中英文版低溫罐安裝施工方案

1、越南太原梅塞爾1000m3低溫液體貯槽 施工組織設(shè)計 Vietnam Taiyuan Messer 1000m3 cryogenic liquid tank 蘇州制氧機股份有限公司Suzhou oxygenerator Share LTD越南太原梅塞爾1000m3低溫液體貯槽項目Vietnam Taiyuan Messer 1000m3 cryogenic liquid tank project施工組織設(shè)計Construction Organization Program2016-05-22編制 201607-10修訂2016-05-22 prepared 2016-07-10 Revisio

2、n四 川 省 化 工 建 設(shè) 有 限 公 司 第 九 分 公 司Ninth sub-company of Sichuan Chemical Construction LTD蘇州制氧機股份有限公司Suzhou oxygenerator Share LTD.越南太原梅塞爾1000m3低溫液體貯槽項目Vietnam Taiyuan Messer 1000m3 cryogenic liquid tank project施工組織設(shè)計Construction Organization Program施工單位Construction unit編制Editor審核Check批準Ratify總包單位審批意見Th

3、e total package unitsApproval comments 2016年 月 日建設(shè)/監(jiān)理單位意見SupervisionUnit opinions2016年 月 日目 錄table of Contents1.工程概況51. Project Overview52. 適用范圍72. Scope73. 編制依據(jù)及相關(guān)標準規(guī)范103. Basis and related standards104. 施工準備、施工程序及施工方案104. The construction preparation, construction procedures and construction schem

4、e105珠光砂裝填705. Perlite filling706、設(shè)備整體冷試716, overall equipment cold test717、安全注意事項727. Security Considerations728、質(zhì)量保證體系及質(zhì)量控制758, quality assurance and quality control759、進度控制及施工計劃進度表789, and construction schedule control plan schedule78蘇州制氧機股份有限公司Suzhou oxygenerator Share LTD越南太原梅塞爾1000m3低溫液體貯槽項目Vie

5、tnam Taiyuan Messer 1000m3 cryogenic liquid tank project施工組織設(shè)計Construction Organization Program1.工程概況1. Project Overview1.1 工程名稱：越南太原梅塞爾1000m3低溫液體貯槽 1.1 Project Name: Taiyuan Vietnam Messer 1000m3 cryogenic liquid tank1.2 建設(shè)單位：越南梅塞爾 1.2 Construction units: the more Nanmeiseer1.3 設(shè)計單位：蘇州制氧機股份有限公司1.3

6、The design unit: suzhou oxygen generator co., LTD 1.4 工程建設(shè)地點：越南1.4 Project Location: Vietnam1.5 低溫儲罐概況：1.5 cryogenic tanks Description:外罐直徑 13 m 內(nèi)罐直徑 10.3 m；外罐高度 17 m 內(nèi)罐高度 13.65 m外罐主體材料 Q235B 內(nèi)罐主體材料 S30408儲罐容積 1000m3 物料名稱 LN2儲罐設(shè)計溫度： 外罐：常溫 內(nèi)罐：19650Tank outer diameter of 13 meters, the inner tank of 1

7、0.3 meters.The outer tank height 17 m ,The outer tank body material Q235B, The inner tank height 13.65 m, The inner tank body material S30408. Tank volume 1000m3, Material name LN2, design temperature: Outer tank:, the inner tank at room temperature: -196 50 。1.6工程簡介：1.6 Project Description:越南太原梅塞爾1

8、000m3低溫液體貯槽由蘇州制氧機股份有限公司設(shè)計、供貨，由我公司承擔現(xiàn)場組焊安裝任務(wù)。該工程項目技術(shù)要求高，施工難度大，對施工組織和和施工技術(shù)要求高，施工過程中必須每一道工序嚴格要求，保證每一項工序質(zhì)量，從而保證工程質(zhì)量。Vietnam Taiyuan Messer 1000m3 cryogenic liquid tank from Suzhou oxygenerator Share LTD design, supply, Borne by the company site welding installation tasks. The project technically demandi

