储罐制作及安装作业中英文指导书 储罐制作安装英文指导书

1、CSPC Nanhai Petrochemicals ProjectSEPCO Electric Power Construction Corp CSPC NANHAI PETROCHEMICALS PROJECTCSPC 南 海 石 化 项 目FABRICATION AND ERECTION OF TANK WORK INSTRUCTION储罐制作及安装作业指导书WORKING INSTRUCTION：WI-8710-8100-2006REVDATEREASON FOR ISSUEBYCHKDREVIEWAPPRA22 JUL 2003 Issue for Review and approv

2、alWFLHJCHYDPS0024 AUG 2003Issue for implementationWFLHJCHYDPS0112 SEP 2003Issue for implementationWFLHJCHYDPS022 NOV 2003Issue for implementationWFGHMZXSDPRevision Information修改记录Rev版次Section No.章节号BSF review record No.BSF审查单序号Description of main changes主要修改内容025 Sections gAttachment B SEPCO2 QUALIT

3、Y SYSTEM ORGANIZATION CHART FOR FABRICATION AND ERECTION OF TANK”增加了“SEPCO2 储罐制作与安装的质量管理组织结构”3.1Sepcos working scope dont conflict with sepco2s; Because we adopt three grade checking before acceptanceSepcos工作范围与Sepco2s不冲突，因为我们采用的是三级验收。55Add safety , welding & survey procedures, issued by SEPCO增加了SEP

4、CO安全、焊接和焊接程序Attachment C 6Add” LAYOUT JOBSITE OF STORAGE TANK”增加了“储罐施工现场布置图”9.3.77Add” cleaning oil , grease and contaminant on the plate surface with fresh water before blasting.”增加了“在抛丸前用清水清洁钢板表面的油，油脂及污染物。”9.3.88Add” Surface cleanness and surface profile should be relatively inspected with photo i

5、n the GB8923” rustiness and antirust grade of steel plate surface before blasting”增加了“表面清洁度和轮廓根据GB8923涂装前钢材表面腐蚀等级和除锈等级所规定的图片进行对照观察检查”9The DFT is complied with DEP required system! The paint system number is 15 in the latest revisions of the coating the DEP and the SP, but storage tanks system number

6、 is 1.210Delete” and antisepsis”删除了“and antisepsis”Attachment D11 12 13 14 15 1 6 Add ”JSA”10.2.1010.3.2310.4.17Add” Welding detail see 12 section.”增加了“焊接细节见12节”10.2.7Add “Only welders qualified to weld full penetration from one may make welded one side full penetration.”增加了“只有单面焊透合格的焊工才能进行单面焊透。”10.

7、2.8Add”Electrodes and welding parameters shall be the same as required by the appropriate WPS and PQRs.”增加了“焊条与焊接参数应该与WPS和PQRs的要求一致。”12.1.1Add “ASME ”12.1.2Add “A list of qualified welders shall be submitted to PMC for approval before the construction of tank.”增加了“储罐施工前，合格的焊工应报PMC批准。”12.4.2.7Reinfor

8、cing pads or testing have mentioned in 12.2 section.加强板试验已经在124.2.7节中说明。11.4Add ”All nozzles required to be full penetration welds.”增加了“所有的管口要求全熔透焊接。”16.3Add “Erection in accordance with GB128-90 or applicable contract required code. Many different requirements so should use the most strict code.”增加

9、了“安装按照GB129-8-90或可适用的合同规定的规范，许多不同的要求被用时采用最严格的标准。”14.8Add” with theodolite ”增加了“用经纬仪”0215.8Delete “The unpainted parts shall be protected from rusting.”删除了“并对未涂漆部位进行防锈保护。”Add” The unpainted parts shall be grinded after the weld joint has been completed.”增加了“未刷漆部分在焊接完后用磨光机进行打磨处理”16.1Add”PR-8710-8100-0

10、056 Rev.01 Quality Inspection”增加了“PR-8710-8100-0056 Rev.01质量验收”Attachment EAdd “Welding Procedure Sheet”增加了“焊接工艺评定“10.3.9Add” When the each layer shell plate installs, moved shell plate of over 2m should not be assembled and welded in order that personnel go away and come in start construction proce

