安装手册英文版.docx

安装手册英文版.docx

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安装手册英文版

INTERNATIONALSTEELSERVICESINC.

FosterPlaza,BuildingNo.7

661AndersenDrive

Pittsburgh,PA15220

USA

ErectionManualFor

DUAL8,000LPHACIDREGENERATIONFACILITY

AND16,000LPHSILICAREDUCTION

HandanIron&SteelCo.Ltd

Handan,China

IssueDate:

August31,2009

TABLEOFCONTENTS

PAGE

1.0Introduction

1.1General1

1.2SafetyAspects1

1.3DefinitionofTerms1

2.0ProjectSummary

2.1TankFarmArea3

2.2SilicaReductionSystem（SRP）3

2.3AcidRegenerationPlant（ARP）4

3.0ErectionPlan

3.1ControlDocuments6

3.2DivisionofEngineeringandScopeofSupply6

3.3ProjectExecutionOrganizationandManpower6

3.4PlanningMeetings8

3.4.1InitialPlanningMeeting8

3.4.2OtherMeetings8

3.4.3WeeklyMeetings8

3.5ProjectRecords9

3.5.1FieldActivityLogs9

3.5.2WeeklySummaryReport10

3.5.3VarianceLogs10

3.5.4FieldClarificationRequests10

3.5.5AsBuiltRecords10

3.6PrincipalConstructionActivities11

3.7ConstructionPlanning11

3.7.1Schedule12

3.7.2LikeActivity（grouping）Considerations13

3.7.3ConsiderationforItemsRequiringAdditionalField14

3.7.4ConsiderationfortheEquipmentSize15

3.7.5EquipmentShippingScheduleConsideration15

3.7.6WeatherConsiderations17

4.0Civil

4.1GeneralCivilandFoundations18

4.1.1AnchorBoltDesign18

4.1.2FoundationPads19

4.2GoodEngineeringPractices19

4.3FormworkandShoring20

4.4RemovalofFormwork20

4.5MasonryConstruction21

5.0StructuralErection

5.1ErectionPlanGeneral23

5.2ElementsofErectionPlan23

5.3StructuralSteelErectionGuidelines24

5.3.1SteelErectionActivities-Primary24

5.3.2SteelErectionActivities–General24

5.3.3NotificationsBeforeCommencementofSteelErection25

5.3.4SiteLayout25

5.3.5HoistingandRigging26

5.3.6VisualInspectionofCranes26

5.3.7Deficiencies26

5.3.8InspectionFrequency26

5.3.9OtherConsiderations27

5.3.10StructuralStability27

5.3.11Walking/WorkingSurfaces27

5.3.12CoveringRoofandFloorOpenings28

5.3.13InstallationofMetalDecking29

5.3.14DerrickFloors29

5.3.15ColumnAnchorage29

5.3.16BeamsandColumns30

5.3.17DiagonalBracing30

5.3.18DoubleConnections30

5.3.19ColumnSplices30

5.3.20PerimeterColumns30

5.4Systems-EngineeredMetalBuildings31

5.4.1General31

5.4.2FallingObjectProtection31

5.4.3FallProtection31

5.4.4OtherConsiderations32

5.5Roofing33

5.5.1General33

5.5.2FallProtectionRequirements34

5.5.3OtherConsiderations34

6.0Mechanical

6.1General37

6.2TankFarmArea38

6.2.1StorageTanks38

6.2.2AqueousAmmoniaTank39

6.2.3AmmoniaSealPot39

6.2.4TruckUnloading/LoadingArea39

6.2.5SumpsandPumps40

6.2.6TransformerVault40

6.3SilicaReductionPlant40

6.3.1NeutralizationTank40

6.3.2WPLSolidsDewateringSystem42

6.3.2.1SedimentationTank42

6.3.2.2FilterPressandSludgeHoldingBin43

6.3.2.3CakeTransferTruckStation43

6.3.3WPLPurificationOperation44

6.3.3.1WPLHeatersandUILCoolers44

6.3.3.2UILandPILPumpingTanks44

6.3.3.3TwopHAdjustmentTanks,CoagulationTankand44

Agitators

6.3.4SRPTreatmentChemicalMakeUpandDosingTanks45

6.3.4.1PolymerDissolutionTankandAgitator45

6.3.4.2PolymerSolutionHoldingTank45

6.3.5Pumps46

6.3.6NeutralizationVentScrubberandFan46

6.4AcidRegenerationPlant47

6.4.1General47

6.4.2Roaster47

6.4.2.1SteelVessel47

6.4.2.2RefractoryInstallation48

6.4.2.3InsulationandCladding53

6.4.2.4SprayBooms53

6.4.2.5HotGasDuct-RoasterToVenturiScrubber54

6.4.3VenturiScrubberandSeparator54

6.4.4Absorber56

6.4.5ScrubberNo.1andScrubberNo.258

6.4.6VenturiScrubberPumps,ScrubberNo1and2Pumps59

6.4.7FanRoom59

6.4.8ExhaustFan（ID）59

6.4.9SeparatorandStack60

6.4.10PILConcentrationSystemandPumps60

6.4.11CombustionSystem60

6.5UnderRoasterOxideEquipment61

6.5.1RoasterSlideGateValve/RoasterExpansionJoint/62

DischargeChute

6.5.2OxideLumpBreaker62

6.5.3RotaryValves62

6.5.4HotScrewConveyer62

6.5.5VibratingScreen63

6.5.6ManualSlideGateValves63

6.5.7OxideTransportPiping63

6.6OxideBinArea63

6.6.1OxideBin64

6.6.2BinVentFilter64

6.6.3OxideBlower64

6.6.4TargetBox64

