上海SECCO90万吨每年乙烯工程26万吨每年丙烯睛装置塔类设备安装方案

1、 WORD 29/28受控文件编号:SECCO90万吨/年乙烯工程 26万吨/年丙烯睛装置塔类设备安装方案 修改码：发放编号：有效期：印数：持有人：集团第设公司年 月 日目 录 TOC o 1-3 h z HYPERLINK l _Toc54669553一、One 编制依据Preparation basis PAGEREF _Toc54669553 h 3HYPERLINK l _Toc54669554二、Two概述General PAGEREF _Toc54669554 h 3HYPERLINK l _Toc54669555三、Three.施工工序working procedure of c

2、onstruction PAGEREF _Toc54669555 h 4HYPERLINK l _Toc54669556四、Four.施工准备prepare for construction PAGEREF _Toc54669556 h 5HYPERLINK l _Toc54669557五、Five设备验收check and accept equipment PAGEREF _Toc54669557 h 5HYPERLINK l _Toc54669558六、Six.基础验收Check and accept the foundation PAGEREF _Toc54669558 h 6HYPER

3、LINK l _Toc54669559七、Seven平台、梯子安装install ladder and flat roof PAGEREF _Toc54669559 h 7HYPERLINK l _Toc54669560八、eight.垫铁和地脚螺栓gasket of iron plate and anchor bolt PAGEREF _Toc54669560 h 8HYPERLINK l _Toc54669561九、nine.找平、找正adjust and level PAGEREF _Toc54669561 h 9HYPERLINK l _Toc54669562十、ten.二次灌浆The

4、 second grouting PAGEREF _Toc54669562 h 11HYPERLINK l _Toc54669563十一、eleven.塔件安装 Install the fittings in the tower PAGEREF _Toc54669563 h 11HYPERLINK l _Toc54669564十二、twelve清理与封闭Cleaning and closing PAGEREF _Toc54669564 h 19HYPERLINK l _Toc54669565十三、thirteen气密性试验 air tight test PAGEREF _Toc54669565

5、 h 19HYPERLINK l _Toc54669566十四、fouteen质量保证体系Quality assurance system PAGEREF _Toc54669566 h 20HYPERLINK l _Toc54669567十五、fifteen. HSE措施HSE measures PAGEREF _Toc54669567 h 25HYPERLINK l _Toc54669568十六、sixteenJHA分析JHA analyses PAGEREF _Toc54669568 h 26一、One 编制依据Preparation basis1)26万吨年丙烯腈施工图纸Lanzhou

6、Design Institute of SINOPEC 260,000 t/y AN construction drawing.2)钢制塔式容器4710-2000Tower type Steel Vessel3)化工塔类设备施工与验收规HGJ211-85code for construction and acceptance of chemical equipment as tower4)钢结构工程施工与验收规GB50205-2002Code for Construction and Acceptance of Steel5)塔填料与件标准STANDARD FOR TOWER PACKING

7、AND INTERNALS SD-00-TSC-MS-00196)降液管塔盘标准STANDARD FOR DOWNCOMER TRAYSSD-00-TSC-MS-0037二、Two概述General 在26万吨年丙烯腈装置中共有塔类设备17台，其中有重型设备-两台反应器（R-1101A/B），其他超长和超重的塔还包括：急冷塔T-2001-A/B、吸收塔T-2002、回收塔T-3001、脱氢氰酸塔T-3002、成品塔T-3003，这些设备的安装为本装置的关键所在，塔的具体参数如下图所示：There are 17 sets of equipment like tower in 26KT/Y AN

8、project, two sets of reactor（R-1101A/B）is heavy, other overlength and overweight tower include: Quench Column T-2001-A/B、asbsorber column T-2002、recovery column T-3001、head column T-3002、product tower T-3003，installation of these equipment is key in this project. Particular parameter of tower is lik

