1、.編號： 15-06 部-Stepan-SHF-601The 50,000t/a polyester polyol projectof Stepan (Nanjing) Chemical Co., Ltd.斯泰潘（南京） 5 萬噸 / 年聚酯多元醇項目儀表施工方案Instrument Construction Plan編制 Prepare by：安全 Security by ：審核 Reviewby：批準 Approve by ：Nanjing Chemical Construction Co., Lid南京南化建設有限公司13. Mar. 2015.目 錄 Contents第一章工程概況GE

2、NERAL . 3第二章： 制依據(jù)CHAPTER 2- REFERENCE3第三章： 表 物工作量CHAPTER 3- INSTRUMENTQUANTITYOF WORK3第四章：施工的主要程序CHAPTER 4-MAIN CONSTRUCTIONPROCEDURE4第五章：主要施工方法和技 要求CHAPTER 5-CONSTRUCTIONTECHNICAL REQUIRES AND QUALITY STANDARD7第六章： 量控制和 、 劃CHAPTER 6-QUALITYCONTROL AND INSPECTION TEST PLAN29第七章：主要施工機具CHAPTER 7- -MAN

3、POWER34第八章： 力 CHAPTER 8-LABOR ORGANIZATION.34第九章：施工 度 劃CHAPTER 9-CONSTRUCTION PROGRESSSCHEDULE .35第十章：安全保 措施、 JHA 及文明施工CHAPTER FIVE SAFETYASSURANCE SYSTEM, JHA AND HOUSEKEEPING37.第一章：工程概況Chapter 1-General本工程為斯泰潘（南京）化學有限公司新建5 萬噸 /年聚酯多元醇項目，工程范圍主要包括：行政辦公和電控樓，空壓站、門衛(wèi)和稱重，焚燒爐，冷卻水系統(tǒng)，消防泵房，事故水池，工藝裝置區(qū)，倉儲區(qū)等。Thi

4、s is an expansion project of BASF-YPC Company Limited, the management team is IET,TAR work involved in area 1 mainly includes existing instrument exchanges, remove, and resetting, new instrument installation, cable tray laying and cable pulling.儀表種類主要有：控制閥、開關閥、流量計、差壓變送器、壓力變送器、溫度變送器、分析儀表、氣體檢測儀等儀表。 Va

5、rious instruments covered like control valve, on-off valve, integrated flow meter, DP transmitter, pressure and temperature transmitter, fork liquid level switch and toxic gas detector.第二章：編制依據(jù)Chapter 2- Reference招標文件自動化儀表工程施工及質量驗收規(guī)范GB50093-2013 Chinese instrumentconstruction work code.石油化工儀表工程施工技術規(guī)

6、程SH3521-2007 Petrochemical instrumentconstruction work code.電氣和儀表回路檢驗規(guī)范GB/T25921-2010自控安裝圖冊HG/T21581-2010電氣裝置安裝工程爆炸和火災危險環(huán)境施工及驗收規(guī)范GB50257-96建筑工程施工現(xiàn)場供用電安全規(guī)范（GB50194-93 ）；Power Supply and Utility Safety Regulations on Construction Engineering Site GB50194-93建設工程安全管理條例第三章：儀表實物工作量Chapter 3- Instrument qu

7、antity of work名稱單位數(shù)量名稱單位數(shù)量溫度儀表臺36調節(jié)閥臺18壓力變送器臺24過程開關臺86差壓變送器臺2分析儀表臺5差壓液位變送器臺15有毒氣體檢測儀臺2液位儀表臺16儀表電纜米39666流量儀表臺29橋架米2122開關閥臺51儀表管路米1147.第四章：施工的主要程序Chapter 4-Main construction procedure1.主要施工程序流程圖施工前準備 preparationbefore construction圖紙會審joint review of drawings設計交底designdisclosure領、檢設備材料receive,checkequi

8、pmentand materials預埋管、件安裝embedded pipe,支托架立柱預制安裝Support儀 表 單 校盤柜及底座制作安裝cabinetfittings installationbracketcolumninstallation ofInstrumentsinglfabricationandinstallatioprefabricatede calibrationn橋架、就地盤柜接線箱安裝tray, cabinetwiring配合工藝一次部件安With裝 the電纜保護管安裝Cable protectionbox on site installationinstallati

9、on process once partpipe installation電纜敷設cable導壓管、氣源管、伴熱管安Impulse裝現(xiàn)場儀表安裝site instrumentlayingcontrol, air supplypipe, heatingpipeinstallation儀 表 導 壓 管 試 壓Instrumentguide管線上儀表拆除、隔離閥關閉pressure pipe pressureDismantlethe pipelineInstrument,testisolation valve closed試壓、試漏 Pressure校、接線calibration, wiringt

