储罐制作作业指导书.docx
《储罐制作作业指导书.docx》由会员分享,可在线阅读,更多相关《储罐制作作业指导书.docx(51页珍藏版)》请在冰豆网上搜索。
储罐制作作业指导书
CSPCNANHAIPETROCHEMICALSPROJECT
CSPC南海石化项目
FABRICATIONANDERECTIONOFTANKWORKINSTRUCTION
储罐制作及安装作业指导书
WORKINGINSTRUCTION:
WI-8710-8100-0013c
SEPCOElectricalPowerConstructionCorporation
山东电力基本建设总公司
REV
DATE
REASONFORISSUE
BY
CHK’D
REVIEW
APPR
A
22JUL2003
IssueforReviewandapproval
WF
LHJ
CHY
DPS
00
24AUG2003
Issueforimplementation
WF
LHJ
CHY
DPS
01
12SEP2003
Issueforimplementation
WF
GHM
ZX
LHJ
目录
TABLEOFCONTENTS
1.0PURPOSE目的
2.0SCOPE范围
3.0RESPONSIBILITIES职责
4.0PROJECTSUMMARIZATION工程概述
5.0WRITINGREFERENCE编制依据
6.0PRIMARYCONSTRUCTIONSCHEME主要施工方案
7.0PROCESSFLOW工艺流程
8.0ERECTIONPROCESSREQUIREMENT安装工序要求
9.0TANKPREFABRICATION罐体预制
10.0TANKERECTION罐体组装
11.0ACCESSORYINSTALLATION附件安装
12.0WELDANDWELDINGLINEINSPECTION焊接及焊缝检验
13.0GEOMETRICDIMENSIONANDDIMENSIOMNINSPECTIONOFTANKS
罐体的几何尺寸和尺寸检验
14.0FILLINGTESTING充水试验
15.0ANTICORROSIVEPAINTING防腐涂漆
16.0CONSTRUCTIONACCEPTANCE工程验收
17.0LABORFORCEPLAN劳动力计划
18.0EQUIPMENTFORCONSTRUCTION施工机具使用计划
19.0JSA工作安全分析
ATTACHMENT:
CALCULATIONONHOISTINGVERTICALPOST
附录:
提升立柱计算说明书
1.PURPOSE目的
Toprovidespecificationandrequirementforoil/watertankfabricationinCSPCNanhaiPetrochemicalsProject,Steam&PowerPlantProject.Thisinstructioncanactasadirectioninmakinganderectingtankstoensuretheprojecttocompleteontimeandwithgoodquality.
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。
2.SCOPE范围
Thisinstructioncompliestothefabricationanderectionofoil/watertanksinCSPCNanhaiPetrochemicalsProject,Steam&PowerPlantProject(exceptingforthermalinsulationandantisepsis).
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(不包括保温、防腐)。
3.RESPONSIBILITIES职责
3.1SEPCO2isresponsibleforthefabrication,erection,inspectionandtestingofoil/watertanks.
山东电建二公司负责油罐、水箱的制作及安装、检验和试验。
3.2SEPCO1isresponsiblefortheexcavationfabrication,inspectionandtestingoftanksfoundation.
山东电建一公司负责油罐、水箱基础开挖、制作、检验和试验。
3.3SEPCOisresponsiblefortheinterfacecoordinationandqualitycheckandacceptance.
基建总公司负责接口协调和质量验收。
4.PROJECTSUMMARIZATION工程概述
4.1PROJECTBRIEFINTRODUCTION工程简介
8oiltanks,2desaltingtanksand2coagulatingtanksneedtobeerectedonsiteforCSPCNanhaiPetrochemicalsSteam&PowerProject.Themaximumcapacityoftanksis8350m3.Watertanksarenormalpressurecontainers,whichstructuralformisverticalcylindersteelweldeddomerooftank.GradeofsurfacefinishisSa
.Insideshellneedanepoxylining,whiletheoutsideistobepaintedforprotection;Oiltanksarelowpressurecontainers,whichstructuralformisverticalcylindersteelweldeddomerooftank.GradeofsurfacefinishisSa
.Insideshellrequiresafirstcoat,whileoutsiderequiresthermalinsulationafterprimer,inter-coatandtopcoat.