11、ss. After the tank is promoted above 600 mm, Expansion ring of the tank supported with a wood, then the moved shell shall be assembled and weild ., one by one in order the type process.”增加了“在每层壁板安装时留一张2m以上的壁板不组对焊接以便在施工过程中人员出入，等储罐被提升600mm以上时，胀圈用道木支撑，然后组对此壁板并进行焊接，依次类推。”The WI is WI-8710-8100-0013c REV

12、 01s upgrade .此作业指导书是WI-8710-8100-0013c REV 01 的升版.PAGE 1目 录TABLE OF CONTENTS1 PURPOSE目的 2 SCOPE范围 3 RESPONSIBILITIES职责 4 PROJECT SUMMARIZATION工程概述 5 WRITING REFERENCE编制依据 6 PRIMARY CONSTRUCTION SCHEME主要施工方案 7 PROCESS FLOW工艺流程 8 ERECTION PROCESS REQUIREMENT安装工序要求 9 TANK PREFABRICATION罐体预制 10 TANK ER

13、ECTION罐体组装11 ACCESSORY INSTALLATION附件安装 12 WELD AND WELDING LINE INSPECTION焊接及焊缝检验 13 GEOMETRIC DIMENSION AND DIMENSIOMN INSPECTION OF TANKS罐体的几何尺寸和尺寸检验14 WATER TESTING充水试验 15 ANTICORROSIVE PAINTING防腐涂漆 16 CONSTRUCTION ACCEPTANCE工程验收 17 LABOR FORCE PLAN劳动力计划 18 EQUIPMENT FOR CONSTRUCTION施工机具使用计划 ATT

14、ACHMENT A: CALCULATION ON HOISTING VERTICAL POST附录A：提升立柱计算说明书 ATTACHMENT B: SEPCO2 QUALITY SYSTEM ORGANIZATION CHART FOR FABRICATION AND ERECTION OF TANK 附录B SEPCO2 储罐制作与安装的质量管理组织结构ATTACHMENT C: LAYOUT JOBSITE OF STORAGE TANK附录C： 储罐施工现场布置图ATTACHMENT D: JOB SAFETY ANALYSIS附录D：工作安全分析ATTACHMENT E: WELD

15、ING PROCEDURE SHEET附录E 焊接工艺评定1. PURPOSE目的 To provide specification and requirement for oil/water tank fabrication in CSPC Nanhai Petrochemicals Project, Steam & Power Plant Project. This instruction can act as a direction in making and erecting tanks to ensure the project to complete on time and wit

16、h good quality.在于制订南海石化汽电联产项目油罐、水箱制作的规范及要求，作为以后制作及安装的指导，确保工程高质量的按期完工。 SCOPE范围 This instruction complies to the fabrication and erection of oil/water tanks in CSPC Nanhai Petrochemicals Project, Steam &Power Plant Project (excepting for thermal insulation and antisepsis).本指导书适用于南海石化汽电联产项目油罐、水箱的制作及安装（

17、不包括保温）。 RESPONSIBILITIES职责 3.1 SEPCO2 is responsible for the fabrication, erection, inspection and testing of oil/water tanks.山东电建二公司负责油罐、水箱的制作及安装、检验和试验。3.2 SEPCO1 is responsible for the excavation fabrication, inspection and testing of tanks foundation.山东电建一公司负责油罐、水箱基础开挖、制作、检验和试验。3.3 SEPCO is respo

18、nsible for the interface coordination and quality check and acceptance. 基建总公司负责接口协调和质量验收。 PROJECT SUMMARIZATION工程概述4.1 PROJECT BRIEF INTRODUCTION工程简介8 oil tanks, 2 desalting tanks and 2 coagulating tanks need to be erected on site for CSPC Nanhai Petrochemicals Steam & Power Project. The maximum cap

19、acity of tanks is 8350 m3. Water tanks are normal pressure containers, which structural form is vertical cylinder steel welded dome roof tank. Grade of surface finish is Sa. Inside shell need an epoxy lining, while the outside is to be painted for protection; Oil tanks are low pressure containers, w