10、esting, leak testing現(xiàn)場儀表二次安裝Secondary fieldinstrumentation配合單體試車single系統(tǒng)聯(lián)校 systemcommissioningjoint calibration交 工驗收acceptance.2.準備工作Preparation1 ）組織施工有關人員進行交底，充分做好施工圖會審工作，及時解決圖紙中發(fā)現(xiàn)的問題，從而為施工階段爭取時間。Organize technical clarification and DWG review, problemsexisting in DWGs shall be quickly solved to ga

11、in more time for TAR.2 ）根據(jù)設計圖和有關資料編制好設備材料表和有關施工資料，熟悉設計的規(guī)范、標準、設計圖紙以及有關的操作說明等資料。Prepare material list and related constructiondocumentsasperdesignedDWGandrelativedocuments.Befamiliarwithcodes,standards, DWGs and guidelines.3 ）熟悉施工有關的資料及圖紙，了解現(xiàn)有儀表的原理及接線柜位置。Be acknowledgeablewithconstructionrelateddocume

12、ntsandDWGs,beclearwithexistinginstrumentphilosophy and junction box location.4 ）對施工班、組進行全面系統(tǒng)的技術交底，上崗人員能熟悉圖紙，明確施工任務和施工要點，規(guī)范及特殊要求。 Technical clarification to construction team shall be complete and systematic, make sure construction personnel are familiar wit DWGs, work content and requirements.5 ）及時了

13、解設備、材料到貨情況，設備到貨時，一定要根據(jù)廠家提供的裝箱單、技術資料，會同業(yè)主、監(jiān)理單位開箱檢驗，核實儀表設備材料的規(guī)格，型號及數(shù)量是否符合設計要求，并做好記錄，并在干燥清潔的條件下妥善保管。Be clear with material and equipmentstatus,open-boxinspectionjointlywith IETand BYCas per packinglist andtechnicaldocuments provided by manufacturer, check if equipment and material specification, typean

14、d quantity are satisfied, and record made, all equipments and materials received shall bewell kept.6 ）準備好干燥清潔的房間，作為調校室，環(huán)境應符合要求。班組要檢查機具是否完好，檢驗期是否有效，校驗儀表的等級是否符合要求。A cleanroom will beprepared tobe ascalibration room which shall comply with environmental requirements. Machines and toolsshallbe checkedwi

15、th completenessand expiresby the groupand instrumentshallbechecked with its grades.7) 施工機具的準備。 Preparation on construction machines and tools(1) 根據(jù)圖紙及工作量準備各種施工工具； Prepare various construction machines and tools as per DWG and work quantity.(2) 現(xiàn)場嚴禁使用活動扳手，需要按照儀表規(guī)格書、安裝圖、管道ISOMETRICS圖準備同規(guī)格的套筒、 梅花、開口扳手等

16、。 Movable wrench is not allowed to be used on site, sleevesand open-end wrench shall be prepared as per the specification provided in specification,hook-ups, and pipe isometrics.2施工前期1 ）儀表安裝受裝置作業(yè)、工藝設備、工藝管道、土建等專業(yè)的現(xiàn)場條件限制，不宜提前進行，但一些安裝可在前期完成或部分完成。如：Site conditions limit advance constructionof TAR instru

17、ment erection considering plant operation, process equipment & piping , civil, however, some installation can be finished at pre-TAR or partially finished.(1) 儀表單體調校，閥門強度試驗。Instrument unit calibration, valve strength test.(2) 橋架支架預制。 Cable tray support fabrication(3) 部分主橋架安裝。 Partial main cable tray

18、 erection(D477i piperack replacement,D472i piperack partial cable tray erection, D473i piperack cable tray)(4) 變送器支架預制。 Transmitter support fabrication(5) 盤柜基礎預制 Cabinet foundation fabrication(6) 接線箱支架預制。 Junction box support fabrication(7) 接線箱、氣源分配器安裝。 Erection of junction box and air distributor.3

19、 .施工中期Middle stage of TAR在工藝設備、管道安裝陸續(xù)完成，整個工作已初步明朗，儀表安裝進入施工高潮，這段時間工期緊，任務重，且多種工種交叉作業(yè)， 應妥善安排施工計劃。At this time, most processequipment and piping erection has been finished, instrument erection enters into climax;tight time, heavy task and multi-trades crossing requires a detailed and strict schedule.施工高

