年產(chǎn)90萬噸乙烯裝置壓縮機組工程施工組織設計方案

1、. . . . 年產(chǎn)90萬噸乙烯裝置壓縮機組施工方案目錄Content1工程概況General of project12編制依據(jù)References22.1編制說明Instructions22.2執(zhí)行規(guī)和標準Standards and specifications23施工組織Construction organization43.1主要工程實物量Main construction items53.2施工安排Construction arrangement53.3施工機具準備Construction machinery and apparatus preparation63.4施工人員安排Per

2、sonnel arrangement63.5施工進度計劃Construction progress schedule74質(zhì)量控制計劃Quality control plan74.1質(zhì)量方針與質(zhì)量目標74.2質(zhì)量目標：74.3質(zhì)量保證體系Quality assurance system85壓縮機組施工技術(shù)措施Compressors construction technical measures85.1施工總體要求：General construction execution requirements85.2設備開箱檢查：Visual inspection of equipment115.3基礎(chǔ)驗

3、收與處理：Foundation treatment and acceptance115.4機組就位、找平找正Locate level and align assembling units145.5機組就位、找平找正Locate, level and align assembling units155.6二次灌漿Secondary grouting175.7系統(tǒng)管線安裝的技術(shù)要求Technical requirements for system piping installation195.8乙烯壓縮機組Ethylene compressor units225.9丙烯壓縮機組Propylene

4、refrigeration compressor units295.10甲烷制冷壓縮機組Methane refrigeration compressor units356HSE 控制計劃 HSE control plan406.1HSE“六個零”目標：HSE “Six Zero” targets406.2施工現(xiàn)場的安全控制 Safety control on construction site407附錄Appendix437.1乙烯二標段壓縮機安裝工程設備一覽表Equipment list of ethylene compressors installation work437.2施工機具與消

5、耗材料Construction machinery and consumable materials447.3壓縮機冷態(tài)找正曲線圖 Curve of cold state alignment of compressors477.4工作危險性分析(JHA)表Hazard Assessment Worksheet517.5乙烯二標段壓縮機安裝工程進度計劃Construction schedule plan of ethylene compressors installation work531 工程概況General of project年產(chǎn)90萬噸乙烯工程是某石化股份公司、某石化股份公司和某公司

6、合資的大型石化項目，位于某市金山區(qū)漕涇某化學工業(yè)園區(qū)。乙烯裂解裝置為該工程的龍頭項目，計劃于2002年年底開始土建施工、2003年4月15日開始安裝施工、2004年12月28日機械完工、2005年3月投料開車、同年五月開始商業(yè)運行。 Shanghai SECCO 900kt/y Ethylene Project, located in Shanghai Chemical Industrial Park, is financed and executed by the joint venture of SINOPEC Co. Ltd, Shanghai Petroleum & Chemi

7、cal Co, Ltd and BP Company. Ethylene heaters installation is the most important part of this project. It is proposed to commence civil construction at the end of 2002; commence installation construction on April 15th,2003, complete machinery construction on December 28th, 2004; commissioning in Marc

8、h, 2005 and start the commercial operation in the same year.90萬噸/年乙烯裂解裝置由ABB LUMMUS/SEI聯(lián)合進行EP總承包，其工程管理由某石油化工XX公司的一體化項目部（IPMT）負責，齊魯石化工程建設公司作為CM公司代業(yè)主進行施工管理。The joint venture of ABB & LUMMUS/SEI contracted the engineering and procurement work of 900kt/y ethylene complex project. The IPMT of SECCO P

9、etroleum & Chemical Co, Ltd. is responsible for the project management. The QI LU Petroleum & Chemical Engineering Construction Company is the Construction Management Company.某90萬噸/年乙烯工程中冷區(qū)、熱區(qū)、烯烴轉(zhuǎn)換區(qū)與裂解爐區(qū)的1#、2#、3#、4#裂解爐由某石化集團工程(原第設公司)承建。在所承擔的施工區(qū)域中共有3臺壓縮機組，分別是乙烯壓縮機組、丙烯壓縮機組、甲烷制冷壓縮機組The Third Co