9、e next list:序号No设备位号Item设备名称name设备类型(型式)type外形尺寸dimension区域area单位unite数量quantity主体材料material重量(吨台)weight(T/set)1R-1101- A/B反应器reactor9400mm*30460mm10台set2C.S497*22T-2001-A/B急冷塔Quench Column除沫塔盘defoaming tray6900mm*20710mm20台set2C.S+316LSS1083T-2002吸收塔asbsorber column填料塔盘filling5800mm*53350mm20台set1C

10、.S+304SS3334T-3001回收塔recovery column浮阀塔盘float valve tray4200/5800mm*68500mm30台set1SS+CS3505T-3002脱氢氰酸塔head column浮阀塔盘float valve tray2800/3000mm*40000mm30台set1SS+CS736T-3003成品塔product tower浮阀塔盘float valve tray4200mm*37670mm30台set1SS+CS123.27T-3004乙腈塔浮阀塔盘float valve tray1800mm*15950mm30台set1410SS+CS(

11、SR)11.7708T-3005分层器尾气洗涤器30台set1C.S+瓷环1.0269T-4001尾气洗涤器40台set1C.S+瓷环1.95410T-5001轻有机物汽提塔浮阀塔盘float valve tray1700mm*24775mm50台set1SS+CS20.54411T-6201气体洗涤器62台set1C.S+瓷环0.75512T-8001脱氢氰酸塔浮阀塔盘float valve tray1200mm*46950mm80台set1C.S+304L+C-27643.79313T-8002干燥塔浮阀塔盘float valve tray2500mm*38400mm80台set1C.S+

12、304L74.20514T-8003成品塔浮阀塔盘float valve tray1000mm*40900mm80台set1C.S25.85515T-8004尾气洗涤器80台set1C.S+瓷环1.130三、Three.施工工序working procedure of construction施工准备preparation for construction设备验收check and acceptequipment吊装就位Lifting to position找平找正alignment灌浆grouting塔内件安装install the fittings in the tower检查验收chec

13、k and accept基础验收Accepting foundation设备运输Transport equipments清理封闭Cleaning and closing梯子平台附塔管线安装install ladder/ flat foof and pipe attaching on the tower塔体保温heat preservation for tower气密试验air tight test压力试验test of press四、Four.施工准备prepare for construction(1).技术准备prepare for technic1).相关施工人员应熟悉和施工图有关技术规

14、程、施工方案。施工前有专责技术人员进行施工方案交底。Constructing personnel must know well technic rules scheme of construction and about construction drawing. Specific responsibility technic personnel must tell worker his real intentions about scheme for installing tower before construction.2).施工前应通过图纸会审，明确与设备施工有关专业工程配合的要求。T

15、ogether Checking about drawing ought to be over, know about request for construction of equipment. 3).凡涉与材料、设计和工程质量表中的容修改，均应作出书面记录并经有关人员签字。Modification about material、design and quality list must be track record with writing, at the same time constructing personnel should make signature.(2).施工前的准备pr

16、eparation before construction1).水、电、路应畅通。Water、electricity and road must be connected.2).施工现场地面应处理坚实，适于吊车行走。The ground of construction site must be 五、Five设备验收check and accept equipment1)交付安装的设备与附件，必须符合设计要求，并附有出厂合格证明书与安装说明书等技术文件。Delivery of equipment and accessory shall conform to design requirements

17、, and with mill certificates and erection manual.2)设备开箱检验应在业主、监理、总承包商、施工单位的共同参加下进行。对照装箱单与图样，检查与清点以下容，并填写“设备开箱检验记录”。Unpack and check of equipments shall execute when Client, Supervisor, general Contractor and Construction Company are all present. Check following contents according to packing list and

18、 fill in “record of Unpack and check of equipments”.箱号、箱数与包装情况；Box number, box numbers and package;设备名称、类别、型号与规格；Name, type, model and specification of equipments;设备外形尺寸与管口方位；Dimension and pipe mouth position of equipments;设备件与附件的规格、尺寸与数量；Specification, dimension and quantity of equipments internals

