重油发电机组安装施工组织设计.docx
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重油发电机组安装施工组织设计
1机务部分施工方案
ConstructionSchemefortheMachinerysection
1.1主厂房行车吊装
Mainbuildingbridgecraneinstallation
1.1.1吊装步骤TheLiftingProcess
1)将履带吊开至标识位置,松钩,挂钢丝绳。
Risingthecrawlercraneuptothemarkposition,loosenthehookandsuspensionthesteelwireropes.
2)将钢丝绳按照标识位置将固定端的行车大梁绑扎好,确保起吊时大梁平稳,必要时可利用链条葫芦调平。
Makingthesteelwireropesinaccordancewiththemarkpositionandbiddingcranerunawaybuckstayofthefixedends.Thenkeepingthebuckstayrisesmoothlywhenhangingupthecrawlercrane.Itnecessarytousethechainblockwithsteelstructureadjustthebalance.
3)利用吊车将该行车大梁吊至大跑车轨道上,并用钢丝绳、枕木和垫块将大梁固定平稳。
Usingcranehangupthecranerunawaybuckstaytothetrackofbridgemotor,atthesametime,usingsteelwireropes,sleeperandcushionblockfixandkeepthecranerunawaybuckstaystably.
4)用同样的方法吊装扩建端的大梁和两条大梁的连接件组合体,同样放置在大跑车轨道上。
Usingthesamewayliftthebuckstayofextensionendsandtheconnectionpieceunitoftwobuckstaysthenputtheseontothetrackofbridgemotor
5)将两片大梁连接组合。
Conntectingandcomposingthetwobuckstays
6)将小跑车吊到大梁轨道上就位。
Lifting“thesmallracingbike”tothetrackofbuckstay,anditwillbepositionedonthistrack
7)将驾驶室吊至行车下。
Liftingthedrivingroomtoundersideofthebuckstay
8)利用卷扬机将驾驶室吊至行车大梁端头下面,并与行车连接。
Usingthewindingengineliftthedrivingroombelowthebuckstayends,andthenconnectswiththecranerunaway
9)将行车向里拖运至合适的位置并锁定。
Pullingthecranerunawayinnerofthestructure,thenfindthesuitableplaceandshockit.
10)接电源,运入试吊重物,进行行车试吊。
Connectingtheelectricalpower,andtrytolifttheheavy.
1.2柴油发电机组吊装
Generatorunitinstallation
1.2.1发电设备安装
Generatorequipmentinstallation
工艺流程:
Constructionflow
基础检查→划线→拖运轨道制作安装→柴油机安装→发电机安装→设备中心找正→设备连接→二次灌浆→设备中心复查
Inspectiontothefoundation→settingout→makingandinstallingthetrackusedtohaulequipment→installdieselengine→installgenerator→Adjustingandpositioningtheequipment→equipmentattachment→secondarygrouting→reexaminingthecenterofequipment
1.2.1.1柴油机安装
Installdieselengine
Ø基础检查、清理并复核中心线;
Examiningfoundation,cleaningandrecheckthecentralline
Ø按照图纸文件要求打制垫铁基础,配制、安装垫铁,垫铁与基础接触密实四角无翘动。
Thepackingironfoundationshouldbeforgedaccordingtothedrawingandfilesandconfectedandinstalledthepackingiron.Thepackingironandthebasefoundationshouldtouchclose-grained.
Ø设备经检查无变形等重大缺陷;
Inspectingtheequipmentsanddon’tfindseriousdefects
Ø采用行车将柴油机吊装就位;
Usingbridgecranetopositionthedieselengine
Ø使用水平仪、千斤顶等调整设备,直至设备纵横中心线及轴承水平标高符合设计图纸要求;
Usinggradienter,jacketc.toadjusttheequipment,untilthecenterandlevelelevationoftheequipmentmeettherequirementofthedrawing
1.2.1.2按照以上步骤将发电机安装就位;
Followthestepsabovetopositionthegenerator:
1.2.1.3柴油机与发电机设备连接;
Connectthedieselengineandgenerator
1.2.1.4基础二次灌浆;
Thebasafoundationsecondarygrouting
1.2.1.5设备中心线及水平标高复查;
Reexaminethecenterlineandlevelelevationoftheequipment
1.2.1.6弹性支座安装。
Installplatform
1.2.2机械辅助系统安装
Installauxiliarymachinerysystem
1.2.2.1机械辅助系统主要包括辅助模块、轻质燃油系统、重质燃油系统、压缩空气系统、冷却系统、充气系统、排气系统、混油水系统、水处理系统、机房附属消防系统、燃油加热蒸汽发电系统及其他辅助系统(具体安装方法可参考润滑油系统与燃油系统的安装);
Auxiliarymachinerysystemincludeauxiliarymodules,lightfuelsystem,heavryfuelsystem,compressairsystem,coolingsystem,aerationsystem,exhaustsystem,mixingoilandwatersystem,watertreatmentsystem,fireextinguishersystemandotherauxiliarysystem(specificinstallantionmethodpleaseconsultlubricatingoilsystemandfuelsysteminstallation)
1.2.2.2充气及排气模块、冷却水箱、油过滤器及进油管宜与烟道同步安装,连接对口过程中严禁强拉或附加外力,避免设备变形和移位;
Inflatableandexhaustmodules,coolingwatertank,oilfiltersetc.shouldbeinstalledsynchronizationwithtewel.Connectingtheequipmentshouldnotpullseriouslysoastoavoidshiftingandmetamorphosingoftheequipment.