9、ng, difficult construction, construction and construction organization and technical requirements, the construction process must each procedure strict requirements to ensure the quality of every step to ensure project quality.1000m3貯槽體積大、重量大、是散裝到貨，部分零部件在廠里預制成形，在現(xiàn)場組裝成整體。由于施工現(xiàn)場情況復雜，又是登高作業(yè)，加上產(chǎn)品結(jié)構(gòu)的特殊性，對

10、施工工藝和安裝質(zhì)量要求很高。1000m3 tank bulky, heavy, bulk arrival, some parts in the factory pre-shaped, assembled on site as a whole. Due to the construction site complex, but also a climbing operation, with the particularity of product structure, construction technology and install high quality requirements.儲槽

11、內(nèi)槽主體材質(zhì)為S30408不銹鋼、外槽主體材質(zhì)為Q235B。外槽起保護絕熱層作用，絕熱層為填充的珠光砂。內(nèi)槽底部絕熱采用泡沫玻璃磚，在玻璃磚與內(nèi)槽底板間澆注了負荷分配板，負荷分配板也起到保護玻璃磚的作用。Inner tank body is made of S30408 stainless steel, Q235B the main material  An outer  Trough protective outer insulation effect, heat-insulating layer is filled with perlite. The bottom of

12、 the groove using insulating foam glass tiles, glass tiles and between the inner groove bottom poured a load distribution plate, the load distribution plate also protects the glass tile effect.2. 適用范圍2. Scope of application2.1 本方案適用于越南太原梅塞爾1000m3貯槽的安裝，2.1 program applies to Vietnam Taiyuan Messer 10

13、00m3 storage tank installatio2.2 施工方法：采用倒裝法進行安裝施工。2.2 Construction Methods: Installation From top to bottom下圖為儲槽外形圖The following figure shows the Storage tank Dimensions四川省化工建設(shè)有限公司第九分公司Ninth sub-company of Sichuan Chemical Construction LTD 3. 編制依據(jù)及相關(guān)標準規(guī)范3. Basis and related standards3.1 大型焊接低壓貯槽的設(shè)計及

14、制造API620-20093.1 "design and manufacture of large welded low pressure sump" API620-20093.2 承壓設(shè)備無損檢測JB4730-20053.2 "Pressure Equipment NDT" JB4730-20053.3 立式圓筒型鋼制焊接儲罐施工及驗收規(guī)范GB50128-20053.3 "vertical cylindrical steel welded storage tanks construction and acceptance of" G

15、B50128-20053.4 現(xiàn)場組裝立式圓筒平地鋼質(zhì)液化天然氣儲槽的設(shè)計與制造GB/T26978-20113.4 "Field assembly of vertical cylindrical flat steel LNG storage tank design and manufacture of" GB / T26978-20113.5 工業(yè)金屬管道工程施工規(guī)范GB50235-20103.5 "Industrial metal pipe construction norms" GB50235-20103.6 現(xiàn)場設(shè)備、工藝管道焊接工程施工規(guī)范GB5

16、0236-20113.6 "field devices, process piping weld construction norms" GB50236-20113.7 低溫儲槽施工圖及技術(shù)文件3.7 cryogenic storage tank construction drawings and technical documents4. 施工準備、施工程序及施工方案4. The construction preparation, construction procedures and construction scheme4.1 作業(yè)條件和技術(shù)準備4.1 Operati

17、ng conditions and technical preparation4.1.1 施工機具和材料準備：根據(jù)施工圖紙和施工技術(shù)方案，準備安裝用各種工、機具和材料，包括運輸、吊裝、起重、安裝、施工用材料等；4.1.1 construction equipment and material preparation: According to the construction drawings and construction technology program, ready to install with a variety of workers, equipment and materi

18、als, including transportation, lifting, lifting, installation, construction materials and so on;設(shè)備及機具表Apparatus and equipment list序號NO設(shè)備名稱Device Name規(guī)格型號Specifications Model單位unit數(shù)量quantity備注remarks 1汽車吊crane25T臺1臨時用2直流電焊機DC welding machineBX2-400-2/zx-400臺4焊接3葫蘆提升裝置Lifting device含葫蘆、扒桿、吊耳等套1罐體提升4焊條

