印度某1x600MW热电厂水冷壁及刚性梁安装手册.docx

1、印度某1x600MW热电厂水冷壁及刚性梁安装手册THE HANDBOOK FOR WATERWALL AND BUCKSTAY ERECTION(1X600 MW THERMAL POWER PLANT, INDIA)CONTENTS1.BASIS FOR PREPARATION 错误！未定义书签。2. PREPARATION AND CONDITIONS BEFORE OPERATION 42.1Technical Preparation 42.2 Operators Allocation 42.3 Instrument and Tool 52.4 Machinary Equipment 5

2、2.5 Safety Apparatus 52.6 Precedure Change 63. OPERATIONAL METHODS, PRECEDURE AND DETAILS 63.1 Methods 63.2 Procedure 63.3 Details 73.3.1 Equipment Examination 73.3.3 Header Clean-up and Pipe Ball Passing Test 73.3.4 Waterwall Assembly 83.3.5 Buckstay and Ironwork Assembly 83.3.6 Door Hole Assembly

3、83.3.7 Waterwall and Buckstay Component Mounting 83.3.8 Cautions 94. CONTROL POINTS SETTING-UP, USUAL QUALITY ISSUES AND PREVENTION 94.1 Control points 94.2 Quality standards and requirements 104.3 Prevention 124.4 Requirements on quality record 135. SAFETY 135.1 Safety Prevention and Measures 135.2

4、 Regarding to the Construction Staff 145.3 Requirements on all the Machinery, Tool, Lifting Wires and Devices： 141. Basis for Preparation Technical Specifications on the Electric Power Construction and Acceptance(boiler part) DL/T504796 Quality Inspection and Assessment of Coal-fired Power Plant Con

5、struction(boiler part, 1996 edition) Specifications on the Quality Acceptance of Structure Steel Engineering and Construction GB502052001 Standards on the Quality Inspection and Assessment of Structure Steel Engineering and Construction GB5022195 Lifting and Delivery(Water and Hydrogen Power Press)

6、Operational Procedure on the Safety of Electric Power Construction(coal-fired power plant part) DL5009.12002 Standards on Quality Inspection and Assessment of Coal-fired Power Plant Construction(welding part) Technical Specifications on Safety of Temporary Electricity at Construction Site Relevant f

7、iles such as design drawings, bidding documents, contract and so on.For the above standards, the newest will prevail if any published.2. Preparations and Conditions before Operation2.1 Technical PreparationNo.Necessary ConditionsRemarks1For the drawings, the problems discovered in the reviewing proc

8、ess were resolved, and they had been handed down, of which it were kept with records.2Operation instruction preparation and discussion completed, approved, and distributed and recorded within the list.3Commence Report approved4All the necessary procurement or machined parts completes with the statis

9、tic, approval after reported to material supply department, and already purchasing.5The drawings have been distributed with record.6Relevant papers, such as self-inspection record, construction record, on-site meeting record, inspection forms, etc, were all distributed within list.7The construction

10、staff shall move to get familiar with the drawings and requirements on the technique and quality, and make the construction scope, contents and order defined.8Regarding to safety, the technical explanation and signature of its document was completed.2.2 Operators Allocation PostNumberObligationLifti

11、ng and Assembling Chief-in-Charge1Being in charge of lifting and assemblyTechnician1drawing, scheme, acceptance and measurementConstruction Supervisor2coordinate with acceptance and measurement, find out structural memberslifting Operators4equipment lifting, combination, downloading and transporting

12、 coordinating worker10coordinate with equipment lifting, combination, downloading and delivering.Erection Operators40frame erection, equipment counting, ball passing and site clearance, assembly at ground, erection in high.Scaffolding Operators6scaffolding, steel cat ladder, soft cat ladderWelders15

13、on-site weldingWarehouse Management Staff1management on the tool or equipment accessing to the warehouseOperators6hoister operationDrivers3on-site transportationProfessional Safety Supervisors2onsite safety and well-management of construction2.3 Operational Instrument and ToolNo.NameTypeAmountRemark

14、s1steel tape measurer100m1qualified through contrast, and being on shelf time.2steel tape measurer50m1qualified through contrast, and being on shelf time.3chain block10t4qualified through tensile force test4chain block5t4qualified through tensile force test5chain block3t20qualified through tensile f