20、hich structural form is vertical cylinder steel welded dome roof tank. Grade of surface finish is Sa. Inside shell requires a first coat, while outside requires thermal insulation after primer, inter-coat and top coat.南海石化汽电联产项目现场安装有储油罐8座、除盐水箱2座、凝结水箱2座，罐的最大容积为8350m3，其中水箱为常压容器，结构形式为立式圆筒钢制焊接储罐，顶部为拱顶，除

21、锈等级为Sa，罐壁内侧为环氧树脂衬里，外侧涂漆防护；油罐为低压容器，结构型式为立式圆筒钢制焊接储罐，顶部为拱顶，除锈等级为Sa，罐壁内侧为一遍底漆，外侧涂底、中、面漆后保温防护。4.2 PROJECT ITEMS工程项目 PROJECT ITEMS SCHEDULE工程项目一览表序号ITEM名称NAME代号CODE规格SIZE（直径*高度）DIA.*HEIGHT容积CUBAGE（m3）重量WEIGHT（kg）数量QUA罐顶形式ROOF FORM1储油罐OIL TANK T869120*206283126，5001带肋拱顶DOME WITH RIB2储油罐OIL TANKT868222.5*21

22、8350192，0001带肋拱顶DOME WITH RIB3储油罐OIL TANKT868122.5*218350192，0001带肋拱顶DOME WITH RIB4储油罐OIL TANKT868322.5*218350192，0001带肋拱顶DOME WITH RIB5储油罐OIL TANKT866220 *206283158，0001带肋拱顶DOME WITH RIB6储油罐OIL TANKT866120 *206283158，0001带肋拱顶DOME WITH RIB7储油罐OIL TANKT867117.5 *14336770，0001带肋拱顶DOME WITH RIB8储油罐OIL

23、TANKT865110 *13102131，7001带肋拱顶DOME WITH RIB9除盐水箱DESALTING TANKT8441A21.2*12.24084113，0001带肋拱顶DOME WITH RIB10除盐水箱DESALTING TANKT8441B21.2*12.24084113，0001带肋拱顶DOME WITH RIB11凝结水箱COAGULATING TANKT847116*12.2230969，0001带肋拱顶DOME WITH RIB12凝结水箱COAGULATING TANKT848122.7*14.65655137，0001带肋拱顶DOME WITH RIB4.3

24、 Butt joint (fully melt) will be adopted for annular plates and lap joint for bottom center plates ; butt joint (welding line fully melt) be adopted for shell plates, and lap joint for tank roof, butt joint for every plate part. Roof form is dome roof with rib.罐底板边缘板采用对接接头（全部熔透），中幅板采取搭接接头；罐壁板采用对接接头（

25、全熔透焊缝）；罐顶板采取搭接接头,每一等分板间采用对接接头。罐顶的结构形式全为带肋拱顶。4.4 The reeling, sand blasting, painting of steel plates shall be finished in workshop. Erection, including process of assembly, weld, inspection, testing, thermal insulation and antisepsis, will be done at jobsite erecting location.钢板的卷制、喷砂、涂漆在车间完成。储罐在现场的

26、安装位置进行安装，现场安装包括组对、焊接、检验、试验、保温、防腐等工序。5. 编制依据 WRITING REFERENCE Construction drawings and related document施工图纸及相关文件 GBJ128-90 Construction, Check and Acceptance Specification of Vertical Cylinder Steel Welded Oil TankGBJ128-90立式圆筒形钢制焊接油罐施工和验收规范 DEP34.51.01.31-CSPC Standard Vertical Tanks Selection, De

27、sign and FabricationDEP34.51.01.31-CSPC标准立式油罐-选择、设计和制作 DEP30.48.00.31-CSPC Painting and Coating of New EquipmentDEP30.48.00.31-CSPC新施工项目的涂漆和覆层 DEP64.51.01.31-CSPC Standard Vertical Tanks Field Erection and TestingDEP64.51.01.31-CSPC标准立式油罐-安装和实验 DEP80.47.10.31-CSPC System & Facility Fire Protection D

28、EP80.47.10.31-CSPC系统和设备的防火保护 DEP30.48.70.30-CSPC Glass Liner of Facility and Piping DEP30.48.70.30-CSP设备和管道的玻璃衬里 Construction Quality Inspection Plan QC-8420-8600-0001施工质量检验计划 QC-8420-8600-0001 g 热保温6. PRIMARY CONSTRUCTION SCHEME主要施工方案6.1 Construction scheme: According to the construction characteri