20、潮主要工作如下：Main works for this time1) 分支橋架（接線箱至儀表） 、氣源管線敷設 （氣源分配器至氣動閥門） 。Branch cable tray laying (from junction box to instrument), air distributor wire pulling(from air distributor to pneumatic valve )2) 電纜敷設。 Branch cable pulling(from junction box to instrument)3) 導壓管安裝。 Pressure pipe installation4)

21、 安裝儀表、 校接線。 New and dismantled instrument installation, pressure test, leakagetest, wiring calibration.5) 回路測試。 Loop test4施工后期Late stage of TAR在所有安裝工作結束后，要對整個安裝工程進行“三查四定 ”和系統(tǒng)聯(lián)校、儀表投運工作，此項工作必須會同業(yè)主和監(jiān)理等有關人員，根據(jù)施工驗收規(guī)范要求，對整個儀表施工全面檢查，記下不合格點，并逐個給予解決，最終辦理交付驗收工作。When allinstallationworkfinished, work out punch

22、 list and clean all items remained, then conduct system calibrationand instrument commissioning jointly with IET and BYC related personnel. A full inspectionis required to find out non-conformances andsolve one byone.IET,BYC, MAV1 andsupervision unit shall be involvedin system loopcalibrationand mak

23、edecisions,finally,acceptance work will be performed.第 五 章 ： 主要 施工 方 法和 技 術 要求 Chapter5-Constructiontechnical requires and quality standard.1. 儀表盤柜的安裝Dashboard cabinet installation1) 盤柜到現(xiàn)場后，為避免設備損壞，要盡量減少搬運次數(shù)。Cabinet arrives at the scene,in order to avoid damage to the equipment, to minimize handling

24、 times.2) 設備開箱時在安裝地點附近開箱，使用撬棍時不得以盤面為支點，以免損傷盤柜。拆箱時有庫管、廠家、及監(jiān)理等相關人員在場，對于明顯的設備缺陷，作好記錄并報有關人員。When the equipment is installed out of the box near the location of the box, not to the diskas a fulcrum when using a crowbar, so as not to damage the disk enclosure. There Kuguan,manufacturers, and supervision a

25、nd other related personnel present during the unpackingof equipment for obvious defects, make records and report to the relevant personnel.3) 盤柜在開箱時， 由技術員按安裝圖標好開箱先后順序， 在開箱后運至基礎過程中要保證設備及人身安全。由于盤體較重，要用力平穩(wěn)、一致。不允許劇烈振動和撞擊。盤到位后，還要仔細核對其型號是否正確，零部件、缺件、損壞件核對后做好記錄。Enclosure at the boxby pressing the Setup icon

26、 technician good out of the box the order, shipped to the baseafter the unpacking process to ensure that equipment and personal safety. Due to heavy plate body, to force a smooth and consistent. Do not allow excessive vibration and shock.After the disc in place, but also carefully check the model is

27、 correct, parts, missing parts, damaged parts after checking make a record.4) 盤柜找平、找正時，先精確的找好第一塊，再以第一塊為基準，將其它依次調整找平、找正。 Enclosure leveling, alignment, first the first one to find a good accurate, then the firstone as a reference, the other in order to adjust the leveling, alignment.5) 同一系列規(guī)格相鄰兩盤、柜、臺

28、的頂部高度允許偏差為2mmm;In the same seriesspecifications of two adjacent plates, cabinets, table top height tolerance for 2mmm6) 當同一系列規(guī)格盤、 柜、臺間的連接處超過 2處時，頂部高度允許偏差為 5mm ；When the junction of the same series specifications cubicle, desk between more than two, top height tolerance of 5mm;7)相鄰兩盤、 柜、臺接縫處正面的平面度允許偏

29、差為1mm ；Two adjacent plates, cabinets,front desk seams flatness tolerance of 1mm;8)當盤、柜、臺問的連接處超過5 處時，正面的平面度允許偏差為5mm ； When the disc,connection cabinets, desk and asked the more than 5, the front of the flatness tolerance of 5mm;9) 相鄰兩盤、柜、臺之間的接縫的間隙，不大于 2mm 。 Two adjacent cubicle, the gap between the s

30、eams of the station, no more than 2mm.2. 接線箱安裝 Mounting of junction boxes1) 接線箱應安裝在水平面或平臺上， 接線箱的安裝位置應便于操作和維護。 Junction boxes shall be installed at grade or on the platform. Location of junction boxes will generally bedecided by considering operability, ease of maintenance.2) 接線箱應根據(jù)施工圖進行安裝。Junction b