其他辅助系统可根据设备到货及土建施工情况分散安装。
Otherauxiliarysystemwillbeinstalledseparatelyaccordingtoactualsituation.
1.3烟道制作安装及烟囱吊装
Gasductfabricationandinstallation,chimneylifting
1.3.1烟道制作
Gasductfabrication
作业前应做的准备工作和必须具备的条件
PreparativeWorkandEssentialQualifications
Ø设计施工图纸满足现场施工并已会审,单线图已标注焊缝编号;并根据施工图纸和技术要求编制材料需用计划。
Drawingmeetstherequirementofconstructionandbeapproved;Drawoutmaterialplanaccordingtothedrawingandtechnicalrequirement.
Ø制定详细的管道安装工序和工序控制点(见证点“W”,停工待检点“H”)。
Establishdetailedpipinginstallationprocedureandcontrolpostoftheworkingprocedure(witnesspoint“W”,stopworktowaitexamining“H”)
Ø施工方案经批准并已作技术安全交底,施工组织健全,施工人员熟悉本专业的施工工艺程序、质量标准和安全作业措施。
Constructionschemehasbeapprovedanddotechnicalclarificationsbeforeconstruction,constructionorganizationisintegrate,workersarefamiliarwithconstructionsequence、qualitystandardandsafemeasure.
Ø管子、管件、管道附件及密封紧固件应符合国家现行有关标准,具有出厂合格证。
Pipe,pipecomponent,sealingcomponentandrelatedequipmentmeetnationalcurrentstandardandpossesscertification.
Ø施工机具准备:
链条葫芦2t/1t各4只,尼龙吊带2条,25t汽车吊1台,焊机3台,10t千斤顶4个,割炬、砂轮机、水平尺、线锤、榔头、卷尺、对口钳若干,空压机1台,卷管机1台,焊条烘箱1个。
Prepareconstructiontoolsandmachinery:
cuttingtorch,grindingmachine,levelinginstrument,wrench,hammer,tape,severalpincers,aaircompressor,apiperoller,aweldingrodoven.
1.3.1.1施工方法及步骤
Constructionmethodandpocess
Ø烟道制作所采用的钢材,应具有质量证明书,并应符合设计的要求。
当对钢材的质量有疑问时,应按国家现行有关标准的规定进行抽样检验。
Therolledsteelusedtomakegasductshouldpossesscertificationandmeetthedesignrequirement.Ifdoubtabouttherolledsteelquality,itwilldosamplinginspectionaccordingtorelatednationalrule.
Ø施工前应对钢材表面质量进行检查,除应符合国家现行有关标准的规定外,尚应符合下列规定:
当钢材表面有锈蚀、麻点或划痕等缺陷时,其深度不得大于该钢材厚度负偏差值的1/2;
Inspectthesurfaceoftherolledsteelbeforeconstruction,tallywithnationalcurrentrelatedstandard,andalsoconformtodefollowstipulation:
whentherooledsteelsurfacehasdefectjustlikerustiness,scratchassoon,thedefectdepthshouldnotgreaterthanthanthe1/2D-valueoftherolledsteel.
Ø在烟道制作前,放样和号料应根据工艺要求预留制作和安装时的焊接收缩余量及切割等加工余量。
Inpre-production,settingouttheflueandfeedshouldbesetasideunderthetechnologicalrequirementsofthemanufactureandinstallationofweldingcontractionallowanceandcuttingmachiningallowance.
