchanger3Installationofthe bottoms of tank1、Confirming the orientation of the annular plate of the bottom2、Paving annular plate3、Paving bottom plate4、Welding and RT of t

12、he butt weld 300mmin distance from the edge the annular plate5、Welding of bottom plate6、Leakage vacuum testing of bottom welds4Installationofthebottomcircle of shell1、Confirming the orientation of the first circle shell2、 Lift shells to their position and adjust and checkshells for proper levelness

13、and verticality;setting ofshell supports3、Welding of vertical welds5Installationof1、lifting and adjusting of shellsPage 2 of 19中国石油工程建设（集团）公司喀土穆炼油厂扩建项目经理部第六工程处The Sixth Construction of CPECCKhartoum Refinery Expansion Project Management Officethesecondcircle of shell2、Welding of vertical welds3、Weld

14、ing of circular welds4、Grinding of welds5、RT6Endingofbottoms1、Welding of T-welds between shells and rims2、Completion of butt welds of annular plate3、 Completion of butt welds between bottom plates and annular plates4、RT and leakage testing of welds7Installationoffloating roof1、Confirming of assembli

15、ng orientation of floating roof2、Paving, adjusting, welding and vacuumleakage test for the base plates of floating roof3、Locating, adjusting, welding of external side plates of floating roof and kerosene leakage testing of fillet welds and vertical welds4、Installation of frames, trusses and clapboar

16、ds5、Paving, welding and vacuum leakage testing of deck8Installationofthe other circles of shell1、Lifting, locating and adjusting of shells2、Welding of vertical welds3、Welding of circular welds4、Polishing of welds5、RT9Installationofstiffen ring1、 Fixing and lifting and locating (with shells together)

17、2、Welding10Installationofwind girder1、Confirming the position and installation of tripod2、Lifting and assembling of wind girders3、Welding and completion of handrail11Installationofhorizontal projection1、Assembling and lifing2、Welding12Drainage of tank1、Resilience observing of foundations of tanks2、C

18、leaning inside tanks13Installationofspiralstairway,platformsandhandrail1、Installation of top platforms and middle platforms2、Installation of tripods of spiral stairway3、Liftng and locating of upper and below segment of spiral stairways4、Installation and welding of handrails14Installationofoil gage p

19、ipe1、Alignment and hatch of orientation of floating roof2、Installation of racks and stingers upper and below pipe3、Lifing and adjusting of oil gage pipe15Installationofturning floating ladder1、Installationof guiding rail of turning floatingladders2、 Assembly, lifting and in position of floating ladd

20、ers16Installationofdrain pipe1、Adjustment of orientation of drainpipes2、Installation, in position and pressure test17Installationofheater1、 Confirming of installing position2、Pressure testing after the completion of installation18Settlementtestafter water filled1、Settlement observation2、Intensity te

21、st of tank body19Coatingandinsulation1、Derusting by sandblast and coating2、Insulation of tank20Installationofsealing mechanism1、Confirming of installing orientation and equationing2、Installation and in position21Sealing mechanismHydraulic testing seal mechanism by water filling of tanks22Taking over

22、 and acceptance1、Collection and cleaning up of as-built data2、 Submitting of taking over and acceptance certificates3 Main construction methodTaking consideration ofconstructing duration, the local geologic condition and water supply, the two tanks are to be constructedDeckBottomsimultaneously by th

23、e method of water-fill.Sketch of water-fill of the tanks3. 1 Requirement of water for constructionAdopt to freshwater , water resource shold be the purified fire-fighting water camefrom the Refinery and the temperature of the water can not be lower than 5 C .3.2 Construction method3.2.1 Prefabricati

24、on of oil tankPage 4 of 19jj中国石油工程建设（集团）公司喀土穆炼油厂扩建项目经理部第六工程处Masuring positionpermitted deviation(mrmLength AB、CD± 2mmWidth AC、BD EF± 2mmDeference between diagonals (AD-BC< 3mm3.2.1.1 Prefabrication of annular platesDimension measuring position of annular plate FDTwo rims should be left

25、as adjusting plate for each tank and cut the materials according to site dimensions and symmetrically lay the two plates separately.3.2.1.2 Prefabrication of bottom plateThe welding shrinkage and slope of bottom should be taken for consideration whencut the materials of bottom plates and calculate t