19、烘干箱Electrode drying boxRDL4-200臺1焊條烘干用5動力配電箱Power distribution box大號臺240KVA6動力配電箱Power distribution box小號臺47型材切割機Cutting Machine400臺18兆歐表Insulation monitor臺19真空泵Vacuum pump臺1底板真空10平板真空盒Flat vacuum box081米個1底板真空11角型真空盒Angle vacuum box08-1米個1大腳縫真空12角磨機Angle Grinder100臺10臺13直型鋼板吊卡Hoisting Equipment of

20、Steel 3T個4鋼板吊裝4.1.2 組織準備：施工組織除人員準備外，還應(yīng)根據(jù)施工方案在安裝施工前檢查施工現(xiàn)場是否滿足安裝施工條件。4.1.2 organize preparation: In addition to the construction organization personnel preparation, the construction program should be based on the installation and construction before the construction site to check whether the installat

21、ion and construction conditions.1、施工人員組織1, construction workers organization組建1000m3 儲槽工程項目部：organize 1000m3 storage tank project department項目經(jīng)理：黃棟良施工經(jīng)理：劉中清檢驗員：冷永成安全員：劉中清（兼）Project Manager: Dongliang HuangConstruction Manager: Zhongqing LiuInspector: Yongcheng LenSecurity Officer: Zhongqing Liu (con

22、currently)其余作業(yè)人員根據(jù)工程需要委派，特種作業(yè)人員進場時需持證上崗。為保證施工質(zhì)量和施工進度，本工程施工人員按照施工進度要分步進場，其中部分管理人員為兼職。All other operations personnel according to the engineering need to delegate, special operations personnel approach need certificates. In order to ensure the construction quality and progress of the construction, the

23、 construction personnel in accordance with the construction schedule to step by step approach, in which part of the management staff for part-time.項目經(jīng)理： 1人施工經(jīng)理： 1人質(zhì)檢員（兼）： 1人材料員（兼）： 1人安全員（兼）： 1人冷 作 工： 2人焊 工： 4人電 工： 1人鉗 工： 1人油 漆 工： 1人保 溫 工： 2人普 工： 5人合 計： 18人Project Manager: 1Construction Manager: 1Ins

24、pector (and): 1Materials, staff (and): 1Security Officer (Chief): 1Cold as workers: 2WELDER: 4 peopleElectrician: 1Pliers workers: 1Paint work: 1Bao Wen workers: 2General workers: 5Total: 182、施工材料組織2, the construction material organization工程主材： 廠家提供。工程輔材： 按需采購。Engineering Main Material: provided by

25、the manufacturer.Engineering auxiliary materials: demand procurement.4.1.3 技術(shù)準備：熟悉現(xiàn)場施工圖紙和有關(guān)資料，掌握相關(guān)技術(shù)要求。安裝施工前必須對所有參加安裝的人員進行技術(shù)交底，使其熟悉施工方案，確保方案能夠正確、順利和安全的實施。4.1.3 technical preparations: Familiar with the construction drawings and site information, acquire the relevant technical requirements. All parti

26、cipants must install personnel technical tests before installation and construction, to familiarize them with the construction program, to ensure that the program correctly, smooth and safe implementation.1）施工現(xiàn)場要求1) the requirements of the construction site為保證設(shè)備施工的正常進行，安裝隊進場前，所有現(xiàn)場廠房、土建基礎(chǔ)等基本設(shè)施必須施工完畢，

27、主要設(shè)備已基本到達現(xiàn)場，工程能夠無間斷的進行。現(xiàn)場吊裝位置要足夠，路面情況符合吊裝需要。建設(shè)單位除保證水電氣三通，尚需提供預裝、儲存等必要場地。因為工程施工時間緊張，為保證工作時間緊湊，安裝隊需要連續(xù)加班工作，建設(shè)單位應(yīng)提供人員進出、環(huán)境設(shè)施等方便。In order to ensure the normal construction equipment, the installation team approach, all on-site plant, construction and other basic infrastructure construction must be compl