Ø下料切割前应将钢材切割区域表面的铁锈、污物等清除干净,气割后应清除熔渣和飞溅物;切割时根据卷管的弧度方向和焊接方向将钢板对应边开出单边坡口,坡口加工宜采用机械方法,也可采用氧乙炔焰等加工方法,在采用氧乙炔焰加工坡口或切割后,必须除去坡口表面的氧化皮,熔渣及影响接头质量的表面层,并将凹凸不平处打磨平整;
Thesteelmaterialunderthecuttingareabeforecuttingthesurfacerust,dirtandotherclean,gascuttingshallberemovedaftertheslagandflyingmaterial;cuttingpapertubeaccordingtothearcdirectionandthedirectionofthesteelplateweldedoutsingleslopecorrespondingportside,groovemechanicalmethodsshouldbeadopted,itcanbeusedandotherprocessingmethodsoxyacetyleneflame,usingoxyacetyleneflameintheprocessingorcuttinggroove,thegroovesurfacetoremoveoxide,slagandimpactofjointqualityofthesurfacelayer,Departmentpolishedsmoothandrugged;
Ø下料完毕后在卷管时,应逐渐轧小钢板的弧度,不可一次将钢板弧度变化过大,卷管将完成时应随时测量管道的椭圆度,对超标的地方及时进行处理和修正,将烟道椭圆度控制在规范要求的范围内。
Afterthefeedingtubeinvolume,shouldgraduallyrollingsmallplateinradians,notoncetoplateradianschangestoolarge,thevolumeshouldbecompletedatanytimetheovalitymeasurementpipeline,onthelocaltimeforprocessingandtheflueellipsecontrolrequirementsinthespecificationrange.
Ø烟道卷制完成并测量确认无误后,即可进行烟道的焊接。
焊接质量的好坏,将直接影响到以后的运行安全及使用寿命,故焊条型号的选用应严格遵守设计文件的要求,进货的焊条应具备制造厂的质量证明书(合格证)及质保书。
为保证焊接质量,焊条在施焊前必须按照《焊条质量管理规程》的规定进行烘烤,烘烤时严格遵照规定的时间和温度。
Rolltocompleteandmeasurethefluecheckedandverified,canbeweldedtotheflue.Thequalityoftheweldingquality,willdirectlyaffectthesafeoperationofthefuture,andlife,sothechoiceofelectrodetypeshouldstrictlycomplywiththerequirementsofdesigndocuments,purchasetheweldingrodshouldhavethemanufacturer'squalitycertificate(qualifyingcertificate)andwarrantybook.Toensuretheweldingquality,weldingelectrodeinthefacilitiesmustfollowbeforethe"rodofqualitymanagementprocedures"provisionsofbaking,bakinginstrictaccordancewiththestipulatedtimeandtemperature.
Ø焊接时应将坡口及其内、外侧表面不小于15mm范围内的油垢、铁锈、毛刺及其它杂物等清除干净,并不得有裂纹、夹层等缺陷。
WeldingwhenGrooveandmedialandlateralsurfaceisnotlessthanthe15mmrangeofoilydirt,rust,Burrandotherincidentals,clean,andnodefectssuchascracks,sandwich.
Ø焊接检验按照DL5007-92《电力建设施工及验收技术规范》(火力发电厂焊接篇)要求,采用1%超声检验,若有不合格应对相应的地方立即进行返修,返修后重新进行超声检验直至合格。
WeldinginspectioninaccordancewithDL5007-92theelectricityconstructionspecificationsforconstructionandacceptance(part1)thermalpowerplantweldingrequirements,with1%ultrasonicexamination,iftheyhavenotqualifiedtodealwiththeappropriateplacetoreworkimmediately,refurbishedultrasoundexaminationuponuntilqualified.
1.3.2烟道安装
Gasductinstallation
1.3.2.1安装条件要求
Installationrequirement
Ø烟道已制作完成,并经验收合格。
Gasducthasbeenfabricatedandbeacceptancecheck
Ø发电机组设备已吊装就位。
Generatorunithasbeeninstalled
Ø烟囱已吊装就位。
Chimneyhasbeeninstalled
1.3.2.2安装原则
Installationprinciple
Ø根据现场设备到货及安装情况,烟道安装方法可采用从烟囱中间向两侧安装,也可以从一侧向另一侧安装;
Accordingtotheon-siteequipmentarrivalandinstallationstatus,theflueinstallationmethodcanbeusedfromthemiddletoinstallonbothsidesofthechimney,orfromonesidetotheothersideoftheinstallation;
Ø组合件组合后应对整体组件的尺寸进行检查(复核边长、对角线、焊接焊缝以及变形数据等);
Assembliesarecombinedtodealwiththesizeoftheoverallcomponentchecks(diagonallength,review,welding,andtransformdata,etc.);
Ø组合件完成后,应清除组合件内部杂物,组合件应有适当的刚度,做好临时加固,焊接吊装吊耳等,并经验收认可;
Assemblyiscompleted,youshouldcleartheAssemblyinternaldebris,theAssemblyshouldhaveappropriatestiffness,stopgapreinforcement,weldinghoistingetc,andexperienceyourauthorized;
Ø焊口应平整光滑,严密不漏,焊渣、药皮应清除干净,安装焊口应预留在便于施工及安装的地方;
Assemblyiscompleted,yo