空分装置施工方案

　 空分装置施工方案

　一、工程概况

　?本工程是XX气体有限公司12000Nm3/h空分装置的一期工程，用于建造一套12000Nm3/h的空分装置，包括液化和充瓶系统。工程占地面积为26300平方米。总投资额为11000万元，预期于2004年3月投产。YY公司负责工程的设计工作，ZZ公司负责工程监理。主体设备中空分冷箱由杭氧制造，氧压机由HY供货，空压机、氮气压缩机、膨胀机DCS系统、分析仪表及部分阀门采用进口设备。在业主和监理公司管理下，施工单位以包工、包料、包工期、包质量的总包方式承接施工。整个工程土建交安于11月中上旬，安装工程总工期为150日历天。本工程在施工过程中，必须做到合理规划场地、科学组织、统筹安排和采用先进的施工技术和施工工艺。确保本工程优质、安全、正点完成。

　二、编制依据

　?1、HY提供的冷箱部分的设计施工图及工艺流程图

　?2、HY提供的冷箱安装施工说明

　?3、HY提供的安装施工规范

　?4、金属制件的除油清洗HT8009-88

　?5、大型空分设备安装技术规范HTA1107-93

　?6、铝制空分设备安装焊接技术条件?HTA5411-2001

　三、主要施工技术措施

　?1、冷箱底板的安装

　?在冷箱底板安装前，会同业主现场代表、监理工程师及土建承包商对基础进行验收。在基础上应明显地标识标高基础线和纵横中心线，并应有沉降观测点，基础外观不得有裂纹、蜂窝、空洞、露筋等缺陷，按照杭氧及天辰设计院的图纸对基础的尺寸进行复测检查，其允许偏差应符合杭氧的图纸及GB50231-98规范要求。

　?基础处理

　?基础验收合格后，用水准仪测量基础底板标高,应满足设备图纸的要求，空分基础表面混凝土水平度不应超过5/1000,全长不应超过15mm.基础底板及底板间的水平度不应超过1/1000.下塔支架,粗氩塔Ⅱ支架基础底板及底板间水平度不大于1/1000。然后将基础上的碎石、泥土、积水等杂物清理掉。如果基础底板的水平度超过图纸的要求，那就需要用钢板在基础底板上面找平，钢板的宽度要与冷箱板的骨架的型钢相同，找平后，用水准仪测量，水平度不应超过图纸要求且全长不应超过2mm。

　?2、冷箱板的安装

　?基础底板标高校正好后，即可进行冷箱板的安装，在安装冷箱板时相邻两面可在地面上预拼装成整片或角型，每片对角线长度误差及四边垂直度误差如下：

　?尺寸公差带

　?大于至

　?10002000±3

　?20004000±4

　?40008000±5

　?800012000±6

　?1200016000±7

　?1600020000±8

　?20000?±9

　?基础框架与骨架型钢间可用薄钢板衬垫调整箱板上端面水平。衬垫的钢板其宽度应与相应的型钢尺寸相同。

　?骨架间的安装螺母与螺栓应点焊牢，骨架间的型钢其内侧为间断焊，间距为150mm，焊缝长50mm。其外侧为连续密封焊，整个冷箱外的连续焊必须保证冷箱的气封性要求。

　?下部冷箱板安装完毕，并再次校正无误后，即可进行基础框架灌浆。

　?冷箱安装垂直之偏差≤1.5/1000，但冷箱总高垂直偏差不得大于20mm。

　?冷箱内的设备吊装的方法如下：

　?冷箱板的第一层先留两块板不装，第二层冷箱板留两块板不装，已装的冷箱板与基础底板牢固焊接好，冷箱板的标高及垂直度调整好。

　?在吊装铝制压力容器时，应采取保护措施，以防止损伤表面。

　?设备的安装采用集中安装，将下塔、粗氩塔Ⅱ及主换热器的支架安装好，先将下塔与冷凝蒸发器组合、粗氩塔Ⅱ下段及主换热器就位并调整垂直度，下塔的吊装应用随机吊耳。就位后，用铅垂线在塔四周检查其垂直度。如不垂直，可在其底座下面衬垫薄钢板。其尺寸应与支架面宽度相此三台设备采用120t吊车吊装，吊装的参数如下：

　?下塔与冷凝蒸发器组合的吊装：

　?吊装参数

　?外形尺寸：~?19910mm

　?设备重量：~21.25t

　?设备就位位置：冷箱内2200mm高的下塔支架上

　?就位标高：~21790mm

　?吊装方法：

　?下塔与冷凝蒸发器组合是冷箱内最重的设备，数量共有一台,根据该设备重量及就位高度，拟采用进口全液压120t汽车吊吊装就位，吊车型号为TG-1200M.?