19、 and accessories;设备表面损坏、变形与锈蚀状况。Damage, distortion and corrosion of equipments surface.3)在安装之前，对已开箱检验过的设备与零部件要妥善存放和保管。对于不锈钢设备，严禁与碳钢材料接触。Store and keep the equipments and components which have be checked before installation. Strictly prohibit stainless steel equipments to contact with carbon steel ma

20、terials.六、Six.基础验收Check and accept the foundation1)基础交接应具备的条件：Foundation to turn over shall have following conditions:质量合格证明书、测量记录与其它技术资料；Quality certificates, measurement record and other technical documents;基础外观不得有裂纹、蜂窝、空洞与露筋等缺陷；There is no defects on foundation surface, such as crack, cavity and

21、pocket, socket and exposed reinforcement;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）物上应标明坐标轴线；设计要求作沉降观测的设备，其基础上应设有沉降观测水准点。Draw obvious datum line, centerline on foundation; mark axis of reference on related building; Set up bench mark of settlement observation on foundation if requires;2)基础尺寸与位置允许偏差应符合下列规定。Permi

22、tting warp for Size of foundation and location must answer for the next rules.项次item偏差名称name of warp允许偏差值（mm）value of Permitting warp1基础坐标位置（纵、横轴线）location of base coordinate(vertical and level axes)202基础各不同平面尺寸each of plane dimension for foundation+0-203基础上平面外形尺寸plane externality dimension up to fo

23、undation凸台上平面外形尺寸plane externality dimension up to protruding plate凹穴尺寸dimension of concave20+0-20+20-04基础上平面的水平度：Level degree for top of plane每米every meter全长span5105竖向偏差：Erect warp每米every meter全长span5206预埋地脚螺栓anchor bolt buried beforehand标高（顶端）level(top)中心距（在根部和顶部两处测量）distance to center(measure at

24、bottom and top)+20-027预埋地脚螺栓孔hole of anchor bolt buried beforehand中心位置 center position深度depth孔壁铅垂度vertical degree for cliff of hole +20-010 10Allowance deviation of foundation size and location shall conform to design specifications.3)基础周围土方应回填、夯实与平整；砼强度达到设计要求；地脚螺栓无损坏、不生锈。Surrounding earthwork of fo

25、undation shall backfill, compact and smoothen; Strength of concrete conform to design requirements; anchor bolts have no destruction and corrosion. 4)基础表面不得有油垢或疏松层；放置垫铁处（至周边50mm）应铲平，铲平部位水平度允许偏差2mm/m。No oil or loosen layer on foundation surface; position to place stow-iron shall spade, allowance devi

26、ation of levelness is 2mm/m.5)基础与设备之间的绝热以与图纸上有特殊要求的设备，应按设计技术文件执行。Insulation between foundation and equipment and equipment which special required on drawing shall accord with design documents.七、Seven平台、梯子安装install ladder and flat roof 为了在地面上最大限度的安装塔类设备的平台和梯子，塔设备被运到现场后，将塔水平的放在地面上，并将塔体垫起距离地面2米，将预制好的平台

27、和梯子以与护栏按照图纸安装就位。吊装的过程中由于吊耳和吊装钢丝绳的影响，在管式吊耳以上每层平台的某部分将受到影响而不能安装到塔体上。剩余的部分等到塔体安装就位后再进行安装，具体方法是：塔体未吊装前，将受影响不能安装的平台在塔体上的焊接护板先焊接到塔体上，同时将牛腿也焊接到位，在塔体直立就位后，工作人员站在已安装好的同层平台上，挂好安全带，用吊车将受到吊装影响的平台和它的栏杆吊装到已焊接好的牛腿位置，先将现安装的平台两边和原平台的接触处对焊好，然后将现在安装的平台和吊装前已安装好的牛腿焊接为一体，焊完一处，再往前移到下一处，直至焊接完整个平台。 In order to install flat

28、roof and ladder of equipment maximum on the ground, when the equipment is moved to the site, the tower will been lay on the level ground, at the same time the tower will filled up 2m distance level to the ground, flat roof and ladder that have been made is installed to the tower body according to dr

