施工方案英.docx

施工方案英.docx

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施工方案英

TableofContents

Chapter1General

1.General

1.1Nameofproject：

FabricationandinstallationofICtankbodyforBPZhuhaiPTA2#projectwastewatertreatmentplant

1.2Locationofproject:

inthePTA2#plantofBPZhuhaiChemicalCo.,Ltd

1.3Client：

BPZhuhaiChemicalCo.,Ltd

1.4Contractor：

PaquesEnvironmentalTechnology（Shanghai）Co.,Ltd

Scopeofwork：

FabricationandinstallationofshellbodyoftwoICreactorsof11mdiameterand24mheight;withspiralstairs;fabricationandinstallationofonecirculatingtankof6.5mdiameterand16.6mheight.

Chapter2Reference

2.Reference

2.1ConstructiondrawingdesignedbySino-pecShanghaiEngineeringCorporation

2.2DesignSpecificationofVerticalCylinderSteelWeldedStorageTankGB50341-2003

2.3CodeforconstructionandacceptanceofverticalcylindricalsteelweldedstoragetanksGB50128-2005;

2.4WeldingProcedureSpecificationofSteelPressureVesselJB4708-2000;

2.5NonDestructiveTestingofPressureVesselJB4730-94;

2.6Construction&AcceptanceSpecificationofMiddle&LowPressureChemicalEquipment

2.7SteelManholesandHandHolesHG/T21514-2005

2.8Construction&AcceptanceSpecificationofMiddle&LowPressureChemicalEquipmentHGJ209-83;

Chapter3Constructionsequence

3.Constructionsequence

Chapter4ConstructionPreparation&Method

4.ConstructionPreparationandConstructionMethod

4.1ConstructionPreparation

4.1.1Constructiontechnicalpreparation

（1）Siteassemblyweldingofreactorshallbeprovidedwiththefollowingtechnicaldocuments:

ØDesignconstructiondrawings;

ØWeldingprocedurespecificationreportandweldingprocessregulations;

ØConstructionmethod

ØConstruction&acceptancecodeandspecification.

（2）Organizetechnicalpersonneltoperformjoint-checkofdrawingsbeforeassemblyofreactor.

（3）Organizetechnicalclarificationforworkteambeforeconstructiontospecifyworkcharacteristic,constructionprogress,constructionmethod,technicalrequirements,andqualitystandardandsafetymeasures.

4.1.2Constructionsitepreparation

（1）Constructionsiteisproposedtobearrangedaccordingtoconstructionplotplan（Attachment1）.Assemblyweldingplatformandconstructionequipmentshallbeplacedtodesignatedposition.

（2）Constructionequipment&toolsmustbewithreliablecapability;toolsandfixtures,templeshouldbequalified.Measuringinstrumentsshallbewithininspectionperiod.

（3）Theelectricalpowersupplyforconstructionisrequirednotlessthan150Kw.

（4）Thewatersupplyforwatertestoftankbodyisrequirednotlessthan50m3/hr.

4.1.3Materialacceptance

（1）Steelplate,SSplate,sectionsteelandaccessoriesusedfortheworkshallconformtodesignrequirement,requirementsinCarbonStructuralSteelandLowAlloySteelHotRolledSteelThickPlateandSteelBandGB3274-88,CarbonStructuralSteelandLowAlloySteelHotRolledThinSteelPlateandSteelBandGB912-89.PerformmaterialreceivinginspectionaccordingtoProcurementProcedureQG205-2001.

（2）Allmaterialsandaccessoriesshallbewithmanufacturer’squalitycertification.Iffailuretomeetthis,materialsandaccessoriesshallbere-checkedandqualifiedbeforeusing.

（3）Platestobeusedmustbecarriedwithappearanceinspectionbeforeusing.

（4）Checksteelmaterialsforquality,sizeandplatesforstraightnessbeforeusing.

（5）Acceptanceofweldingmaterial

ØWeldingrodmustbewithqualitycertificate,completepackagebeforewarehousing.

ØWeldingrodqualitycertificationshallincludetype,band,size,manufactureranddateofproduction.

（6）Contentsofweldingwirequalitycertificationshallinclude:

ØGradeofsteel,batchNo.,size,weight,manufactureranddateofproduction;

（7）Purityofargoncannotbelow99.9%;

（8）SSmaterialsandCSmaterialsshallbestoredseparatelyonsite.SSmaterialscannotbecontactedwithCSmaterialsduringconstruction.

4.2Constructionmethod

4.2.1Accordingtoexternaldimensionsandweightofequipmentandforsakeofsafety,ICreactorfortheprojectshallbeinstalledbyreversemethodbyhydraulicliftingdevice.i.e.firstlaybottomplatesofreactoronthefoundationandtightenwithclamp,thensetoutdatumlineoftankwall.Accordingtothedatumlineoftankwall,assemblyandweldthefirstbandplate.Afterweldingthestraightseam,lifttheunitbyhydraulicjack,liftthefirstbandplatetothesameheightofsecondbandplate.Afterassemblyandwelding,reverseaholeattheoutersideofthesecondbandplate,liftinordertillcompletionofassemblyofthetank.Whenassemblythelastbandplate.Leaveaplatenottobeassembledwhenassemblingthelastbandplatewhereshallbetheaccessforthemanpowerandmaterials.

4.2.2Processcharacteristicofreverseinstallationbyhydraulicliftingmethod

（1）　Reverseinstallationbyhydraulicjackandspecialliftingdevicecanreducehighworkandscaffolding.