　?25吨吊车抬尾,根据120t汽车吊性能表，取吊车工作半径11m，吊车臂杆长度34.8m，此时额定荷载为23t，大于吊装荷载，满足吊装要求，在设备吊装竖立过程中，采用一台25吨液压吊车提吊设备尾部，按提吊设备尾部的荷载为设备重量的一半，则尾部提吊荷载为13t，根据液压吊车性能表取吊车工作半径7m，吊车臂杆长度9.5m，此时额定荷载为13.7t，大于提吊设备尾部的荷载，满足吊装要求。

　?吊装场地的处理

　?吊装场地必须按要求用道渣将路面铺设好.而且用压路机将路基压实至16吨/m2地耐力。

　?吊装机械性能选用

　?TG-1200M吊车臂长L=34.8米

　?工作半径?R=9米

　?额定起重量?Q=25吨

　?25吨汽车吊?臂长L=9.5米

　?工作半径?R=7米

　?额定起重量?Q=13.7吨

　?设备吊装用索具计算

　?设备总重量21.25吨+吊钩重1.6吨+索具重300千克=23.15吨.

　?采用4根钢丝绳,?每根垂直受力为6吨,

　?设α=600,则sinα=F/F1?F1=F/sin600=6.93吨

　?绳长取为4.5米,取安全系数为5倍,

　?钢丝绳破断拉力应大于6.93T×5=34.65吨

　?吊装平面布置

　?吊车站在设备基础的西面进行吊装，吊装的立面示意见图1?（吊装立面示意图）。

　?索具配备

　?卸扣：15t?2?个

　?吊索6×37-Ф52?2根每根长度20m，两弯四股

　?提吊设备尾部吊索：6×37-Ф52?一根长度16m一弯两股

　?图1：下塔与冷凝蒸发器组合吊装立面示意图

　下塔与冷凝蒸发器组合吊装平面图

　其它设备在冷箱内的摆放位置如下图

　?设备安装的顺序如下：

　?下塔与冷凝蒸发器组合→粗氩塔Ⅱ与粗氩冷凝器组合→粗氩塔Ⅱ下段→上塔上段→上塔下段→粗氩塔Ⅰ→粗氩液化器→膨胀空气冷却器→纯氩塔与纯氩冷凝蒸发器组合→主换热器

　设备都放进冷箱后，即可进行其余冷箱板的安装。冷箱立板安装完后，在冷箱顶上安装两根用于吊装的H型钢（220），分别位于下塔及粗氩塔Ⅱ的中心。摆放位置如上图。冷箱内其他设备的就位采用卷扬机牵引吊装就位。

　?设备的焊接

　?冷箱内设备对口的焊缝四条

　?粗氩塔Ⅱ一条

　?上塔下塔两条

　?纯氩塔一条

　?主冷与上塔对接的焊口采用双人双面同时横焊，担任塔体环缝焊接的焊工应按规定要求经考试合格持证上岗。双面横焊前应焊接模拟焊接试板，焊接试板的焊接环境、工艺条件、焊工、氩气等应与实际产品施焊时一致。模拟试板焊接应进行100%X射线照相，不低于JB4730Ⅱ级要求。模拟试板合格后方可进入塔的组对、焊接。