29、awing. Because of affection of lifting lug and lifting rope, each flat roof some part from lifting lug to top will been limited, and cant been installed to the tower body. After the tower is installed to the ground, the leaving part will beinstalled. Detail way is: before tower is installed, affecti

30、ng welding protecting board of fiat roof first will be welded to the tower body, at the same time the cattle leg are welded to protecting board，after the tower is installed to the ground. The workers stand on the flat roof that hasbeeninstalled, at the same time work should tie safe belt，affecting f

31、lat roof and ladder will be installed to location with lifting crane, first two sides of later installing flat roof will be welded with two sides of installing flat roof that have been installed, and then the flat roof is welded to the cattle leg, after a set of the cattle leg is welded, and we can

32、start to welded the next set of the cattle leg, until all of the cattle legs is welded.八、eight.垫铁和地脚螺栓gasket of iron plate and anchor bolt1).地脚螺栓应配螺母和垫圈，地脚螺栓应受力均匀。Anchor bolt should be qualified the nut and gasket, the force on the anchor bolt must be uniformity. 2).每个地脚螺栓旁至少有一组垫铁，垫铁应尽量靠近地脚螺栓。At lea

33、st a set of gasket of iron plate is near the anchor bolt;gasket of iron plate should close with anchor boltproximally.3).相邻两垫铁组的间的间距应为500mm左右。Space between Two sets of gasket of iron plate that is border should be around 500mm.4)每组垫铁一般不超过四块，少用薄垫铁。放置平垫铁时，最厚的放在下面，最薄的放在中间，设备找正后应互相点焊牢固。Each set of doubl

34、er plate four block at most, thin doubler plate should be used little. when even double plate is placed, the thickest double plate must be placed underside and the thinnest double plate must be placed in middle, their spot welding must be firm after equipment is seek position.5).每组垫铁均应放置平稳，接触良好，垫铁表面

35、的油污应处理干净；塔体找正后，各组垫铁均应被压紧，可用0.25公斤手锤逐组敲击，听声音检查。Each set of double plate should be placed calmly and touchedfully, the oil and dirt on the surface of double plate should be clean. After tower is centered align, each set of double plate should be pressed strictly, knock on the double plate according to

36、 order, we can check by sound.6)垫铁组高度：中小型设备3060mm，大型设备50100mm；Height of stow-irons: for mid or min scale equipment is 3060mm，for large scale equipment is 50100mm.7)塔的找正,找平应按基础上的安装基准线对应塔上的基准测点进行测量调整.we must according to benchmark line of base and benchmark point, When we measure and rectifyAlignment

37、of tower.8）平垫铁与斜垫铁的规格斜垫铁应与项次一样的平垫铁配合使用。如有特殊要求，可采用其他规格或加工精度的垫铁。垫铁面积 A=b L ，选用垫铁时以表中平垫铁面积为准。九、nine.找平、找正adjust and level1)找正与找平应按基础上的安装基准线（中心标记、水平标记）对应塔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：Adjust and measure bench mark of tower related to installation datum line to adjust and level, adjustment and leveling shal

38、l conform to following specifies:a.塔支承（裙式支座、耳式支座、支架等）的底面标高应以基础上的标高基准线为基准；Elevation of tower base (skirt, earlap support, bearing carrier) shall base on elevation datum line on foundation;b.塔的中心线位置与管口方位应以基础上的中心线为基准；Centerline and pipe mouth orientation of equipment shall base on centerline on foundat

39、ion;c.塔的方位应以基础上距离设备最近的中心线为基准；Orientation of upright tower shall base on the centerline on foundation which is nearest to equipment;d.塔的铅垂度应以塔的上下封头切线部位的中心划线为基础。Vertical degree of tower shall base on center lineation of tangent for towers top and bottom head. e.塔体找正的补充测点宜在下列部位选择measure point in that b

40、ody of tower is adjusted should is selected at these position. 主法兰面main flange surface塔体铅垂的轮廓面figure surface of towers vertical 在绝热的塔体上同一水平面互成90的两个方位上，引出上、中、下三个测点件，各测点件必须通过塔中心轴线，且有测量标计。fetch out three measure point from two positiones where adiabatic body of tower is 90in the same level, each of mea