29、stics and field environmental requirement, shell plates and braces of oil/water tanks shall be prefabricated in the plant offsite before their assembly (i.e. bending, derusting by sand blasting and painting of shell plates and braces.) first, then be transported to jobsite for assembly. Reverse asse

30、mbly method is adopted, that is to say, tank will be assembled from roof downward to bottom. The erection sequence is: tank bottom, roof sheeting, tank, facilities, facilities outside the tank, and at last railing platform. The assembly shall be done with 25T hydraulic track crane, and chain fall sh

31、all be adopted for erection. Scaffolds shall be built both inside and outside of tank for erection process.施工方案：根据油罐、水箱的施工特点和现场环保需要，此油罐、水箱的壁板及支撑组装前，在安装现场外的工厂内先进行预制（即壁板及支撑的折弯、喷钢砂除锈及油漆），再运输到安装现场进行组装，组装时采用倒装法，也就是自罐顶到底板的装配、制造顺序；安装顺序为：罐底、顶板、筒体、设备、外壳外部设备、栏杆平台；组装采用25t汽车吊，安装采用倒链提升；安装时罐内外搭设脚手架.6.2 Erection p

32、latform: Bottom plates of oil/water tanks act as temporary work platform for shell plates assembly. 组装场地：油罐及水箱底板作为临时平台，用作壁板组装。7. PROCESS FLOW工艺流程 Process flow chart of oil-tank fabrication and erection:油罐制作安装工艺流程图： Workshop prefabrication process flow chart:车间预制的工艺流程图： Drawings joint checkupReceived

33、 material inspectionConstruction technology deliverlaying off and groove process Reeling Sand Blasting Painting and NumberingTransported to jobsite 图纸会审进厂检验施工技术交底下料及坡口加工卷板 喷砂涂漆并编号运输到现场 Jobsite erection process flow chart:现场安装流程图：construction preparation acceptance of foundationlaying bottom plateswe

34、ld of bottom center platesassembly and weld of top plate assembly and weld of curb angleassembly of temporary column for dome roofassembly and weld of roof platesassembly and weld of ribs for rooferection of hoisting vertical columnhoisting shell platesassembly and weld of the subsequent coursefinis

35、hed weld inspectionfillet weld shell plates to bottom platesweld shell plates to annular platesvacuum side leaking of seams on the bottom plates acceptance of geometric dimensionerection of fittingserection of stair platformfilling water testinganticorrosion and thermal insulationacceptance of the f

36、inished construction施工准备基础验收 铺设底板 中幅板焊接 最上层壁板装配、焊接包边角钢组对、焊接临时拱顶支柱组装 罐顶板装配、焊接罐顶肋板装配、焊接提升立柱安装提升壁板装配、焊接下一层壁板依次提升组焊其他各层壁板罐壁焊缝检验最下层壁板和底板的角焊缝焊接 中幅板与边缘板焊接底板焊缝真空测漏 罐体几何尺寸验收 附件安装梯子平台安装充水试验防腐、保温竣工验收ERECTIING PROCESS REQUIREMENT安装工序要求 8.1 CONSTRUCTION PREPARATION施工准备8.1.1 Drawings shall be checked up by relate

37、d personnel. Particular attention shall be paid to checking the general dimension and junctions dimension of tanks. Learn the usage and basic working principle of oil/water tank. Make clear technical standard &requirement and primary construction workload according to the acceptance specification. I

38、n the event any misunderstanding or mistake on the drawings is discovered, the problem shall be reported and solved before construction.熟悉图纸，组织有关人员进行图纸会审。重点审核油罐及水箱的整体尺寸及连接点尺寸，弄清油罐及水箱用途及基本工作原理，并且对照验收规范，弄清技术标准及要求和主要工程量，图纸设计不清或错误，应及时反映，落实清楚后方可施工。8.1.2 Organize the related erecting personnel to provide

39、technology delivery. Project summarization, time limit, primary construction workload, primary technology requirements, construction specifications and standards, construction process and methods, the problems to which particular attention shall be paid, key points of the drawings and quality contro