　?1、施焊前的准备工作

　?脚手架必须安全牢固，脚手架平面至焊缝的高度以1400mm为宜。4台手工氩弧焊机，预热用的乙炔及氧气。

　?主冷及上塔焊口附近的周长要复查一遍，以防止周长偏差超标而无法焊接。

　?坡口准备，用机械方法清理焊接区域，按下图所示加工坡口。

　?焊口组对用的工具准备

　?焊口组对用的工具采用不锈钢及铝板制作，如下图：

　?2、塔体的焊接

　?定位焊及正式焊接不得在雨天或相对湿度80%以上的环境下进行。

　?组对定位焊必须保证板边错边量及塔体垂直度，上塔垂直度允许偏差1/1000且不得超过8mm。

　?焊接顺序应根据定位焊后塔体的垂直度及塔板水平度确定，利用焊后变形来进一步矫正垂直度及水平度。

　?组对定位焊及正式焊接均采用两人同时双面横焊，覆盖层采用单人焊接。

　?焊后经外观检验后须对焊缝作100%X射线检查，并应符合JB/TQ601附录D的Ⅱ级标准的规定

　?如焊缝经X射线检查不合格而需返修时，应用机械方法清除缺陷后补焊，返修不得超过三次。

　?返修二次以上应得到安装单位总工程师批准才可进行。

　?3、焊接中的其他要求

　?焊接环境：雨天或环境相对湿度≥90%时不得施焊

　?坡口加工采用机械方法，并确保组对、定位焊时有足够的、均匀的间隙

　?组对、定位焊及正式施焊必须在模拟试板合格后进行

　?正式施焊开始后，中途焊接中断时间不得超过15分钟

　?焊接时用气焊枪预热时，应在塔外侧预热，并避开坡口区

　?应尽量设法缩短氩气管，可将氩气瓶放在接近施焊区域的平台上

　?应选择合理的焊接顺序，保证塔体的垂直度

　?预热温度要控制在150℃以内。

　?冷箱内管道的焊接

　?管道安装应按照塔内管道图进行。不得任意更改管道走向。

　?冷箱内的管子及管件安装前均需要脱脂，脱脂采用碱洗脱脂。

　?1)?管子在下料前先脱脂，脱脂后应注意防止第二次污染。

　?2)?阀门脱脂前，应经研磨试压合格，然后拆成零件清除铁锈等物，浸入溶剂内浸泡1~1.5小时，金属垫片用同样方法脱脂。

　?3)?非金属垫片的脱脂，应使用四氯化碳溶剂。垫片浸入溶剂内1.5~2小时，然后取出，悬挂在空气流通处逐个分开吹干，直至无溶剂气味为止。

　?4)?脱脂的结果可用下述方法检查：

　A?用波长3200~3800埃的紫外光检查脱脂件表面，无油脂萤光为合格。

　B?用清洁干燥的白色滤纸擦拭脱脂件表面，纸上无油脂痕迹为合格。

　C?用溶剂脱脂的脱脂件必须将残存溶剂彻底吹除直至无溶剂气味为止。用碱液脱脂者，必须用无油清水冲洗洁净至中性，然后干燥。

　?5)?管子及管道组成件，均采用浸泡法脱脂，碱性脱脂液的配方如下：

　配方重量比

　?方案一氢氧化钠0.5~1

　碳酸钠5~10

　硅酸钠3~4

　水余量

　?方案二氢氧化钠1~2

　磷酸钠5~8

　硅酸钠3~4

　水余量

　?管道在安装前应做好一切准备工作。检查容器方位、阀门进出口的方位是否正确。管件应彻底清洗干净，并严格脱脂。同时开好焊接坡口。

　?对塔内铝管道预制的要求如下：

　?预制场地必须垫有橡胶板或木板，不得与黑色金属同一场地加工

　?严禁金属硬物撞击铝管道

　?工作人员的工作服、手套必须是干净的，不得有油迹

　?敲击工具应选用木质、紫铜或硬橡胶榔头

　?搬运或吊装应采用尼龙吊带吊装

　?清洗后的管道和零件应存放在干燥处，远离酸、碱、盐类，以防腐蚀

　?在制作过程中，应轻搬轻放，防止管道损坏

　?工件焊接时，焊接地线不可随意搭在工件上，应做专用工具，不准在管道上引弧

　?加热管道与低温液体管道、液体容器壁面的平行距离应不小于300mm，交叉距离应不小于200mm。

　?管道外壁与冷箱型钢内壁距离应符合下列要求：

　?低温液体管道不小于400mm

　?低温气体管道不小于300mm

　?管道的安装间距应≥100mm

　?管道在施焊前需自然对准。绝不允许借助机械和人力强行对准，以免增加对接应力

　?凡铝管壁厚δ≥5mm口径DN大于或等于80mm对焊处须加嵌不锈钢衬圈。φ12×2φ18×2铝管加外套管环角焊。

　?在安装中，如配管不能连续进行时，各开口处务必加盖或用塑料布包扎。

　?在流量孔板前后，须有足够的直管段，孔板前为20倍管径，孔板后为10倍管径，且不允许存在影响测量精度的因素。管道焊缝内表面应磨平，垫片不可深入管子内径。并要仔细检查孔板的安装方向，不得装反。

　?安装铝管的工具设备不得生锈，钢刷要用不锈钢刷。

　?3、阀门的安装

　?冷箱内的阀门，应在所有容器就位后，管路安装前进行安装?