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。
4.2PROJECTITEMS工程项目
PROJECTITEMSSCHEDULE
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
ROOFFORM
1
储油罐
OILTANK
T8691
φ20*20
6283
126,500
1
带肋拱顶
DOMEWITHRIB
2
储油罐
OILTANK
T8682
φ22.5*21
8350
192,000
1
带肋拱顶
DOMEWITHRIB
3
储油罐
OILTANK
T8681
φ22.5*21
8350
192,000
1
带肋拱顶
DOMEWITHRIB
4
储油罐
OILTANK
T8683
φ22.5*21
8350
192,000
1
带肋拱顶
DOMEWITHRIB
5
储油罐
OILTANK
T8662
φ20*20
6283
158,000
1
带肋拱顶
DOMEWITHRIB
6
储油罐
OILTANK
T8661
φ20*20
6283
158,000
1
带肋拱顶
DOMEWITHRIB
7
储油罐
OILTANK
T8671
φ17.5*14
3367
70,000
1
带肋拱顶
DOMEWITHRIB
8
储油罐
OILTANK
T8651
φ10*13
1021
31,700
1
带肋拱顶
DOMEWITHRIB
9
除盐水箱DESALTINGTANK
T8441A
φ21.2*12.2
4084
113,000
1
带肋拱顶
DOMEWITHRIB
10
除盐水箱DESALTINGTANK
T8441B
φ21.2*12.2
4084
113,000
1
带肋拱顶
DOMEWITHRIB
11
凝结水箱COAGULATINGTANK
T8471
φ16*12.2
2309
69,000
1
带肋拱顶
DOMEWITHRIB
12
凝结水箱COAGULATINGTANK
T8481
φ22.7*14.6
5655
137,000
1
带肋拱顶
DOMEWITHRIB
4.3Buttjoint(fullymelt)willbeadoptedforannularplatesandlapjointforbottomcenterplates;buttjoint(weldinglinefullymelt)beadoptedforshellplates,andlapjointfortankroof,buttjointforeveryplatepart.Roofformisdomeroofwithrib.
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(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。
4.4Thereeling,sandblasting,paintingofsteelplatesshallbefinishedinworkshop.Erection,includingprocessofassembly,weld,inspection,testing,thermalinsulationandantisepsis,willbedoneatjobsiteerectinglocation.
钢板的卷制、喷砂、涂漆在车间完成。
储罐在现场的安装位置进行安装,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WRITINGREFERENCE
a.Constructiondrawingsandrelateddocument施工图纸及相关文件
b.GBJ128-90Construction,CheckandAcceptanceSpecificationofVertical
CylinderSteelWeldedOilTank
GBJ128-90《立式圆筒形钢制焊接油罐施工和验收规范》
c.DEP34.51.01.31-CSPCStandardVerticalTanks–Selection,Designand
Fabrication
DEP34.51.01.31-CSPC《标准立式油罐-选择、设计和制作》
d.DEP30.48.00.31-CSPCPaintingandCoatingofNewEquipment
DEP30.48.00.31-CSPC《新施工项目的涂漆和覆层》
e.DEP64.51.01.31-CSPCStandardVerticalTanks—FieldErectionandTesting
DEP64.51.01.31-CSPC《标准立式油罐-安装和实验》
f.DEP80.47.10.31-CSPCSystem&FacilityFireProtection
DEP80.47.10.31-CSPC《系统和设备的防火保护》
g.DEP30.48.70.30-CSPCGlassLinerofFacilityandPiping
DEP30.48.70.30-CSP《设备和管道的玻璃衬里》
h.ConstructionQualityInspectionPlanQC-8420-8600-0001
施工质量检验计划QC-8420-8600-0001
6.PRIMARYCONSTRUCTIONSCHEME主要施工方案
6.1Constructionscheme:
Accordingtotheconstructioncharacteristicsandfieldenvironmentalrequirement,shellplatesandbracesofoil/watertanksshallbeprefabricatedintheplantoffsitebeforetheirassembly(i.e.bending,derustingbysandblastingandpaintingofshellplatesandbraces.)first,thenbetransportedtojobsiteforassembly.Reverseassemblymethodisadopted,thatistosay,tankwillbeassembledfromroofdownwardtobottom.Theerectionsequenceis:
tankbottom,roofsheeting,tank,facilities,facilitiesoutsidethetank,andatlastrailingplatform.Theassemblyshallbedonewith25Thydraulictrackcrane,andchainfallshallbeadoptedforerection.Scaffoldsshallbebuiltbothinsideandoutsideoftankforerectionprocess.