40、lling point and safety precautions shall be interpreted.组织有关安装人员进行技术交底。交代工程概况、施工工期及主要工程量；交代主要技术要求和执行的规程规范及标准；交代施工顺序及施工方法，指出应注意的问题和有关处理方法；指出图纸中的关键之处，指出质量控制点；交代安全注意事项等。 8.1.3 Compile tooling material plan and start to stock.编制工装材料计划并备料8.1.4 Construction equipment & tools and field preparation:施工机具、施工场

41、地准备： Received lifting facility inspection before entering site.起重设备进厂检查。 Tools room, oxygen ethyne room and electric weld machine switchboard distribution.现场工具室、氧气乙炔房及电焊机配电盘布置。 Manual electric weld machine and other facilities arrangement preparation.电焊机等其它设备工器具准备布置。 Depositary distribution for mate

42、rials, wastes and finished products.原材料、废料及成品堆放场地布置。Employee temporary rest room, electrodes room and drying room distribution. 职工临时休息室、焊条库及烘干室布置。 Others.其它 8.1.5 Preparation for tools, instruments, auxiliary facilities and safety protecting equipment: Tools and instruments of all types shall comply

43、 with the construction & safety requirement and gauges shall be inspected for acceptance. All of the safety facilities and equipment shall comply with appropriate specifications.工器具量具辅助设施安全防护用品等的准备：各种工器具符合施工及安全要求；各种量具经检验合格；安全设施及安全用品符合安全规定。8.2 Design and fabrication of tooling system工装设计制作 Design and

44、 fabrication of special equipment for hoisting tank walls筒壁提升专用工具设计制作。 Design and fabrication of special support for shell plates arrangement壁板放置专用支架设计制作。Design and fabrication of special tooling system for settling tank walls reinforcing rings into place筒壁加强环就位专用工装设计制作。8.3 Materials inspection befo

45、re entering the factory 材料入场检验8.3.1 Carbon steel plates and sections shall conform to the accepted standards of the countries in which the tanks are to be fabricated or the steel is to be rolled.碳钢板和附件应符合储罐的制作和钢板卷制的国家验收标准。8.3.2 The steel shall contain not more than 0.23% carbon, 0.05% sulphur and 0.

46、05% phosphorus.钢材中各成分含量C0.23%，S0.05%，P0.05%。8.3.3 The steel shall have a guaranteed minimum ultimate tensile strength of at least 363 N/mm2 and a maximum ultimate tensile strength of not more than 510 N/mm2. The steel shall have a guaranteed yield strength of at least 206 N/mm2. The steel shall have

47、 an elongation not less than 22%.钢材应保证最小极限抗拉强度至少为363N/mm2且最大极限抗拉强度不超过510N/mm2，屈服强度至少为206 N/mm2，不小于22%的延展性。8.3.4 Tank shell plates and bottom annular plates shall display adequate notch toughness, as shown below: 储罐的壳体板和底部环型板应有足够的切口韧性，表示如下： Plate thickness板厚（mm）Ultimate tensilestrength极限抗拉强度（N/mm2）Mi

48、nimum Charpy-Vvalue (J)最小却贝V型切口值（J）Test temperature (C)实验温度（）12.5IMPACT TESTS NOT REQUIRED无要求冲击实验12.543027+2012.543041-58.3.5 Mechanical testing机械测试8.3.5.1 Mechanical testing is not required for roof and bottom plates for which the thickness is determined for practical reasons and not by stress cons

49、iderations.由于顶部和底部板的厚度由实践理论确定且不考虑压力，因此力学实验对顶部和底部板不要求。8.3.5.2 For shell plates and for the bottom annular plates, tests shall be made on specimens taken from each plate thickness with a frequency of one test per 25 000 kg of steel or part thereof.对于壳体板和底部环型板，用每25000kg的钢材做一个实验的频率对每一个厚度的板进行抽样实验。8.3.6 M

50、ill certificates shall show all the properties of materials guaranteed by its specification and any additional requirements.工厂证明书表明了通过规范及一些附加要求而保证的材料的所有特性。8.3.7 Structural bolts shall comply with GB 123, grade 8.8.结构螺栓遵从GB123，8.8级罐体预制TANK PREFABRICATION9.1 TEMPLET PREFABRICATION样板预制 9.1.1 The length