31、oxes shall be installed in accordance withconstruction drawings and/ or instruction by BYC s supervisor.3) 當不在接線箱內工作時，所有的接線箱蓋板必須完全關閉。3. 儀表支架 instrument support1) 儀表立柱和其它支架應根據(jù)已批準的圖紙進行制作安裝。Stanchions and other supportsshall be fabricated and installed in accordance with approved drawings.2) 在制作完成后，立柱和

32、支架應立即進行表面處理并刷底漆。Surfacepreparationandprimer coating shall be applied for all stanchions and supports immediately after completionof fabrication.3) 在鋼結構進行防火處理前，應將支架安裝到結構件上。When a support is attached to astructural member, the work shall be carried out before fireproofing of the member4) 儀表立柱為 2 寸鍍鋅鋼管

33、。 The instrument stanchions shall be of 2 inch steel pipe as arule.4. 基礎槽鋼的安裝 foundation channel steel fabrication and installation在設備安裝前，基礎槽鋼應水平地固定到地面上?；A型鋼應平直并固定良好。基礎的.尺寸應與設備底座一致。其水平度的允許誤差為1 mm/m 。當基礎底座的長度大于5m 時，全長允許誤差為5mm 。Prior to installation of equipment, the channel base shall be fastenedto t

34、he floor horizontally. The profiled steels of the foundations should be straight and wellfixed.Their sizes shouldcomplywith equipmentbases.The allowableerror for linearityshallbe 1 mm/m.In case the lengthof the bottomseat of sectionalsteel is 5m, theallowable error in full length shall be 5mm.5. 現(xiàn)場儀

35、表安裝 Field instrument installation1) 總括： General(1) 儀表的中心距操作地面的高度宜為1.2m-1.5m 之間；the elevation of the center of instrument should be 1.2m(2) 顯示儀表應安裝在便于觀察示值的位置；install indicative meter at position easy to read.(3) 儀表不應安裝在有振動、潮濕、易受機械損傷、有強電磁場干擾、高溫、溫度變化劇烈和有腐蝕性氣體的位置；instrument should not be installed in po

36、sitions of vibration, humidity, easy be damaged by machine, strong magnetic disturbance, high temperature, sharp temperature change and corrosion gas.(4) 安裝過程中不應敲擊、震動儀表。儀表安裝后應牢固、平正。儀表與設備、管道或構件的連接及固定部位應受力均勻，不應承受非正常的外力。No knocking and vibrating instrument during installation. Installed instrument shou

37、ld be firm and even. The stress at the connection joints and fixed position between instrument and equipment, pipe and structure should be symmertrical, no abnormal stress from outside.(5) 儀表設備的安裝位置、連接型式、方向、標高原則上按照施工圖進行,安裝的細節(jié)和使用方法按照說明書的要求進行。Principally, the installation position, connection type, or

38、ientation and elevation of instrument should be in accordance with construction drawing, details and usage methods referring to specifications.(6) 在滿足了測量精度和控制靈敏的條件下,應考慮安裝在操作、 維修、觀察方便的地方 ,不宜安裝在震動、潮濕、高溫、宜受機械損傷、強磁場干擾、腐蝕性強的地方。Instrument, up to the requirements of measurement precision and control sensit

39、ivity, should.be installed in location convenient for operation, maintenance and observation. They shallnot be installed in a position of variation, humidity, high temperature, easy to be mechanically damaged, strong magnetic field disturbance and strong causticity.(7) 儀表設備的進線引入孔不應朝上,以避免油水、灰塵進入接線端處。

40、Theintakeholeof instrumentshouldnot be upwardto avoidoil, waterand dustfromentering into connection joint.(8) 直接安裝在工藝管道間的控制閥、流量計、一次元件等，應在工藝管道吹掃完畢后進行安裝。 Field thermometer, pressure meter and testing instrument will be installed as per standard DWG. Control valves, flow meters and inline instruments i

41、nstalled directly in the process piping shall only be installed after piping blowing and flushing.(9) 在安裝完成后，儀表及其附件應進行適當?shù)谋Ｗo，防止因其它施工引起儀表及附件受 到 可 能 的 損 害 或 污 染 。 Immediatelyafterinstallation,theinstrumentsandtheiraccessories shall be suitably protected by a bag, weatherproof or fire-resistant sheeting