15、orce test6chain block2t60qualified through tensile force test7jack10t48shackle5t129shackle3t4010steel ruler1m211steel ruler2m212glass pipe level50m113polishing machine1001014guide rope100m215B.W plier2016plumb line417electric grinder1018hanger rod adjusting tool119Sample Maker220cutter & auxiliaries

16、6including meters, belt, oxygen and ethyne cylinders21level bar450mm222jemmy several23iron wedgeseveral2.4 Operational Machines and ToolNo.NamesAmountFunctionsRemarks1250t, crawler crane1Lifting of waterwall & components and buckstays230t, gantry crane1working with the truck350t, crawler crane1downl

17、oading, transportation, and larger parts lifting and assembly450t, truck crane1downloading and transportation525t, low-frame plate truck1transportation610t, plate truck1transportation7air compressor1ball passing and clean-up2.5 Safety Devices and ToolNo.NameTypeAmountRemarks1safety belt202eye protec

18、tor203guard rope2004safety rope(with isolating layer)5005check circuit breaker86safety net6m6m307fire extinguisher52.6 Procedure TransitionIt can be started when the steel structure erection of boiler building was qualified by overall inspection, as well as the field and paths for equipment transpor

19、tation and downloading carried out with clean-up, planning and compaction to be ready.3. Erection Methods, Procedures and Details3.1 MethodsWaterwall erection schedule proceeds in divisions, coordinated with partial combination. That is the buckstays will be lifted to their corresponding elevations

20、in prior to carrying on waterwall hoisting; major parts of buckstays and waterwall will be hanged up from the bottom of furnace and other waterwall will be filled in from the top of furnace according to the size of frame space of top plate. Waterwall is erected from top to bottom. When one layer was

21、 finished, its supposed to go on butt joint and centering at soon and erect buckstays, and then comes to the next layer.3.2 Procedures3.3 Contents3.3.1 Equipment Examination Check the amount, type, quality and material to make sure whether they meet with the requirement or not. If any, it must be re

22、solved immediately. Due to being different types of components, it is necessary to check out the code, shipment number to make a arrangement. When the box is opened, it ought to be verified and kept with records, as per shipment list and drawing. Equipment in the same box should be concentrated at t

23、he same place and numbered, other smaller components can be stored in warehouse. All the components on the same equipment need be counted at once, such as, tube panel, headers, fire peep hole, door holes, hanger rods, buckstay, steel member auxiliaries, etc. All the alloy devices will be carried out

24、 with spectro analysis, with marks and records as qualified through inspection, and stored dividently. Defects found in the examination of components: flattening, collision, crack, pin hole, etc; quality and size of welding joint doesnt meet with the requirements; pipe hole and hand hole amount and

25、quality doesnt comply with the regulations; disqualified pipe shape, bending and length, and unflat pipe opening; the bending of headers and buckstays, etc, surpass the allowable limitation; unflat panel with excessive bulks or grooves; need be corrected. Correcting methods: additional welding of jo

26、int, polishing of pipe opening, replacing of pipes, hot bending, and so on.3.3.3 Header Clean-up and Ball Passing Test on Pipes There must be ball passing in prior to the combination of waterwall tubes and headers, for which 12 minutes blowing through compressed air need be conducted to clean up int

27、ernal ash deposit and redundant. And watch whether falling items exists or not, as a result of hole drilling. Steel balls(for types, refer to the following) and compressed air with a pressure force of 46kg/cm2, will be adopted. And ball passing ought to be undergone in the sequence that ball laid af

28、ter tube blowing.Passing Ball Diameters(mm)bending radiusoutside pipe diameterD16032D160D132R3.5D10.85D00.80D00.70D02.5D1R3.5D10.85D00.80D00.70D01.8D1R2.5D10.75D00.75D00.70D01.4D1R1.8D10.70D00.70D00.70D0R1.4D10.65D00.65D00.65D0Note: DOinside diameter of pipe(as for inlet pipe, D1 is actual measured

29、data)/D1outside pipe diameter/Rbending radius Ball handing-down would be documented and managed. Those tubes already past with balls should be marked and sealed, as well as headers sealed with steel sheet after header clean-up confirmed qualified after survey from QC personals and consultants. Relev

30、ant documents need be signed after ball passing is over, without loss of anyone. It can be considered to use a steel brush and rebar to remove the rust, meditation remainant, glass rins,etc, inside the header under no effectiveness by compressed air clean-up. For those tubes failed in ball passing, it was surposed to find out the locations and replace the tubes or short ones.3.3.4 Waterwall Assembly To reduce the man-hour as working in h