51、 of arc templet shall be more than 2.5m.弧形样板长度应大于2.5m。 9.1.2 One straight templet shall be used to test the convex and concave curvature of tank bottom and wall, with length no less than 1m.直线样板一个：用于检查罐底和罐壁的凸凹度，其长度不小于1米。9.1.3 Templet shall be made of =0.75mm galvanized sheet iron.样板用=0.75mm镀锌铁皮制成。 9

52、.2 TANKS BOTTOM PLATE PREFABRICATION罐底板预制 9.2.1 Alignment drawings shall be made according to the design requirements and actual specifications of steel plates before bottom plate prefabrication. Diameter of the plate should be amplified by 0.1%0.2% of designed diameter in order to compensate weld s

53、hrink of bottom plate . (Cone curvature of bottom plate has been taken into consideration).底板预制前应根据设计要求及实际钢板规格绘制排板图，排板直径宜按设计直径放大0.1%0.2%,以补偿底板的焊接收缩（此已考虑了底板的锥度）。9.2.2 According to the alignment drawings, a semiautomatic cutting machine shall be used for cutting plates.The cutting machine can also be

54、used to make groove in arc annular plates.按照排版图，用半自动切割机进行下料，对于弓形边缘板应用半自动切割机打坡口。9.2.3 After finished cutting plates, hoist the bottom plate onto an abrasive conveyer belt for removing rust.将下好的底板，吊至抛丸机传送带上，进入抛丸机抛丸除锈。 9.2.4 Blow away dust and iron powder on steel plates after being processed in an abr

55、asive by using an air-compressor.利用空压机压力风，吹净抛丸后钢板上的尘土及铁粉。 9.2.5 Tank bottom shall be spray painted with zinc-rich epoxy primer by using the airless spray equipment. Dry film thickness shall be 25um.利用无气喷吐机对罐底喷底漆，底漆为环氧富锌底漆，干膜厚度为25um。 9.2.6 Check of dry film thickness shall comply with GB 50205-2001 C

56、ODE FOR ACCEPTANCE OF CONSTRUCTION QUALITY OF STEEL STRUCTURES.Dry film thickness shall be checked with dry film thickness meter. Each component for examining 5 places, everywhere is 3 average value of dry film thickness for mutually being apart from 50 mm measuring points.干膜厚度的测量遵循GB 50205-2001钢结构工

57、程施工质量验收规范。利用干膜测厚仪检查油漆干膜厚度。每个构件检测5处，每处的数值为3个相距50mm测点涂层干漆厚度的平均值。9.2.7 Painting shall not be permitted in the area of 50mm around the welding line on bottom plate.底板的现场焊接焊缝周围50mm范围内不允许刷漆。 9.2.8 Bottom plates will be numbered according to alignment drawings after paint has been dried adequately. Numberi

58、ng method is as following: Tank number plus erection sequence number.待油漆充分干燥后，按照排版图对底板进行编号，具体编号方式如下： 储罐编号+安装序号 9.2.9 Bottom plates shall be piled up and transported according to erection sequence after its numbering.编号完毕后，按照安装顺序摆放、运输。 9.2.10 Inequable clearances shall be adopted for butt joints in a

59、rched annular plates. Outboard clearance shall be 6-7mm while inboard clearance shall be 8-12mm.弓形边缘板的对接接头，宜采用不等间隙。外侧间隙宜为67mm；内侧间隙宜为812mm。9.2.11 Width of bottom center plate shall not be less than 1000mm and length shall not be less than 2000mm.中幅板的宽度不得小于1000mm；长度不得小于2000mm；9.2.12 Distance between a

60、ny two adjacent welding lines in bottom plates shall not be less than 200mm.底板任意相邻焊缝之间的距离，不得小于200mm。9.2.13 Deviation of dimension tolerance of arched annular plates shall be in accordance with requirements in the following form:弓形边缘板的尺寸公差允许偏差，应符合下表的规定。 弓形边缘板尺寸允许公差 PERMITTED TOLERANCE OF ARC ANNULAR