42、, etc. against possible damage or contamination caused by other construction works.2 ） 溫度檢測儀表的主要安裝要求：Installation requirements of temperature measure instrument:(1) 接觸式溫度檢測儀表的測溫元件應安裝在能準確反映被測對象溫度的地方。The temperature device of touch temperature measure instrument should be installed inthe location wher

43、e can accurately reflect the temperature of object.(2) 溫度儀表安裝在保溫的設備或管道上時，一直到溫度計套管的螺紋連接件處都要進行保溫。In case of installing to heat insulated equipment or piping, insulation shall be providedup to the thread portion of thermowell.3 ）壓力檢測儀表安裝的主要要求：Installation of Pressure Gauge(1) 對于測量潮濕氣體、水平敷設的較長的導壓管，安裝坡度應

44、大于1/10 ，并應敷設在無振動的位置。Long horizontal tubing for wetted gas service shall have gradient more than1/10. And select the good position without vibration.(2) 如果壓力表遠離取樣點，應確認取樣點和壓力計之間的差壓。Difference of pressurebetweentapping point andpressuregauge shall beconfirmedif thelocationis far fromtapping point.(3) 應

45、特別關注普通壓力表、氨壓表、 氧壓表和禁油壓力表之間的區(qū)別。Careful attention.may be required for the difference of the gauge for general, for ammonia, for oxygen andfor oil prohibited.(4) 當被測介質壓力波動較大時，應采取緩沖措施。Buffering measures should be takenwhen the target media are subject to major pressure fluctuation.(5) 在安裝完成后，應關緊切斷閥。Afte

46、r installation, take-off valves shall be closedtightly.4 ）差壓變送器的安裝 Installation of differential type transmitter(1) 如果測量介質為蒸汽，應使用冷凝罐， 冷凝罐應安裝在同一高度。If measured fluid issteam, seal pot should be provided. The seal pot shall be at the same elevation.(2) 導壓管應盡可能短。測量液位或壓力的變送器的安裝位置應盡可能靠近取壓管嘴，避免因為產品本身特性而產生不

47、必要的聚合和結晶的危險。Pressureleadtubing shallbeprovided as shortas possible.Transmitters for level or pressureshouldbe installedasclose as possibleto the nozzlein order to avoidunnecessary risk of polymerizationorcrystallization, depending on the product.(3) 正負壓的導壓管應盡可能的平行安裝，并應安裝在環(huán)境溫度相同的地方，固定支架的間距應小于 2m 。 Pr

48、essure lead tubing is installed in parallel as much as possible and shallhave the same environmental temperature. Support shall be fixed to supporting structure less than 2 meters span.5 ） 流量檢測儀表的主要安裝要求：Installation requirements of flow measure instrument:(1) 節(jié)流件的安裝應符合下列要求：Installation of throttle p

49、iece should meet the following requirements.安裝前應進行外觀檢查，孔板的入口邊緣應無毛刺、圓角和可見損傷；Surface check prior to installation, no burr, round angle and visible damage in the exit of spray mouth and entrance of orifice plate.節(jié)流件必須在管道吹掃后安裝；Install throttle piece after piping blowing節(jié)流件的安裝方向，必須使流體從節(jié)流件的上游端面流向節(jié)流件下游端面。孔

50、板的銳邊或噴嘴的曲面?zhèn)葢粶y流體的流向；the installation orientation of throttle must ensure liquid flow from the upstream of throttle to.the downstream. The curve surface of shape margin or spray mouth should face the flowroute of objected liquid節(jié)流件的端面應垂直于管道軸線，其允許偏差為1 0；The surface of throttle should plumb with pipi

51、ng axis, with allowable deviation of 10在水平和傾斜的管道上安裝的孔板或噴嘴，若有排泄孔時，排泄孔的位置為：當流體為液體時應在管道的正上方，當流體為氣體或蒸汽時應在管道的正下方。For orifice plate or spray mouth installed on level or declining piping, its drainage hole, if have, should be positioned as: the opposite upside of piping if the flow is liquid, and the oppos

52、ite downside if the flow is gas or steam.(2) 轉子流量計應安裝在無振動的管道上，其中心線與鉛垂線間的夾角不應超過2 0，被測流體流向必須自下而上，上游直管段長度不宜小于5 倍管直徑；Rotor flow metershould be installed onnon-vibrating piping, with the anglebetween itscenterline and plumb line no more than 20. The direction of objective flow must be fromthe upper to down. And the length of straight piping at the upstream should be no less than5 times of piping diameter.(3) 渦街流量計信號線應使用屏蔽線，上、下游直管段的長度應符合設計要求，放大器與流量計分開安裝時，兩