41、sure point must pass center line of tower.2)找平与找正应符合下列规定：Adjusting and leveling shall conform to following specifies:找平与找正应在同一平面互相垂直的两个或两个以上的方向进行；Adjusting and leveling shall be carried in two or more than two mutually perpendicular directions in same plane;找正与找平均用垫铁来调整，地脚螺栓的紧固要均匀，严禁采用改变地脚螺栓紧固程度的方法来

42、调整。紧固地脚螺栓前后，塔的允许偏差均应符合下表规定：Adjust stow-iron to adjust and level. Uniformly tight the anchor bolt, strictly prohibit to adjust by changing tightness of anchor bolt. before and after tightened anchor bolt，allowing warp of tower must answer for next rules(单位unit：mm)注：H为塔两端部测点间的距离；括号的数字为丝网波纹塔的铅垂度；D为塔的直径

43、。Note: H is distance in the two end measure point, number in the bracket is vertical degree of silk screen ripple tower; D is insider diameter。检查项checking item允许偏差permission warp一般塔common tower与机械衔接的塔tower connect with machine中心线位置location of center lineD2000 52000 103标高elevation5相对标高3 relatively el

44、evation铅垂度vertical degreeH/1000 但不超过30（20）But 30（20）方位position沿底座环圆周测量measure along circle of baseD2000 102000 15沿底座环圆周测量measure along circle of base5塔的高度超过20m时，为了避免气象条件影响，其铅垂度的调整和测量工作应避免在一侧照射与风力大于4级的条件下进行；When height of tower is more than 20m, adjusting vertical degree and measure must avoid to mak

45、e in the condition that a side is sunned and wind power is more than 4 class塔安装调整完毕后，应与时填写“安装记录”，并经监督单位验收签证。After tower is installed, we fill in “record of installation”, and supervising unit should check and accept and visa.十、ten.二次灌浆The second grouting1)灌浆前，灌浆处用水清洗洁净并渗透，积水应吹净，环境温度低于0时，应有防冻措施。Befor

46、e grouting, position of grouting must be cleaned by water and filtered, the water on the base should be clean by blowing. 2)灌浆应依次进行，不得分二次浇灌。We must act on order to grout, two times grouting is forbade.十一、eleven.塔件安装 Install the fittings in the tower1).一般规定commonly regulate件安装应在塔体压力试验合格并清扫干净后进行,件安装时,

47、应严格按图样规定施工,以确保安装质量。When we install the fittings in the tower, we must construct acting with rule of design. After press test of tower is eligibility and cleaning work is finished.塔盘安装时，原则上采用分段安装，为了便于检查，分段宜选择在人孔处，先安装人孔处下部塔盘，以此层塔盘作为操作平台，依次向上逐层安装，分段处人孔上部一层塔盘的通道板应封闭。塔盘的垂直运输采用吊柱，利用滑轮和卷扬机运到人孔平台上，然后用麻绳捆绑运到

48、塔。2).安装塔盘人员应遵守下列规定：When we install tray, we must stand by the next rule:一层塔盘允许承载人数number of worker in a bed tray塔径（mm）radius of tower20002000250025003200320040004000500050006300630080008000人员总数total of personnel234567893)塔盘构件安装宜按下列顺序进行：Installing the component of tray must observe the next order:a、支

49、承点测量；measure bearing pointb、降液板安装；install droping liquid boardc、横梁安装；install beamd、受液盘安装；install accepting liquid boarde、塔盘板安装；install board of trayf、溢流堰安装；install overfall weir g、气液分布元件安装；install component of distributing gas and liquid h、清理杂物；Clean sundriesi、检查人员最终检查；Inspector check finallyj、通道板安装

50、；Install passing boardk、人孔封闭；Close the manholel、填写封闭记录。Fill in closing note4)塔件安装 install inside component of tower(1)件运进现场后要妥善保管，不锈钢件要与碳钢件隔离，下面放置枕木；After inside component is transport to site, we must be kept carefully. Stainless steel inside component must be isolated with carbon steel component，a