28、eted, the main equipment has been basically arrived at the scene, the project can be carried out without interruption. Lifting site location should be enough, the road, subject to the lifting needs. In addition to water, electricity and construction units to ensure that the three-way, still need to

29、provide the necessary space pre-installed storage.Because the construction time constraints, to ensure that working time is compact, continuous installation team needs to work overtime, the construction unit shall provide personnel access, environmental facilities and so convenient.2）基礎(chǔ)檢查清理2) the ba

30、sis of cleaning up檢查所有設(shè)備和場地、基礎(chǔ)設(shè)施基本尺寸和施工質(zhì)量，重點檢查貯槽基礎(chǔ)標高、表面水平度及定位尺寸并清理干凈?；A(chǔ)查對驗收應(yīng)分兩步走，責任要明確。設(shè)備基礎(chǔ)的尺寸和位置的質(zhì)量要求應(yīng)符合相關(guān)的土建標準。第一步建設(shè)單位與土建施工單位以施工圖為準，對各個單體設(shè)備基礎(chǔ)進行驗收。第二步建設(shè)單位與安裝單位以設(shè)備供貨單位的基礎(chǔ)圖為準，逐個基礎(chǔ)進行仔細查對，不符合要求堅決返修?；A(chǔ)驗收資料應(yīng)齊全，應(yīng)有施工設(shè)計單位設(shè)計的基礎(chǔ)設(shè)計藍圖、砼試塊試驗報告、基礎(chǔ)竣工移交單，包括標高誤差、中心偏差、坐標位置等。水平標高基準點，以設(shè)計圖為準。Check all equipment and venu

31、es, infrastructure, basic dimensions and construction quality, focus on examination of the tank foundation level, size and positioning surface levelness and clean. Based check acceptance should take two steps, the responsibility must be clear. Quality requirements of equipment based on the size and

32、location should be consistent with the relevant civil standards. The first step in the construction unit and construction unit to the civil construction plans prevail, for each device based monomer acceptance. The second step in the construction unit and install unit foundation drawing equipment sup

33、ply units prevail, scrutinized one by one basis, and resolutely not meet the requirements for repair. Basic acceptance documents should be complete, should be the basis of the blueprint construction design unit design, concrete test block test report, the completion of the transfer basis, which incl

34、ude elevation error, center deviation, coordinate location. Level elevation reference point to design prevail.3）設(shè)備開箱清點3) inventory of equipment out of the box按照設(shè)備安裝次序?qū)ΜF(xiàn)場設(shè)備進行開箱清點，檢查質(zhì)量，核實數(shù)量，并作好記錄，將存在問題和缺件情況提交建設(shè)單位和設(shè)備供貨單位。開箱清點的依據(jù)是以設(shè)備供貨單位編制的發(fā)貨清單和裝箱清單為準，清點時要求三方人員參加：設(shè)備供貨單位、建設(shè)單位、施工單位。開箱前應(yīng)確認箱號和箱數(shù)，并作好記錄。應(yīng)檢查箱體

35、和包裝情況，箱體是否完好，若已損壞暫不開箱，查明原因后處理。三方確認箱體完好后才能開箱檢查。檢查時，按裝箱清單的序號逐件進行清點，數(shù)量、實物與隨機圖紙核對；檢查裝箱資料是否齊全，材料的材質(zhì)證明書考核項目是否齊全，并加以確認。制造內(nèi)槽的主要受壓元件（筒體、底板、頂蓋、開口補強板等）上應(yīng)有材質(zhì)標記，和檢驗員鋼印。材料外觀質(zhì)量應(yīng)符合對應(yīng)的材料標準和有關(guān)制造標準。清點過程中要認真做好記錄，如設(shè)備名稱、型號和規(guī)格等項目，以及設(shè)備缺件，三方簽字認可，做到責任明確，竣工資料符合要求。數(shù)量清點過程中，同時也應(yīng)進行質(zhì)量檢查，檢查中應(yīng)根據(jù)設(shè)備、機器、儀表等各自的要求填寫主要另部件質(zhì)量檢查記錄，檢查內(nèi)容一般有：（1