（2）　Nosealingfortankbody,smallbindingforceandfrictionforce,canusesingleplateinstallation,convenientforpassinginandoutofpersonandmaterials,communication,ventilationanddusting.

（3）　Equipmentcanbecirculatingusedandcombinedfreelyaccordingtosizeoftank.

（4）　Hydrostaticdriveisstableandwithcontrollability.Liftingspeed,heightandsynchronismcanbeensuredeasily.Bearingcapacityofhydraulicjackshallbeadjustedthroughchangeoilpressure.

（5）Duringliftingoftankshell,tankofbodyshouldbefixedwithfourwireropestoensuresafetyoftankconstruction.

4.3PrefabricationofICreactor

4.3.1Prefabricationofbottomplate（TheplotplanofbottomplaterefertoFigure1-2）

（1）Bottomplatesorreactorshallbearrangedaccordingtoactualdeliveryconditionsofmaterial.Cuttingshallbeperformedafterapprovalbyconcernedunit.Tocompensateweldingseamcontraction,thediameterofarrangementofbottomplatesshallbe1‰~1.5‰morethandesigndiameter.

（2）BottomplatesshalladoptbuttweldingseamandVtypegroove.

（3）

Allowablesizedeviationofbottomplateedgeofreactorshallmeetthefollowingrequirements,shownasthefollowingfigure:

AB、Cdallowabledeviation:

±2mm

AC、BD、Efallowabledeviation:

±2mm

Diagonalallowabledeviation:

≤3mm

（4）Theminimumsizealongradiusdirectionofbottomplateedgeshallnotbelessthan700mm,buttjointsofarcedgeplateshalladoptunequalclearance:

6-7mmforoutsideand8-12mmforinside.

（5）Widthofmiddleplateshallnotbelessthan1000mmandlengthshallnotbelessthan2000mm.

（6）Camberedplatewiththethickness≥12mmshallbeinspectedwithin100mmofbothsidesasperUltrasonicFlawDetectionofSteelPlateUsedforPressureEquipmentZBJ74003-88,inspectionresultshallachievestandardofgradeIII,Ifadoptingflaretocuttheslope,thesurfaceofslopeshallbeinspectedbymagneticorpenetration.

4.3.2Prefabricationofshellplate（Plotplayofshellplatereferstofigure2）

（1）Widthofshellplateshallnotbelessthan500mmandlengthshallnotbelessthan1000mm.

（2）Incaseofwidthchangeofshellplate,thicknessofeachringofshellplateshallnotbelessthanthicknessandmaterialrequirementstorelevantheightindesignregulations.

（3）Longitudinalweldingseamofeachringofplateshallbestaggeredfor1/3ofplatelengthalongthesamedirectionandnotbelessthan500mm.

（4）Prefabricationofshellplateshallbeperformedaspernetsize,perimeterofeachringofplateshallbecalculatedasfollows:

L=2π（innerradius+wallthickness）+numbersofallsteelplates×（amountofweldingcontraction–assemblyclearance）

（5）Deviationofshellplateafterprocessingshallmeetthefollowingtable:

AEB

CFD

Measuringposition

PlatelengthAB（CD）>10m

PlatelengthAB（CD）≤10m

WidthAC、BD、EF

±1.5

±1

LengthAB、CD

±2

±1.5

Differenceofdiagonal

≤3

≤2

Straightness

AC、BD

≤1

≤1

AB、CD

≤2

≤2

（6）Placeshellplateontheplatebendingmachineforrollingaftercutting.Keeptwoendsofshellplatelevelandstraightbeforepre-bending.Prepressthefrontendofshellplatefor150-200mm（incaseofdirectrollingandpressing,150-200mmoftwoendsofshellplatecannotbepressedtobend）,therollandpressofshellplateasperrequiredcamber.Inadoptinghydraulicbendingandforming,itshallbeperformed2-3timestoremoveinternalstress.

（7）Shellplateshallbeplacedonplatformandinspectedwithtemplateafterrollinground,withstraightlinetemplateinverticaldirection,itsclearanceshallnotbemorethan2mm,witharctemplateinhorizontaldirectionanditsclearanceshallnotbemorethan4mm.Chordlengthoftemplateshallbe≥1.5m.

（8）Shellplateshallbeplacedontiretoavoiddeformationafterprefabrication.

4.4AssemblyofICreactor

4.4.1Foundationacceptance

（1）ICreactormustbeperformedwithfoundationsurfacesizeinspectionbeforeinstallationaccordingtocivilfoundationdesignandregulationsinConstruction&AcceptanceSpecificationofMediumandLowPressureChemicalEquipment–HGJ209IC.

（2）Thesurfaceofasphaltsandoffoundationshallbelevelandclosewithoutanyprotrusion,depressedandpenetratedcrack.Convexandconcaveofasphaltsurfaceshallbeinspectedaccordingtothefollowingmethod:

Whenthediameteroftankislessthan25m,drawthelineandmeasurefromthefoundationcentertoaroundoffoundation.Thequantityofmeasurementpointsper100m2forfoundationsurfaceshallnotbelessthan10.（Thearealessthan100m2shallbecalculatedas100m2.）.convexandconcaveoffoundationsurfaceshallnotbemorethan25mm.

4.4.2Assemblyweldingoftankbottom

（1）Steelplateshallbede-rustedandpaintedaccordingtodesignrequirementsbe