51、t the same time sleeper must be placed underside. (2)件安装时,塔盘板、降液板、横梁等可放置在现场保管，但要防止变形、损坏、腐蚀、等情况发生；现场应保持平整清洁；when installing inside component，board of tray、droping liquid board、beam and so on ought to be kept in the site. Site must remain cleaning in order to prevent to distortion、mangle、rust and so o

52、n。 (3)件安装前应将表面清除干净，对塔盘零部件还应编号以便安装，塔盘应进行预组装，预组装时在塔外按组装图把零部件预组装一层，调整并检查塔盘是否符合图样要求；Before installing inside component，surface must be cleaned, each part of tray should be serial number in order to install, tray ought to be beforehandinstall, each part of tray must be installed into one floor with insta

53、lling Drawing outside tower during beforehand installing. Adjust and check tray whether tray answer for request of drawing.(4)塔盘支持圈的水平度、间距进行逐个复测，将水平仪的贮液罐固定在上一层支持圈上或特设的支架上，刻度尺下端放在支持圈测点上，各测点玻璃管液面计读数的差值即为水平偏差值；check again level、space betweensupporting circle of tray one by one，fixup storing liquid kett

54、le of gradienter on up one beds supporting circle, down end of scale ruler place on the measuring point of supporting circle，reducing value liquid level gauge reading for each measuring point of glass tube is level warp value。支持圈上表面水平度允许偏差(mm)up level allowing warp of supporting circle(mm)塔体直径diamet

55、er of tower允许偏差allowing warp D 400031600 D 400054000 D 600066000 D 800088000 D 1000010(5) 相邻两层支持圈的间距允许偏差不得超过 3mm,每20层任意两层支持圈间距允许偏差不得超过 10mm;allowing warp of distancebetween two layers supporting circle cant be more than 3mm， allowing warp of any 2 layers distance in each 20 layers for supporting cir

56、cle cant be more than 10mm;(6) 若经过复测有不符合要求的支持圈,应通知业主并制订业主同意的处理措施,使之达到标准要求;If some supportingcircle second measured doesnt answer for request, we must inform owner and establish dealing with measure and achieve standard request.(7) 降液板的支持板安装偏差应符合下列规定:supporting board installing warp of droping liquid

57、 board must answer for next rules:a螺栓孔水平间距允许偏差为3mm;level distance allowing warp of bolt hole is 3mm；b支持板安装部位允许偏差为2B/100; supporting board allowing warp of installation part is2B/100c支持板倾斜度允许偏差为2G/100; supporting board allowing warp of lean is2G/100d支持板安装位置R1允许偏差为5R1/1000,但不大于6mm; supporting board al

58、lowing warp installing position R1 is5R1/1000, but less than 6mm;e支持板安装位置R2允许偏差为5R2/1000,但不大于12mm; supporting board allowing warp installing position R2 is5R1/1000, but less than 6mm;(8) 降液板安装应符合下列规定:installing drop liquid board must answer for next rules:a降液板的长度和宽度尺寸允许偏差为-40mm和-20mm,降液板螺孔距离允许偏差为1mm

59、;size allowing warp of length and width for droping liquid board is -40mm and -20mm, allowing warp of hole distance for droping liquid board is 1mm;b降液板底端与受液盘上表面的垂直距离允许偏差为3mm;(图3.2.5-2)vertical distance allowing warp between bottom of dropping liquid board and accepting liquid tray is 3mm;c降液板至塔壁通过设

60、备中心的垂直距离允许偏差为6mm;（图3.2.5-3） passing equipment center vertical distance allowing warp between dropping liquid board and inside wall of tower is 6mm;+1-0.5d中间降液板间距允许偏差为6mm;( 图3.2.5) allowing warp of the distance for middle droping liquid board is 6mm;e.固定在降液板上的塔板支承件，其上表面与支持圈上表面应在同一水平线上，允许偏差为+1-0.5mm。S