10、nstruction Company of SINOPEC contracted the installation construction of four heaters in heater area and the installation work in first compressor area (Ethylene compressor and Propylene compressor), hot area, coldarea and Olefin Conversion Unit. There are three compressor units in contracted const

11、ruction area. They are Ethylene compressor unit, Propylene compressor unit and Methane compressor unit.2 編制依據(jù)References2.1 編制說明Instructions2.1.1 本施工方案根據(jù)壓縮機與底座組裝后，整體出廠到貨狀態(tài)、現(xiàn)場不進行解體的原則編制。The proposal is made out based on the principal that the compressors shall be assembled with their foundations, whic

12、h will be delivered to site integrally and will not be disassembled.2.1.2 本方案僅涉與壓縮機安裝部分的施工容，壓縮機組的試車應另行編制，其它專業(yè)（吊裝、運輸、焊接等）應參見各相關(guān)專業(yè)的方案執(zhí)行。This proposal is made for compressor units installation work only, the compressors commissioning proposal shall be made additionally. Other relevant work (lifting, tr

13、ansportation, welding) shall be performed in accordance with the corresponding professional proposals.2.1.3 若本施工方案與ABB LUMMUS、SEI的設計文件、設備的隨機技術(shù)文件有關(guān)規(guī)定不相符時，應按設計文件、隨機技術(shù)文件執(zhí)行。If there is any conflict between this proposal and the design documents provided by ABB LUMMUS and SEI, the relevant requirements o

14、f attached technical documents with equipment, the latter shall govern.2.2 執(zhí)行規(guī)和標準Standards and specifications2.2.1 ABB、SEI設計的施工圖與其它設計技術(shù)文件；Construction drawings of ABB/SEI and other relevant designed technical documents2.2.2 三菱重工提供的壓縮機現(xiàn)場安裝手冊與隨機圖紙；Compressor field installation manual provided by SanLi

15、ng Heavy Industry Co., Ltd. and attached drawings with equipment2.2.3 機械設備安裝工程施工與驗收通用規(guī)GB50231-98；General code of construction and acceptance of machinery equipment installation GB50231-98；2.2.4 壓縮機、空氣、泵安裝工程施工與驗收規(guī)GB50274-98；Compressors, air and pumps installation and acceptance specifications GB50274

16、-982.2.5 壓縮機、風機、泵安裝工程施工與驗收規(guī)GB50275-98；Compressors, fans and pumps installation and acceptance specifications GB50275-982.2.6 乙烯裝置離心壓縮機機組施工技術(shù)規(guī)程SH/T 3519-2002Technical regulations ofethylene complexcentrifugal compressor units construction SH/T 3519-20022.2.7 石油化工裝置設備基礎(chǔ)工程施工與驗收規(guī)SH3510-2000Petrochemical

17、equipment foundation construction and acceptance specifications SH3510-20002.2.8 石油化工設備安裝工程質(zhì)量檢驗評定標準SH3514-2001Quality inspection and assessment standards for petrochemical equipment installation work SH3514-20012.2.9 大型設備吊裝工程施工工藝標準SHJ515-90Heavy equipment lifting and construction processing standard

18、s SHJ515-902.2.10 石油化工施工安全技術(shù)規(guī)程SH3505-1999Petrochemical construction safety technical specifications SH3505-19992.2.11 工程專題會議紀要、施工現(xiàn)場的條件；Special work meeting minutes and the construction field situations2.2.12 某IPTM動設備施工技術(shù)與施工質(zhì)量管理工作細則PR-00-CIJ-MR-0001；SECCO IPTM Power equipment construction technology