26、he theoretical dimension and increase.3.2.1.3 Prefabrication of shells1) Fabrication of shells should be carried out on the prefabricating platform. Draw out the plates paving sketch according to materials arrival and precessing hatch orientation prior to fabrication.2) Bevelling angle and root land

27、 of the shells should be in accordance with welding and drawings requipments.3) the materials of the shells should be cut by the method of seting lines by right angles and the permitted deviation of dimension after cutting in accordance with the following chart:Dimention permitted deviation of the s

28、hellsMeassuring positionButt joit of circular weld(mrmLength of plate AB( CD>10mLength of plate AB(CD<10mWidth AC、BD EF±1.5士 1Length AB、CD±2士 1.5Diferencebetweendiagonals|AD BC|<3<2The Sixth Construction of CPECCKhartoum Refinery Expansion Project Management OfficeMeassuring po

29、sitionButt joit of circular weld(mrmLength of plate AB( CD>10mLength of plate AB<10m(CDStraightness AC 、 BDAB、CD0 10 1<2<23.2.1.4 Prepatation of floating roof with single center deck1) If the offered materials of base plates and top platesd of floating roof are disagree with the drawings

30、, the plates paving chart should be compiled again according to Item 3.3.1 in Standard GB128-90.2) The frefabrication of frames and truss of floating roof should be carried out on the 12mx 24mprefabricatingbench. The prefabricated componentsshould be tagged and the quality of prefabrication should b

31、e in accordance with the executed Standards for Installation of Steel Structure.3) Casing and supports prefabrication should be tagged by their circles to prevent from confusing. When prefabricate the supports, add 100mm to each one for adjusting the unequal settlement of the bottom of the tank.4) T

32、he components prefabricated should be kept carefully.3.2.1.5 Prepatation of wind girderCut the materials according to drawings to fabricated the plate of wind girder and remove the slag of the surface of the plates; the dimension permitted deviation value of plates are the same as the rims.3.2.1.6 P

33、repatation of spiral stairwayIn order to increase work quality, efficiency and sfety assurance, the spiral stairways are to be prefabricated and installed in two segments according to their structure peculiarity. The steps are to be shaped by plate roller.Page 6 of 19中国石油工程建设（集团）公司喀土穆炼油厂扩建项目经理部第六工程处

34、The Sixth Construction of CPECCKhartoum Refinery Expansion Project Management OfficeWeld the tripod and middle platform to the spiral stair way prior to assemble. These work are to be performed during the construction work of shells.Pay attention to the turning direction of the stairway prior to pre

35、fabrication and numbered it to prevent from error.3.2.1.7 Prepatation of stiffen ring1) The fabrication of stiffen ring is to be carried out in segments on the prefabricating bench.2 ) Cut the materials of acr plates, brackets and reinforcing circular plates of the stiffen ring according to the demn

36、esions which are showed in the design drawings. The total lengthof the acr plates and reinforcingcircular plates should be 2m longer than the circumference of the tank as adjusting length of the two joints of each segment when assembly.3.2.1.7 Prefbrication of turning floating ladderThe turning floa

37、ting ladder is to be prefabricated and assembled as a whole on the roof and then lifted and in position. Put up a 1m temporary supporton the roof so that the floating ladder can be assembled and welded conveniently. The fabricating precision of parts of the turning floating ladder are strictly requi

38、red thereby all the holes of the parts should be drilled by machine to meet the precision requirement. Drilling holes of tie rods should be carried out after the plat steel to be welded and adopt to drill the hole of the two tie rods overlap and the deviation or the pitch between the two adjacent ho

39、les no more than ± 1mm.3.2.1.8 Prepatation of gage pipe and guiding pipe1) Prefabrication of gage pipe and guiding pipe should be carried out on the prefabricating bench and assembled assist by a transit to ensure their concentricity.2) After the completion of the Prepatation of gage pipe and g

40、uiding pipe, hatch should be made of the gage pipe and polish the final weld and hatch. 3.2.2 Installation of tanks3.2.2.1 Acceptance of foundationsCheck the foundation as acceptable for proper dimentions according to the design documents and specifications prior to installation. Checkthe following

41、positions for proper dimentions of surface and in accordance with the following regulations:1 ) To make sure there are taking over certificates and check the certificates for completion of centents;2) The permitted deviation of the center elevation of the foundation is ± 20mm;3) To the elevatio

