印度某1x600MW热电厂水冷壁及刚性梁安装手册.docx
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印度某1x600MW热电厂水冷壁及刚性梁安装手册
THEHANDBOOKFORWATERWALLANDBUCKSTAYERECTION
（1X600MWTHERMALPOWERPLANT,INDIA）
CONTENTS
1.BASISFORPREPARATION错误！
未定义书签。
2.PREPARATIONANDCONDITIONSBEFOREOPERATION4
2.1TechnicalPreparation4
2.2OperatorsAllocation4
2.3InstrumentandTool5
2.4MachinaryEquipment5
2.5SafetyApparatus5
2.6PrecedureChange6
3.OPERATIONALMETHODS,PRECEDUREANDDETAILS6
3.1Methods6
3.2Procedure6
3.3Details7
3.3.1EquipmentExamination7
3.3.3HeaderClean-upandPipeBallPassingTest7
3.3.4WaterwallAssembly8
3.3.5BuckstayandIronworkAssembly8
3.3.6DoorHoleAssembly8
3.3.7WaterwallandBuckstayComponentMounting8
3.3.8Cautions9
4.CONTROLPOINTSSETTING-UP,USUALQUALITYISSUESANDPREVENTION9
4.1Controlpoints9
4.2Qualitystandardsandrequirements10
4.3Prevention12
4.4Requirementsonqualityrecord13
5.SAFETY13
5.1SafetyPreventionandMeasures13
5.2RegardingtotheConstructionStaff14
5.3RequirementsonalltheMachinery,Tool,LiftingWiresandDevices：
14
1.BasisforPreparation
ØTechnicalSpecificationsontheElectricPowerConstructionandAcceptance（boilerpart）DL/T5047—96
ØQualityInspectionandAssessmentofCoal-firedPowerPlantConstruction（boilerpart,1996edition）
ØSpecificationsontheQualityAcceptanceofStructureSteelEngineeringandConstructionGB50205—2001
ØStandardsontheQualityInspectionandAssessmentofStructureSteelEngineeringandConstructionGB50221—95
ØLiftingandDelivery（WaterandHydrogenPowerPress）
ØOperationalProcedureontheSafetyofElectricPowerConstruction（coal-firedpowerplantpart）DL5009.1―2002
ØStandardsonQualityInspectionandAssessmentofCoal-firedPowerPlantConstruction（weldingpart）
ØTechnicalSpecificationsonSafetyofTemporaryElectricityatConstructionSite
ØRelevantfilessuchasdesigndrawings,biddingdocuments,contractandsoon.
Fortheabovestandards,thenewestwillprevailifanypublished.
2.PreparationsandConditionsbeforeOperation
2.1TechnicalPreparation
No.
NecessaryConditions
Remarks
1
Forthedrawings,theproblemsdiscoveredinthereviewingprocesswereresolved,andtheyhadbeenhandeddown,ofwhichitwerekeptwithrecords.
2
Operationinstructionpreparationanddiscussioncompleted,approved,anddistributedandrecordedwithinthelist.
3
CommenceReportapproved
4
Allthenecessaryprocurementormachinedpartscompleteswiththestatistic,approvalafterreportedtomaterialsupplydepartment,andalreadypurchasing.
5
Thedrawingshavebeendistributedwithrecord.
6
Relevantpapers,suchasself-inspectionrecord,constructionrecord,on-sitemeetingrecord,inspectionforms,etc,werealldistributedwithinlist.
7
Theconstructionstaffshallmovetogetfamiliarwiththedrawingsandrequirementsonthetechniqueandquality,andmaketheconstructionscope,contentsandorderdefined.
8
Regardingtosafety,thetechnicalexplanationandsignatureofitsdocumentwascompleted.
2.2OperatorsAllocation
Post
Number
Obligation
LiftingandAssemblingChief-in-Charge
1
Beinginchargeofliftingandassembly
Technician
1
drawing,scheme,acceptanceandmeasurement
ConstructionSupervisor
2
coordinatewithacceptanceandmeasurement,findoutstructuralmembers
liftingOperators
4
equipmentlifting,combination,downloadingandtransporting
coordinatingworker
10
coordinatewithequipmentlifting,combination,downloadinganddelivering.
ErectionOperators
40
frameerection,equipmentcounting,ballpassingandsiteclearance,assemblyatground,erectioninhigh.
ScaffoldingOperators
6
scaffolding,steelcatladder,softcatladder
Welders
15
on-sitewelding
WarehouseManagementStaff
1
managementonthetoolorequipmentaccessingtothewarehouse
Operators
6
hoisteroperation
Drivers
3
on-sitetransportation
ProfessionalSafetySupervisors
2
onsitesafetyandwell-managementofconstruction
2.3OperationalInstrumentandTool
No.
Name
Type
Amount
Remarks
1
steeltapemeasurer
100m
1
qualifiedthroughcontrast,andbeingonshelftime.
2
steeltapemeasurer
50m
1
qualifiedthroughcontrast,andbeingonshelftime.
3
chainblock
10t
4
qualifiedthroughtensileforcetest
4
chainblock
5t
4
qualifiedthroughtensileforcetest
5
chainblock
3t
20
qualifiedthroughtensileforcetest
6
chainblock
2t
60
qualifiedthroughtensileforcetest
7
jack
10t
4
8
shackle
5t
12
9
shackle
3t
40
10
steelruler
1m
2
11
steelruler
2m
2
12
glasspipelevel
50m
1
13
polishingmachine
φ100
10
14
guiderope
100m
2
15
B.Wplier
20
16
plumbline
4
17
electricgrinder
10
18
hangerrodadjustingtool
1
19
SampleMaker
2
20
cutter&auxiliaries
6
includingmeters,belt,oxygenandethynecylinders
21
levelbar
450mm
2
22
jemmy
several
23
ironwedge
several
2.4OperationalMachinesandTool
No.