　?冷箱内的冷阀应与相应的支架同时安装并在与该阀相连管道的冷缩方向相反的方位上，使阀杆中心线与冷箱板上开孔中心线有10~15mm的偏心。低温液体阀的阀杆应向上倾斜10~15度。当管道与阀体焊接时，要先把阀门关闭。采取降温措施，使得焊接时阀体温度不高于200℃，以免阀门密封件变形，影响阀门正常使用。

　?阀门安装时，应注意阀体上的箭头方向应与介质流动方向一致。在特殊场合下，有些冷角式截止阀、冷箱外的直通加热阀要反向安装（注意工艺流程图上的标记）

　?切换阀安装时，其转轴要处于水平位置，与切换阀相连的管道在安装前应彻底清除脏物。

　?安装后的阀门启闭应灵活，管道连接后及冷试过程中都要对阀门的启闭状态进行检查。

　?遥控阀门在安装前，应严格校核指令讯号与阀门执行机构动作是否同步，“全开”“全关”位置是否正确，并记录开度指令与阀门实际开度的关系。

　?4、支架的安装

　?塔内管架的设置，应保证被设管架有足够的稳定性和刚性，不能随便晃动，且要考虑到管道的热胀冷缩。

　

　their own conditions to develop the correct road, the maximum to avoid investment risk, gain profit.(three) vigorously promote the brand. To establish brand awareness, awareness of the use of brand, brand value, brand acquisition performance, enhance the competitive strength. Concentrated manpower, careful planning, packaging and publicity of a number of unique, market influence and coverage of the brand, the implementation of key breakthroughs, to enhance the competitive strength, walking business road the competition of alienation and characteristics, the pursuit of stability and development of the market.(four) to promote the integration of resources. To further broaden their horizons, effective integration of resources within the group, the city resources, other industries and regional resources, mutual trust, mutual benefit, seeking win-win principle, in the framework of national policies and regulations, strict inspection and argumentation, legal consultation, examination and approval procedures, strict regulation of economic activities, attract injection the social investment to the industry group, to achieve leveraging the development, ensure that the value of state-owned assets.(five) to strengthen the construction management personnel. Strengthen the management of education and training of cadres and workers of the existing business, firmly establish the concept of the market, enhance the sense of crisis to adapt to market competition, the sense of urgency, improve the ability to respond to market competition, improve management and operation of the market. At the same time, according to the need of industrial development, vigorously the introduction of high-quality management management personnel, and strive to build a high-quality professional management team, hard work, and promote the entire workforce knowledge structure, age structure, structure optimization and upgrading ability, enhance core competitiveness, adapt to the need of market competition.(six) seriously study the policy for policy. Serious research about social support the development of cultural undertakings in the country and the XX policy, especially the policy of industrial development, financial investment policy, financial policy and tax policy, and actively seek policy, projects and funds, enterprise and industry group mission to promote leapfrog development.

　their own conditions to develop the correct road, the maximum to avoid investment risk, gain profit.(three) vigorously promote the brand. To establish brand awareness, awareness of the use of brand, brand value, brand acquisition performance, enhance the competitive strength. Concentrated manpower, careful planning, packaging and publicity of a number of unique, market influence and coverage of the brand, the implementation of key breakthroughs, to enhance the competitive strength, walking business road the competition of alienation and characteristics, the pursuit of stability and development of the market.(four) to promote the integration of resources. To further broaden their horizons, effective integration of resources within the group, the city resources, other industries and regional resources, mutual trust, mutual benefit, seeking win-win principle, in the framework of national policies and regulations, strict inspection and argumentation, legal consultation, examination and approval procedures, strict regulation of economic activities, attract injection the social investment to the industry group, to achieve leveraging the development, ensure that the value of state-owned assets.(five) to strengthen the construction management personnel. Strengthen the management of education and training of cadres and workers of the existing business, firmly establish the concept of the market, enhance the sense of crisis to adapt to market competition, the sense of urgency, improve the ability to respond to market competition, improve management and operation of the market. At the same time, according to the need of industrial development, vigorously the introduction of high-quality management management personnel, and strive to build a high-quality professional management team, hard work, and promote the entire workforce knowledge structure, age structure, structure optimization and upgrading ability, enhance core competitiveness, adapt to the need of market competition.(six) seriously study the policy for policy. Serious research about social support the development of cultural undertakings in the country and the XX policy, especially the policy of industrial development, financial investment policy, financial policy and tax policy, and actively seek policy, projects and funds, enterprise and industry group mission to promote leapfrog development.