19、and construction quality management regulations PR-00-CIJ-MR-00012.2.13 某IPTM工程質(zhì)量管理程序 PR-00-CIJ-QU-0001SECCO IPTM Engineering quality management procedures PR-00-CIJ-QU-00012.2.14 某IPTM施工質(zhì)量規(guī)則 PR-00-CIJ-QU-0002 SECCO IPTM Construction quality regulations PR-00-CIJ-QU-00022.2.15 某90萬噸/年乙烯工程施工組織設計；SECC

20、O 900KT/Y Ethylene Complex Construction execution plan 2.2.16 機組安裝和安裝設計的推薦操作API686Compressor units installation and recommended operation of installation design API6862.2.17 某IPTM離心式壓縮機 SD-00-TSC-MR-0002 SECCO IPTM centrifugal compressors SD-00-TSC-MR-00022.2.18 某IPTM蒸汽透平 SD-00-TSC-MR-0003SECCO IPTM

21、 Steam turbines SD-00-TSC-MR-00032.2.19 某IPTM螺桿式壓縮機 SD-00-TSC-MR-0013-A01 SECCO IPTM Screw compressors SD-00-TSC-MR-0013-A012.2.20 石油、化學品和燃氣工業(yè)設施的離心壓縮機API 617Centrifugal compressors used for petroleum, chemical products and combustion gas industry facilities API 6172.2.21 石油、化學品和燃氣工業(yè)設施的旋轉(zhuǎn)式容積式壓縮機API 6

22、19Rotary and displacement compressors used for petroleum, chemical products and combustion gas industry facilities API 6193 施工組織Construction organization乙烯壓縮機施工隸屬于中石化第設公司某90萬噸/年乙烯工程項目部。在本項目，我公司嚴格按項目法施工，能有效的同某一體化項目組的項目管理相接口。選擇具有豐富管理經(jīng)驗和在同類型裝置工作經(jīng)驗的人員擔任項目部與現(xiàn)場主要管理人員，項目管理與現(xiàn)場管理的實施能有效的同某IPMT的現(xiàn)場管理接口。材料運輸?shù)浆F(xiàn)場情

23、況將按項目程序項目材料控制程序，充分利用固有倉儲設施，盡量減少臨時倉儲建筑，合理地儲備物資，減少材料交接界面、減少運輸量，科學合理的進行施工平面布置?？⒐を炇諏⒆裾漳痴年P(guān)于工程竣工驗收的規(guī)、標準與SECCO有關(guān)要求。Ethylene compressor units installation is part work of ethylene project executed by SINOPEC SNBC. Our company, namely SNBC, will carry out work strictly in accordance with project law and me

24、et SECCO IPMT management requirements. We have selected experienced management who once worked on the similar projects to serve in project department and on construction site. The execution of project management and site management can effectively interface SECCO IPMT management. The materials that

25、have been delivered to site will be managed strictly following the project control procedure-Project Materials Control Procedure and the field warehouses will be efficiently put in use so as to reduce transportation cost and temporary facilities building cost and reserve materials and arrange constr

26、uction in a more reasonable way. The project completion acceptance shall follow national governmental codes and standards of project completion acceptance and the relevant requirements of SECCO.3.1 主要工程實物量Main construction items某90萬噸乙烯二標段主要有離心式壓縮機組2臺(乙烯壓縮機組、丙烯壓縮機組)由蒸汽輪機驅(qū)動，螺桿壓縮機組1臺(甲烷制冷壓縮機組)由電動機變速齒輪箱

27、驅(qū)動。某90萬噸乙烯壓縮機安裝工程中主要工作量(包括壓縮機組的附屬設備)見附錄Shanghai SECCO 900KT/Y Ethylene Complex has two main centrifugal compressor units (Ethylene compressor unit, propylene compressor unit) that are driven by steam turbines, one screw compressor unit(Methane refrigeration compressor unit) that is driven by one shi

28、ft gear box. The breakdown list of Shanghai SECCO 900KT/Y Ethylene compressor units installation work (including the auxiliary equipment of compressor units) can be seen in appendix. 3.2 施工安排Construction arrangement3.2.1 根據(jù)壓縮機、設備的到貨計劃，總體施工安排是壓縮機先吊裝就位再進行壓縮機廠房、平臺與其勞動保護的安裝。According to the arrival sche