36、）外型尺寸是否符合圖紙、工藝文件或竣工圖尺寸要求。（2）有無損傷處，特別是運輸過程中損傷情況。（3）對金屬件查看有無銹蝕、裂紋等，焊接處是否符合圖紙要求和有關(guān)標準規(guī)范要求（是否預彎、加工坡口等）；板材表面是否經(jīng)過表面處理、油漆等。（4）對閥門等查看是否符合設(shè)計圖紙要求。（5）對標準件（法蘭、螺栓、螺母、管件等）檢查是否與標準號相符，抽查每批中的一到兩件，檢查是否與標準件尺寸相符。清點的設(shè)備、機器、標準件和預制另部件等，要編號或按供貨產(chǎn)品代號分類堆放，對于小件和儀電控制元件要入庫保管。設(shè)備清點中發(fā)現(xiàn)的缺陷、缺件等應(yīng)及時辦理簽證手續(xù)，通知有關(guān)單位處理。設(shè)備及材料的清點檢查簽證記錄資料應(yīng)及時收入施工

37、檔案。In accordance with the installation sequence of field devices out of the box inventory, quality checks, verify the quantity, and make records, there will be problems and lack of parts and equipment submitted by the construction unit suppliers.Unpacking the inventory is based on the packing list a

38、nd shipping list prepared by the equipment suppliers of the subject requires personnel to participate in the tripartite when inventory: equipment supply units, construction units, construction units.It should confirm the box number and box number in front of the box, and make records. Check the box

39、and packing, the box is in good condition, If it is damaged temporarily out of the box, identify the reason for treatment. Three confirmed after checking out of the box to the cabinet intact. Inspection, piece by piece, by serial number packing list will be counted, the number of physical random dra

40、wing check; check whether the information is complete packing material material certificate assessment project is complete, and confirm.The main component manufacturing within the pressure tank (cylinder, floor, roof, opening reinforcement plate, etc.) on the material should be labeled, and inspecto

41、rs seal. Material appearance quality should be consistent with the corresponding material standards and manufacturing standards. Inventory process to do a good job records, such as device name, model, and specifications and other projects, as well as equipment missing, tripartite signature recogniti

42、on, be accountable, completion data to meet the requirements.Count the number of process should also be checked for quality inspection should be completed another major component quality inspection records based on their requirements for equipment, machinery, instruments, etc., check the contents in

43、 general are:(1) Dimensions Meets drawings, technical documents or builts size requirements.(2) whether the lesion, especially during transportation damage.(3) to see whether the metal corrosion, cracks, weld meets the requirements of the drawings and the relevant standard specifications (whether pr

44、e-bending, chamfering, etc.); plate surface is subjected to surface treatment, painting and the like.(4) valves, etc. Check with the design drawings.(5) standard parts (flanges, bolts, nuts, pipe fittings, etc.) to check whether the number matches the criteria, sampling each batch of one to two, che

45、ck if it matches with the standard size.    Inventory of equipment, machinery, standard parts and other prefabricated parts, etc., to be supplied by the product code number or classification stacked for small pieces of electrical and instrument control elements to storage vault.

46、Inventory equipment defects found, missing parts, etc. should be timely visa application procedures, notify the relevant units to deal with. Equipment and materials inventory check visa information should be promptly recorded revenues construction archives.4.2 儲罐預制及預拼接4.2 Tank prefabricated and pre

47、splicing 1）清理施工現(xiàn)場，合理利用施工場地，布置要緊湊合理，焊機就近放置，最好放在焊接組裝平臺和貯槽基礎(chǔ)間適當位置，避免焊接電纜太長，或者擺放在干燥通風的房間里，若沒有合適的房間，放在露天時則需設(shè)置防雨防塵棚；閥門、管件、安裝用工具等小東西放在就近干燥通風的貯藏室，還需準備一間小屋，作為暗室。2）槽體組裝場地應(yīng)平整、面積比較大。貯槽四周應(yīng)有5米寬的場地供堆放筒體。本貯槽采用倒裝順序安裝。1) clean up the construction site, the rational use of the construction site, arranged to be reasona