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.
6.2Erectionplatform:
Bottomplatesofoil/watertanksactastemporaryworkplatformforshellplatesassembly.
组装场地:
油罐及水箱底板作为临时平台,用作壁板组装。
7.PROCESSFLOW工艺流程
Processflowchartofoil-tankfabricationanderection:
油罐制作安装工艺流程图:
7.1Workshopprefabricationprocessflowchart:
车间预制的工艺流程图:
Drawingsjointcheckup--------Receivedmaterialinspection--------Constructiontechnologydeliver----------layingoffandgrooveprocess---------Reeling---------SandBlasting----------PaintingandNumbering--------Transportedtojobsite
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
7.2Jobsiteerectionprocessflowchart:
现场安装流程图:
constructionpreparation----acceptanceoffoundation------layingbottomplates-----weldofbottomcenterplates-----assemblyandweldoftopplate-----assemblyandweldofcurbangle----assemblyoftemporarycolumnfordomeroof----assemblyandweldofroofplates----assemblyandweldofribsforroof-----erectionofhoistingverticalcolumn-----hoistingshellplates----assemblyandweldofthesubsequentcourse-----finishedweldinspection-----filletweldshellplatestobottomplates-----weldshellplatestoannularplates----vacuumsideleakingofseamsonthebottomplates----acceptanceofgeometricdimension-----erectionoffittings-----erectionofstairplatform-----fillingwatertesting----anticorrosionandthermalinsulation----acceptanceofthefinishedconstruction
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
8.
ERECTIINGPROCESSREQUIREMENT安装工序要求
8.1CONSTRUCTIONPREPARATION施工准备
8.1.1Drawingsshallbecheckedupbyrelatedpersonnel.Particularattentionshallbepaidtocheckingthegeneraldimensionandjunctionsdimensionoftanks.Learntheusageandbasicworkingprincipleofoil/watertank.Makecleartechnicalstandard&requirementandprimaryconstructionworkloadaccordingtotheacceptancespecification.Intheeventanymisunderstandingormistakeonthedrawingsisdiscovered,theproblemshallbereportedandsolvedbeforeconstruction.
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。
8.1.2Organizetherelatederectingpersonneltoprovidetechnologydelivery.Projectsummarization,timelimit,primaryconstructionworkload,primarytechnologyrequirements,constructionspecificationsandstandards,constructionprocessandmethods,theproblemstowhichparticularattentionshallbepaid,keypointsofthedrawingsandqualitycontrollingpointandsafetyprecautionsshallbeinterpreted.
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。
8.1.3Compiletoolingmaterialplanandstarttostock.编制工装材料计划并备料
8.1.4Constructionequipment&toolsandfieldpreparation:
施工机具、施工场地准备:
a.Receivedliftingfacilityinspectionbeforeenteringsite.起重设备进厂检查。
b.Toolsroom,oxygenethyneroomandelectricweldmachineswitchboard
distribution.
现场工具室