29、dule of compressors and equipment, the general arrangement shall be to lift compressors in position and then to install compressor plants, platforms and personnel protection.3.2.2 根據(jù)施工場地大小，壓縮機結(jié)構(gòu)形式、供貨狀態(tài)，和我公司現(xiàn)有吊裝機具的能力，擬采用一臺500T和250T吊車實現(xiàn)的吊裝工作According to the size of construction site, compressor struct

30、ures, supply status and the lifting equipment owned by our company, it has been proposed to carry out lifting work by one 500T crane and one 250T crane.3.3 施工機具準備Construction machinery and apparatus preparation3.3.1 根據(jù)總的進度計劃和設備到貨計劃，編制施工機具使用計劃，作為機具調(diào)譴的依據(jù)。Based on the general progress plan and equipmen

31、t arrival plan, construction machinery and apparatus employment plan shall be worked outas the dispatching reference. 3.3.2 中小型施工機具應在施工前7天進場，并嚴格按照施工平面規(guī)劃布置。大型施工機具應在施工前3日進場，防止過多的占用施工場地。Middle and small size machinery and apparatus shall be delivered to site seven days ahead of construction, and they s

32、hall be arranged strictly in accordance with the construction layout plan. Large size machinery and apparatus shall be delivered to site three days ahead of construction so that they shall not occupy to much construction space.3.3.3 施工用水、用電工作應在正式施工前完成。Construction water and power supplying work shal

33、l be completed in advance before formal construction is started.3.4 施工人員安排Personnel arrangement3.4.1 參加壓縮機組安裝工程的施工人員應有壓縮機的施工經(jīng)驗，并按專業(yè)配備工藝管線安裝、電氣安裝、配管焊接、儀表與機械專業(yè)等施工力量和相應的管理人員。并根據(jù)工程進度合理的調(diào)配。The personnel who take part in compressor unit installation work shall have compressor installation experiences. The

34、 professional process pipes installation, electric installation, pipes welding, instruments and machinery constructors and the corresponding managing personnel shall be employed. They shall be reasonably arranged according to construction progress.3.4.2 施工人員施工前，針對本壓縮機組的施工特點進行專業(yè)技能培訓和技術(shù)、安全交底，使作業(yè)人員熟知施工

35、技術(shù)要求，和HSE注意事項。Before construction is started, professional technical and skill training and HSE orientation shall be performed aiming at compressor construction requirements so that each personnel shall know construction technical requirements and HSE precautions very well. 3.5 施工進度計劃Construction pr

36、ogress schedule施工進度計劃根據(jù)公司勞動力和資源與SECCO對施工進度要求的計劃進行編制，見附錄。Construction progress schedule shall be worked out based on labor force and resources owned by company and the construction progress requirements of SECCO, see the appendix. 4 質(zhì)量控制計劃Quality control plan4.1 質(zhì)量方針與質(zhì)量目標Quality policy Quality target

37、s:質(zhì)量方針：誠信為本,顧客滿意,創(chuàng)精品工程與國際接軌。Quality policy: Sincerely satisfy client, create elaborate works and meet international standard requirements.4.2 質(zhì)量目標：1.1 單位工程質(zhì)量合格率100,優(yōu)良率98%以上。Unit work qualification rate shall be 100%, excellence rate shall be over than 92%.1.2 現(xiàn)場返工率5%。 Re-work rate shall be 51.3 確保工程

38、優(yōu)良，爭創(chuàng)國家級優(yōu)質(zhì)工程To assure that works shall be qualified and compete for National Excellent Work4.3 質(zhì)量保證體系Quality assurance system按照中石化三公司質(zhì)量保證手冊（2002-C版），建立本工程項目質(zhì)量保證體系，確保各個質(zhì)量管理要素的正常運行，使施工現(xiàn)場質(zhì)量管理處于受控狀態(tài)，實現(xiàn)從傳統(tǒng)質(zhì)量管理方法向現(xiàn)代化管理方法轉(zhuǎn)移。Set the Quality Guarantee System of this project according to Quality Guarantee Man