42、n and levelness of the shells supporting circular beam, the difference between the height of random point on 10m radian can not be more than 6mm and can not be more than 12mm on the whole circle.3.2.2.2 Paving and elding of bottom of the tanks1) Drawing lines on the acceptable foundation of the tank

43、 bottom according to enlarged paving radius of rim and paving orientation; found out the exact position of sides of the anular plate on the ring beamby making use of a transit.2) To lifting and being in position of the rims, pave separately the plates in two symmetrical directions and pay attention

44、to the installation of the bottom bedplate of the butt weld of the anular plate and makeit cling to anular plate.3) Draw paving centerline of bottom plates on the foundation by a transit and then pave the plates from the center of the tank; pay attention to width of lap joint of bottom plates in acc

45、ordance with drawings and specifications; pay attention to the cutting angle and welding on the lap joint.3.2.2.3 Welding of big filletPay attention to the following items:1) The welders should be arranged symmetrically and welding can not be executed several times in nar distance to avoid ellipse a

46、nd fillet deformation by consentration of heat by shrinking unequally.2) After the completion of bottom welding of the inner fillet by hand, dye test shold be carried out as acceptable and then complete the whole weld. 3.2.2.4 Installation of the first circle shells1) Find out he centerline of the b

47、ottom and marked with crossing and draw the circle by acr model plate and punch on the bottom accord to the diameter.2) WeldS =6X 30X50 bumperin every 1500mnon the circle R along the circle direction.3) Adjust the gap of longitudinal weld of 4mm in width by special tools and adjust the verticality o

48、f shells and levelness of top side. Adjust the plates of the whole circle by the method of aligning a plate as sample plate to adjust other plates and check again the gap of the longitudinal weld, verticality of shells and levelness of top side after the completion ofadjustment of all the plates of

49、the circl. Fix the shells by the method of fixing the annular plate on three points to prevent circular plate from upwarping when welding the inner big fillet and put up gangway for the inside operating bench of installing the plates of the next circle.3.2.2.5 Installation of shells of the second ci

50、rcle1) Weld clevis to the top side of the shells of the first circle and the top side and below side of shells of the the second circle and weld hooks of inner scaffold to the shells of the second circle, as the following sketch shows:Sketch For Assembling Clamps Layout Of Shells2) The plates should

51、 be liftd and ecrected according to drawings. Each plate should be welded back bars on heir back and the plates can not be left removable crater in order to ensure their girth; adjust the gaps of jointsof 4± 1mmafter the comletion of erection of the plates; adjust the verticality plates and adj

52、ust the circular welds for equal offset and measure the offsetand ensure the offset is < 3mm and < 1.5mm for longitudinal welds.3) The details welding methods refer to technical measure for welding processing.3.2.2.6 Installation of floating roof with single deck1) The installing position of t

53、he parts of the bottom of the roof should be marked on the bottom and punching, see the following:Position of the supports of the drainage pipe of the roof;Position of the support of heating tray;Position of the bedplates of support of the roof and other attachment;Page 9 of 19中国石油工程建设（集团）公司喀土穆炼油厂扩建

54、项目经理部第六工程处The Sixth Construction of CPECCKhartoum Refinery Expansion Project Management OfficecoThe Sixth Construction of CPECCKhartoum Refinery Expansion Project Management OfficePosition of the acceptive desk of gage pipe and guide pipe2) Martk the benchmark position for installation of roof on th

55、e shell to take advantage for paving the roof compartement and deck;3) Weld the deck directly to the bottom and its paving method and welding processing is the same as the bottom.4) The roof compartment should be prefabricated by segments and installed on site, but two of them should be left and ass

56、embled on site. When asseble the internal and external side plate of the roof compartment, its diameter should be enlarge of 60mm to make up the shrinkage of welding. The kerosene penetration test and air pressure leakage test should be carried out for the roof compartment.5) In order to erect the d

57、eck onto the connecting angle steel, sopt weld some 厂 connecting blocks onto each 1m of edge of the deck and hang the deck onto the connecting angle steel and shim 6mm round steel between the-connecting blocks and the connecting angle steel. Water-fill the tank and fix the roof compartment when it f

58、loats to 400mm and then continue to water-fill. Stop water-fill as soon as the water is to be overflow in to the deck. When assembly, draw the deck tight symmetrically by chain hoists and spot tighten the deck to the connecting angle.6) The welding processing of the roof deck is the same as the bottoms and all the deck p