Names
Amount
Functions
Remarks
1
≥250t,crawlercrane
1
Liftingofwaterwall&componentsandbuckstays
2
≥30t,gantrycrane
1
workingwiththetruck
3
≥50t,crawlercrane
1
downloading,transportation,andlargerpartsliftingandassembly
4
≥50t,truckcrane
1
downloadingandtransportation
5
≥25t,low-frameplatetruck
1
transportation
6
≥10t,platetruck
1
transportation
7
aircompressor
1
ballpassingandclean-up
2.5SafetyDevicesandTool
No.
Name
Type
Amount
Remarks
1
safetybelt
20
2
eyeprotector
20
3
guardrope
200
4
safetyrope（withisolatinglayer）
500
5
checkcircuitbreaker
8
6
safetynet
6m×6m
30
7
fireextinguisher
5
2.6ProcedureTransition
Itcanbestartedwhenthesteelstructureerectionofboilerbuildingwasqualifiedbyoverallinspection,aswellasthefieldandpathsforequipmenttransportationanddownloadingcarriedoutwithclean-up,planningandcompactiontobeready.
3.ErectionMethods,ProceduresandDetails
3.1Methods
Waterwallerectionscheduleproceedsindivisions,coordinatedwithpartialcombination.Thatis―thebuckstayswillbeliftedtotheircorrespondingelevationsinpriortocarryingonwaterwallhoisting;majorpartsofbuckstaysandwaterwallwillbehangedupfromthebottomoffurnaceandotherwaterwallwillbefilledinfromthetopoffurnaceaccordingtothesizeofframespaceoftopplate.Waterwalliserectedfromtoptobottom.Whenonelayerwasfinished,it’ssupposedtogoonbuttjointandcenteringatsoonanderectbuckstays,andthencomestothenextlayer.
3.2Procedures
3.3Contents
3.3.1EquipmentExamination
●Checktheamount,type,qualityandmaterialtomakesurewhethertheymeetwiththerequirementornot.Ifany,itmustberesolvedimmediately.
●Duetobeingdifferenttypesofcomponents,itisnecessarytocheckoutthecode,shipmentnumbertomakeaarrangement.Whentheboxisopened,itoughttobeverifiedandkeptwithrecords,aspershipmentlistanddrawing.
●Equipmentinthesameboxshouldbeconcentratedatthesameplaceandnumbered,othersmallercomponentscanbestoredinwarehouse.
●Allthecomponentsonthesameequipmentneedbecountedatonce,suchas,tubepanel,headers,firepeephole,doorholes,hangerrods,buckstay,steelmemberauxiliaries,etc.
●Allthealloydeviceswillbecarriedoutwithspectroanalysis,withmarksandrecordsasqualifiedthroughinspection,andstoreddividently.
●Defectsfoundintheexaminationofcomponents:
flattening,collision,crack,pinhole,etc;qualityandsizeofweldingjointdoesn’tmeetwiththerequirements;pipeholeandhandholeamountandqualitydoesn’tcomplywiththeregulations;disqualifiedpipeshape,bendingandlength,andunflatpipeopening;thebendingofheadersandbuckstays,etc,surpasstheallowablelimitation;unflatpanelwithexcessivebulksorgrooves;needbecorrected.
●Correctingmethods:
additionalweldingofjoint,polishingofpipeopening,replacingofpipes,hotbending,andsoon.
3.3.3HeaderClean-upandBallPassingTestonPipes
●Theremustbeballpassinginpriortothecombinationofwaterwalltubesandheaders,forwhich1~2minutes’blowingthroughcompressedairneedbeconductedtocleanupinternalashdepositandredundant.Andwatchwhetherfallingitemsexistsornot,asaresultofholedrilling.
●Steelballs（fortypes,refertothefollowing）andcompressedairwithapressureforceof4―6kg/cm2,willbeadopted.Andballpassingoughttobeundergoneinthesequencethatballlaidaftertubeblowing.
PassingBallDiameters（mm）
bendingradius
outsidepipediameter
D1≥60
32＜D1＜60
D1≤32
R≥3.5D1
0.85D0
0.80D0
0.70D0
2.5D1＜R＜3.5D1
0.85D0
0.80D0
0.70D0
1.8D1＜R＜2.5D1
0.75D0
0.75D0
0.70D0
1.4D1＜R＜1.8D1
0.70D0
0.70D0
0.70D0
R＜1.4D1
0.65D0
0.65D0
0.65D0
Note:
DO―insidediameterofpipe（asforinletpipe,D1isactualmeasureddata）/D1―outsidepipediameter/R―bendingradius
●Ballhanding-downwouldbedocumentedandmanaged.Thosetubesalreadypastwithballsshouldbemarkedandsealed,aswellasheaderssealedwithsteelsheetafterheaderclean-upconfirmedqualifiedaftersurveyfromQCpersonalsandconsultants.
●Relevantdocumentsneedbesignedafterballpassingisover,withoutlossofanyone.
●Itcanbeconsideredtouseasteelbrushandrebartoremovetherust,meditationremainant,glassrins,etc,insidetheheaderundernoeffectivenessbycompressedairclean-up.Forthosetubesfailedinballpassing,itwassurposedtofindoutthelocationsandreplacethetubesorshortones.
3.3.4WaterwallAssembly
●Toreducetheman-hourasworkinginh
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