　SelectionParagraphFormatLineSpacingLinesToPointsSelectionParagraphFormatLineSpacingLinesToPointselectionParagraaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaphFormatLineSpacingLinesToPointsSelectionParagraphFormatLineSpacingLinesTSelectionParbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbagraphFoLineSpacingLinesToPointsSelectionParagraphFormatLineSpacingLinesToPointse11111111111111111111111111111111lectionParagraphFormatLineSpacingLinesToPointsSelectionParagraphFormatLineSpacingLinesToPoctionParagraphFormatLineSpaci2222222222222222222222ngLinesToPoints2SelectionParagraphFormatLineSpacingLinesToPointsSelectionParagraphFormatLineSpacingLinesToPointselectionParagraphFccccccccccccccccccccccccccccccccccccccccccccccccccccccccormatLineSpacingLinesToPointsSelectionParagraphFormatLineSpacingLinesToPoctionParagra

　their own conditions to develop the correct road, the maximum to avoid investment risk, gain profit.(three) vigorously promote the brand. To establish brand awareness, awareness of the use of brand, brand value, brand acquisition performance, enhance the competitive strength. Concentrated manpower, careful planning, packaging and publicity of a number of unique, market influence and coverage of the brand, the implementation of key breakthroughs, to enhance the competitive strength, walking business road the competition of alienation and characteristics, the pursuit of stability and development of the market.(four) to promote the integration of resources. To further broaden their horizons, effective integration of resources within the group, the city resources, other industries and regional resources, mutual trust, mutual benefit, seeking win-win principle, in the framework of national policies and regulations, strict inspection and argumentation, legal consultation, examination and approval procedures, strict regulation of economic activities, attract injection the social investment to the industry group, to achieve leveraging the development, ensure that the value of state-owned assets.(five) to strengthen the construction management personnel. Strengthen the management of education and training of cadres and workers of the existing business, firmly establish the concept of the market, enhance the sense of crisis to adapt to market competition, the sense of urgency, improve the ability to respond to market competition, improve management and operation of the market. At the same time, according to the need of industrial development, vigorously the introduction of high-quality management management personnel, and strive to build a high-quality professional management team, hard work, and promote the entire workforce knowledge structure, age structure, structure optimization and upgrading ability, enhance core competitiveness, adapt to the need of market competition.(six) seriously study the policy for policy. Serious research about social support the development of cultural undertakings in the country and the XX policy, especially the policy of industrial development, financial investment policy, financial policy and tax policy, and actively seek policy, projects and funds, enterprise and industry group mission to promote leapfrog development.SelectionParagraphFormatLineSpacingLinesToPointsSelectionParagraphFormatLineSpacingLinesToPointselectionParagraaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaphFormatLineSpacingLinesToPointsSelectionParagraphFormatLineSpacingLinesTSelectionParbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbbagraphFoLineSpacingLinesToPointsSelectionParagraphFormatLineSpacingLinesToPointse11111111111111111111111111111111lectionParagraphFormatLineSpacingLinesToPointsSelectionParagraphFormatLineSpacingLinesToPoctionParagraphFormatLineSpaci2222222222222222222222ngLinesToPoints2SelectionParagraphFormatLineSpacingLinesToPointsSelectionParagraphFormatLineSpacingLinesToPointselectionParagraphFccccccccccccccccccccccccccccccccccccccccccccccccccccccccormatLineSpacingLinesToPointsSelectionParagraphFormatLineSpacingLinesToPoctionParagra

相关关键词： 空分装置工艺流程视频