39、ual (2002-C Edition) compiled by our company to guarantee the normal operation of each management factor so that the quality management of construction site shall be under control and to realize the transformation from traditional quality management method to modernized management method.5 壓縮機組施工技術(shù)措

40、施Compressors construction technical measures5.1 施工總體要求：General construction execution requirements5.1.1 質(zhì)量要求：Quality requirements5.1.1.1 嚴格執(zhí)行公司質(zhì)量方針，要求大型機組試車一次成功；The company quality policy shall be strictly carried out. The commissioning of large machinery units shall be successful in one time.5.1.1.

41、2 與機械相關(guān)系統(tǒng)的靜密封無泄露率為100%，單機試車機械密封無泄露率達到90%以上。The machinery relevant systems shall be 100% leakage proof, single unit shall be over than 90% leakage proof.5.1.1.3 對各種檢測、試驗要一絲不茍，施工記錄要準確、與時、齊全，嚴格執(zhí)行自檢、互檢、專業(yè)檢查等檢查制度。All inspections and testing shall be performed out carefully and precisely. Construction rec

42、ords shall be accurate, complete and in time. The self-inspection, mutual inspection and professional inspection systems shall be strictly carried out. 5.1.2 吊裝要求：Lifting requirements5.1.2.1 機械設備的吊裝與運輸，應執(zhí)行化工工程建設起重施工規(guī)的有關(guān)規(guī)定。Machinery and equipment lifting and transportation shall follow the relevant r

43、egulations of Chemical Work Construction Lifting Specifications.5.1.2.2 設備吊裝和運輸時，不得將鋼絲繩、索具直接綁扎在機加工表面，綁扎部位應適當襯墊，或?qū)⑺骶哂密洸牧习坏檬褂步饘僦苯优c設備表面相接觸，以免損傷設備表面。During equipment lifting and transportation, steel wires and slings shall not directly contact with machinery surfaces. The colligation position shall b

44、e properly padded or the slings shall be properly packed. Hard metal shall not directly contact with equipment surfaces so as to avoid damage to surfaces.5.1.2.3 機械設備的吊裝和運輸，應根據(jù)包裝標記或設備重心確定受力點，作業(yè)過程中，應使機器與主要部件保持水平狀態(tài)。To lift and transport machinery and equipment, the lifting points shall be ascertained

45、according to the mark on packages or the center of gravity of equipment. During work, machinery, equipment and their components shall be held horizontal. 5.1.2.4 吊裝轉(zhuǎn)子時，應使用制造商提供的專用工具。對自制的吊裝工具與索具，應進行200%的工作負荷試驗，時間不得少于1小時。While to lift rotor, special lifting tools provided by manufacturers shall be app

46、lied. Self-made lifting tools and slings shall be subject to 200% of working load testing and it shall last at least one hour. 5.1.3 文明施工與產(chǎn)品保護Civilized construction and products protection 5.1.3.1 現(xiàn)場施工時應實行科學管理，做到文明施工，遵守施工工藝紀律，杜絕野蠻作業(yè)，必須做到“三條線（設備工機具、零配件、材料擺放一條線）”、“三不見天（潤滑油、清洗過的零件、打開的封頭管線管口不見天）”、“三不落地（

47、使用的工量具、拆下來的零件、污油臟物不落地”、“五不準（沒有火票不準動火；不戴安全帽不準進入現(xiàn)場；不系安全帶不準高空作業(yè)；沒有檢查過的起重設備不準起吊；危險區(qū)沒有安全欄或無人監(jiān)護不準作業(yè)”“五不亂用（不亂用大錘、管鉗、扁鏟；不亂拆、亂卸、亂拉、亂頂；不亂動其它設備；不亂打保溫層不亂用其它設備的零件、附件”。做到當班施工當班清，工完料盡場地清；Construction shall be managed in a scientific way. Constructors shall obey construction process disciplines and avoid violations