6.6.5VibratingBin64

6.6.6ManualSlideGate64

6.6.7RotaryValves65

6.6.8BaggingMachines&Auxiliaries65

6.6.9OxideStorageArea65

6.7ElectricalControlBuildingandPumpArea65

6.7.1BoosterWaterSystem66

6.8PipingSystems67

6.8.1PVDFLinedPiping67

6.8.2SolidPP-HandSolidPVDFPiping68

6.8.3Non-AcidPiping68

6.8.4PipeAnchors,SupportsandHangers68

6.8.5PP-HDucting68

7.0ElectricalSystems70

7.1PowerDistributionSystem-Design70

7.1.1GeneralInformation70

7.1.2SEP-ServiceEntrancePanel&TR-1-Transformer71

7.1.3DP-1DistributionPanel71

7.1.4ATS-AutomaticTransferSwitch71

7.1.5MCC-MotorControlCenters71

7.1.6VFDPanels,VariableFrequencyDrives71

7.1.7CableTraysandConduits72

7.2PowerDistributionSystem-ConstructionRecommendations72

7.2.1Scopeoftheserecommendations72

7.2.2GroundingandBonding73

7.2.3ExposuretoHarshEnvironments74

7.2.4ProfessionalInstallation74

8.0Controls&Instruments76

8.1ControlsOverview76

8.2ElectricalConnections77

8.3ProcessConnections78

8.4ConstructionRecommendations78

APPENDIX

（SubmittedasSeparateFiles）

Attachment1RubberLiningCuring,TestingandInspection

Procedures

Attachment2TankPressureTest

Attachment3DailyLogofConstruction/FieldActivity

Attachment4VarianceLog

Attachment5OverallProjectScheduler8_August09

Attachment6HandanSuggestedEquipmentErectionSchedule

Attachment7ISSIDrawingList-August31,2009r0

1.0Introduction

1.1General

ThecontentsofthisManualofConstructionRequirementsforthetwo8,000lpheachAcidRegenerationPlants（ARP）witha16,000lphSilicaReductionPlant（SRP）ofHANDANareproprietarytoInternationalSteelServices,Inc.,andcontainspecificknow-how.ThedisseminationofallorpartsofthisManualtothirdpartieswithoutwrittenpermissionfromInternationalSteelServicesisaviolationofnon-disclosureagreements.

Thisdocumentprovidesguidelinesfortheinstallation.ItisexpectedthatHandanprovidesqualifiedandexperiencedconstructorsupervisorstocarryonthevarioustradenecessaryfortheerection.Theymustbeknowledgablytounderstandtheoveralldesigndocumentsincludingthedrawings,installationmanualsandguidetheirworkersasnecessary.Itisalsoimportantthatsufficientnumbersofskilledandunskilledtradeworkersareavailabletocompletetheassignedresponsibilitiesandthetaskscorrectlyandontime.Allofthenecessarymaterialandtoolsforperformingthetasksshallalsobeavailableatsite.Thesupervisorsmustensurethatallofthepre-requisiteshavebeenmettoallowthetaskthatareplannedtobecompletedonthatday,thatweeketc.aspertheproject’soverallconstructionschedule.

1.2SafetyAspectsThisManualisnotaSafetyManual.SafepracticesandsafeinstallationaretheresponsibilityoftheContractorsandtheOwner.Handan&itsgeneralconstructionleaderentitymusthaveawritten,Health&SafetyPlanforthesafetyofitsworkersaswellasallofthesubcontractor’sworkers.ItisHandanoritsauthorizedSafetyOfficer’sresponsibilitytomakeawareofallofthesiteworkersandvisitors,ifany,ofallofthesafetyaspects.Itiscustomarypractice,thattheSafetyOfficerhasashortmeeting（TailGatemeeting）everymorningtogooverthescheduledworkandsafetyaspectsneededtoexecutetheworkwithallworkersorkeyteamleaders.Teamleadersshallbemadeawarethatthesafetyofallsiteworkersistheresponsibilityoftheleadersand,alloftheworkers.AmongotherthingsalloftheworkersmustbeprovidedwithsafetygearsincludingSafetyHats,SafetyShoes,protectiveglassesetcasnecessarydependingonthetypeofworkvariousindividualsareengaged.

1.3DEFINITIONOFTERMS

ContactororConstructor:

theCompanyundercontractwithHANDANtoperformerectionandinstallationwork.

Owner:

HANDAN

Owner’sRepresentative:

EithertheOwner’sengineer,orapersonrepresentingtheOwner.

Vendor:

ISSIorHandan’sanditscontractors’supplier,orpersonhiredforanyservices

ISSIFieldSupervisor:

ApersonworkingforISSIdirectlyorindirectlywiththeresponsibilitytoguidetheinstallationworkaccordingtoISSIandISSIvendorengineeringdesign,andtopromptlyadvisetheOwnerorhisrepresentativesofdeficienciesofthisworkforcorrectiveactioninordertoarriveatahighqualityinstallation.

2.0

ProjectSummary

OverallAcidRegenerationProject