48、bly compact welder nearest place, preferably on the basis of a storage tank and welding assembly platform between the appropriate location, to avoid welding cable is too long, or placed in dry and ventilated room where, if there is no suitable room, you need to set the time on the open-air shed rain

49、 and dust; valves, fittings, installation tools and other small things on the nearest dry and ventilated storage compartment, need to prepare a hut as a darkroom.2) tank assembly site should be flat, relatively large area. Sump four weeks should be 5 meters wide space for stacking the barrel. The su

50、mp flip the order of installation.4.3 低溫儲槽的施工程序：4.3 cryogenic storage tank construction program:儲槽施工基本程序如下，部分施工程序可能根據(jù)最終圖紙進行調(diào)整。The basic procedure is as follows chart, part of the construction program may be adjusted according to the final drawings.外筒底板- -內(nèi)筒頂蓋-外筒筒體-外筒頂蓋-同時安裝筒體-絕熱層-內(nèi)筒底板-附屬部件The outer

51、cylinder bottom - - Inside the barrel cover - in cylinder barrel - the outer cylinder cap - installed cylinder - Heat insulation spacer layer - Inner cylinder bottom plate - Accessory parts4.3.1 儲罐壁板（包括抗壓圈）預制4.3.1 tank wall (including compression ring) Prefabricated內(nèi)外罐壁板采用總包方提供的板料，檢查直角度、直線度，如發(fā)現(xiàn)直角度和直

52、線度偏差，采用切割方法修正。注：在切割過程中如果發(fā)現(xiàn)材料有夾層、材料表面有嚴重銹蝕等缺陷，應(yīng)停止使用該材料，并及時向總包方書面報告。Inner and outer tank wall using the total package provided by sheet check straight angle, straightness, straight angle and found straightness deviation, using the cutting method amendment. NOTE: If you find that in the process of cutt

53、ing the sandwich material, the surface of serious corrosion and other defects, should stop using the material, and timely written report to the total package.貯槽外槽由底板、筒體、頂蓋、平臺梯子欄桿等部分組成。底板由許多鋼板拼焊而成，它與筒體間由雙面角焊縫連接，此處殘余應(yīng)力較大，焊接下來后產(chǎn)生的收縮力較大，加上底板上拼縫多而長，焊接殘余應(yīng)力復雜，為了使底板焊后變形情況符合圖紙要求，即局部凹凸變形不超過變形長度的2%，只允許中心凸起，且最大

54、不超過圖紙允許值，為減少組焊后的校平工作量，必須采用適當?shù)难b配焊接順序，正確的順序是使筒體與底板間的環(huán)向角焊縫的收縮不牽連到底板的主體，使之能比較自由的收縮，根據(jù)這個原則，將底板分為兩個部分，一部分是和筒體直接連接的邊緣板，第二部分是不與筒體連接的中間板。組裝前先清理基礎(chǔ)表面灰塵、雜物等，可用水沖洗干凈，然后讓其風干。底板示意圖及焊縫情況見圖紙。The tank outside the tank comprises a bottom plate, cylinder cover, ladder platform railings and other parts. The bottom plate

55、 is made of many steel plates welded together, and its cylinder body by a double fillet weld connection, the residual stress is larger and the shrinkage force generated after welding down greatly, and floor seam and long welding. The residual stress is complex, in order to make the plate after weldi

56、ng deformation meet the requirements of the drawings, namely the local convex deformation is not more than 2% of the length of deformation, only allow the center bulge, and the maximum does not exceed the allowable value for drawing, reducing the workload of leveling group after welding, must use appropriate assembly welding sequence, the correct order is to make the cylinder body and the bottom plate between the circumferential fillet weld shrinkage not implicated in the end plate main body, so as to compare the free shrinkage,