48、. They shall meet the following regulations, such as: “Three - put-in-line regulation” (equipment and tools, parts and components, materials shall all be put in lines), “Three- no -opining -to -air” (Lube oil, washed parts, opened sealing pipe opening shall not be opened to air.), “Three no- falling

49、- to -ground” (measuring instruments, removed parts, oil and dirt sundries shall not fall to ground,”“ Five- no -permission” (No fire use without permission; no entry in site without safety helmet, no height working without harness, no lifting without lifting crane inspected, no working in risky are

50、a without supervision and protection); “Five- no misbehavior” ( no misuse of heavy hammer, wrench, shovel; no disassembly, remove, draw, prop up, move equipment, strike insulation layer, use components, parts and accessories of other equipmentwithout instruction. When daily work is finished, the mat

51、erials shall be used up and construction site shall be cleaned.Site construction shall be 5.1.3.2 機器就位的條件和時間：機器周圍地下工程已結(jié)束，設備基礎(chǔ)強度已達到70%以上，基礎(chǔ)驗收合格，周圍環(huán)境適合解體作業(yè)。Condition and time to locate units in position: Underground work around units have been completed, and the equipment foundation hardness has reach

52、ed to 70% above. Foundation has been accepted and the ambience is suitable for disassembly work.5.1.3.3 對現(xiàn)場安裝就位的機器搭設專門的防護棚，同時能保證正常施工。對機器拆卸下來的精密件要收入工具棚，并用軟材料下鋪上蓋。Special shelf shall be built for field located and installed equipment, meanwhile it shall not disturb the normal construction work. The mi

53、nute parts removed from equipment shall be kept in tool boxes and they shall be padded and covered by soft materials.5.2 設備開箱檢查：Visual inspection of equipment施工前須對設備進行開箱檢查并填寫開箱檢驗交接記錄，開箱檢查容如下：Before construction, visual inspection shall be carried out and the inspections shall include the following i

54、tems:5.2.1 核對設備的規(guī)格、型號與設計選型是否一致，根據(jù)裝箱清單清點零配件的數(shù)量等Check equipment specifications, models with design requirements, check quantity of parts according to packing list;5.2.2 檢查到貨設備、配件的外觀質(zhì)量情況，核實底座外型尺寸與螺栓孔尺寸。Check the appearance of the delivered equipment and accessories, check the external dimensions of bas

55、e and the dimensions of bolts 5.2.3 隨機技術(shù)資料、專用工具與計量器具,應清點造冊,妥善保管,保證使用。對精密零配件、計量器具應存放在適宜庫房的貨架上。The technical documents, special tools and measuring instruments shall be checked and put in records and filed. They shall be properly kept. The minute parts and components, measuring instruments shall be st

56、acked on corresponding shelves in warehouses.5.2.4 設備開箱檢查后，對有缺陷、疑問的設備、部件或缺件情況清楚地描述記錄，并形成各方簽字確認的開箱檢查記錄。After visual inspection, the inspection records shall be made concerning the equipment and components that are found be to defected or doubted to have defects and concerning the missed accessories.

57、All relevant parties for inspection confirmation shall sign the records.5.3 基礎(chǔ)驗收與處理：Foundation treatment and acceptance5.3.1 基礎(chǔ)使用前必須辦理中間交接證書?；A(chǔ)移交時必須同時提供下列資料：施工質(zhì)量合格證書與中心、標高、外形尺寸實測記錄、 基礎(chǔ)的沉降觀測點位置與沉降觀測記錄Foundation taking over certificate shall be transacted before it is used and the following documents are required for foundation handing over: Construction Qualification Certificate and Field measured center, elevation, external dimensions, position of settlement plugs and settlement records. 5.3.2 對基礎(chǔ)進行外觀檢查,應滿足下列要求：Foundations shall meet the following requirements by vis