印度某1x600MW热电厂水冷壁及刚性梁安装手册.docx

印度某1x600MW热电厂水冷壁及刚性梁安装手册.docx

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印度某1x600MW热电厂水冷壁及刚性梁安装手册

THEHANDBOOKFORWATERWALLANDBUCKSTAYERECTION

（1X600MWTHERMALPOWERPLANT,INDIA）

CONTENTS

1.BASISFORPREPARATION错误！

未定义书签。

2.PREPARATIONANDCONDITIONSBEFOREOPERATION4

2.1TechnicalPreparation4

2.2OperatorsAllocation4

2.3InstrumentandTool5

2.4MachinaryEquipment5

2.5SafetyApparatus5

2.6PrecedureChange6

3.OPERATIONALMETHODS,PRECEDUREANDDETAILS6

3.1Methods6

3.2Procedure6

3.3Details7

3.3.1EquipmentExamination7

3.3.3HeaderClean-upandPipeBallPassingTest7

3.3.4WaterwallAssembly8

3.3.5BuckstayandIronworkAssembly8

3.3.6DoorHoleAssembly8

3.3.7WaterwallandBuckstayComponentMounting8

3.3.8Cautions9

4.CONTROLPOINTSSETTING-UP,USUALQUALITYISSUESANDPREVENTION9

4.1Controlpoints9

4.2Qualitystandardsandrequirements10

4.3Prevention12

4.4Requirementsonqualityrecord13

5.SAFETY13

5.1SafetyPreventionandMeasures13

5.2RegardingtotheConstructionStaff14

5.3RequirementsonalltheMachinery,Tool,LiftingWiresandDevices：

14

1.BasisforPreparation

ØTechnicalSpecificationsontheElectricPowerConstructionandAcceptance（boilerpart）DL/T5047—96

ØQualityInspectionandAssessmentofCoal-firedPowerPlantConstruction（boilerpart,1996edition）

ØSpecificationsontheQualityAcceptanceofStructureSteelEngineeringandConstructionGB50205—2001

ØStandardsontheQualityInspectionandAssessmentofStructureSteelEngineeringandConstructionGB50221—95

ØLiftingandDelivery（WaterandHydrogenPowerPress）

ØOperationalProcedureontheSafetyofElectricPowerConstruction（coal-firedpowerplantpart）DL5009.1―2002

ØStandardsonQualityInspectionandAssessmentofCoal-firedPowerPlantConstruction（weldingpart）

ØTechnicalSpecificationsonSafetyofTemporaryElectricityatConstructionSite

ØRelevantfilessuchasdesigndrawings,biddingdocuments,contractandsoon.

Fortheabovestandards,thenewestwillprevailifanypublished.

2.PreparationsandConditionsbeforeOperation

2.1TechnicalPreparation

No.

NecessaryConditions

Remarks

1

Forthedrawings,theproblemsdiscoveredinthereviewingprocesswereresolved,andtheyhadbeenhandeddown,ofwhichitwerekeptwithrecords.

2

Operationinstructionpreparationanddiscussioncompleted,approved,anddistributedandrecordedwithinthelist.

3

CommenceReportapproved

4

Allthenecessaryprocurementormachinedpartscompleteswiththestatistic,approvalafterreportedtomaterialsupplydepartment,andalreadypurchasing.

5

Thedrawingshavebeendistributedwithrecord.

6

Relevantpapers,suchasself-inspectionrecord,constructionrecord,on-sitemeetingrecord,inspectionforms,etc,werealldistributedwithinlist.

7

Theconstructionstaffshallmovetogetfamiliarwiththedrawingsandrequirementsonthetechniqueandquality,andmaketheconstructionscope,contentsandorderdefined.

8

Regardingtosafety,thetechnicalexplanationandsignatureofitsdocumentwascompleted.

2.2OperatorsAllocation

Post

Number

Obligation

LiftingandAssemblingChief-in-Charge

1

Beinginchargeofliftingandassembly

Technician

1

drawing,scheme,acceptanceandmeasurement

ConstructionSupervisor

2

coordinatewithacceptanceandmeasurement,findoutstructuralmembers

liftingOperators

4

equipmentlifting,combination,downloadingandtransporting

coordinatingworker

10

coordinatewithequipmentlifting,combination,downloadinganddelivering.

ErectionOperators

40

frameerection,equipmentcounting,ballpassingandsiteclearance,assemblyatground,erectioninhigh.

ScaffoldingOperators

6

scaffolding,steelcatladder,softcatladder

Welders

15

on-sitewelding

WarehouseManagementStaff

1

managementonthetoolorequipmentaccessingtothewarehouse

Operators

6

hoisteroperation

Drivers

3

on-sitetransportation

ProfessionalSafetySupervisors

2

onsitesafetyandwell-managementofconstruction

2.3OperationalInstrumentandTool

No.

Name

Type

Amount

Remarks

1

steeltapemeasurer

100m

1

qualifiedthroughcontrast,andbeingonshelftime.

2

steeltapemeasurer

50m

1

qualifiedthroughcontrast,andbeingonshelftime.

3

chainblock

10t

4

qualifiedthroughtensileforcetest

4

chainblock

5t

4

qualifiedthroughtensileforcetest

5

chainblock

3t

20

qualifiedthroughtensileforcetest

6

chainblock

2t

60

qualifiedthroughtensileforcetest

7

jack

10t

4

8

shackle

5t

12

9

shackle

3t

40

10

steelruler

1m

2

11

steelruler

2m

2

12

glasspipelevel

50m

1

13

polishingmachine

φ100

10

14

guiderope

100m

2

15

B.Wplier

20

16

plumbline

4

17

electricgrinder

10

18

hangerrodadjustingtool

1

19

SampleMaker

2

20

cutter&auxiliaries

6

includingmeters,belt,oxygenandethynecylinders

21

levelbar

450mm

2

22

jemmy

several

23

ironwedge

several

2.4OperationalMachinesandTool

No.

Names

Amount

Functions

Remarks

1

≥250t,crawlercrane

1

Liftingofwaterwall&componentsandbuckstays

2

≥30t,gantrycrane

1

workingwiththetruck

3

≥50t,crawlercrane

1

downloading,transportation,andlargerpartsliftingandassembly

4

≥50t,truckcrane

1

downloadingandtransportation

5

≥25t,low-frameplatetruck

1

transportation

6

≥10t,platetruck

1

transportation

7

aircompressor

1

ballpassingandclean-up

2.5SafetyDevicesandTool

No.

Name

Type

Amount

Remarks

1

safetybelt

20

2

eyeprotector

20

3

guardrope

200

4

safetyrope（withisolatinglayer）

500

5

checkcircuitbreaker

8

6

safetynet

6m×6m

30

7

fireextinguisher

5

2.6ProcedureTransition

Itcanbestartedwhenthesteelstructureerectionofboilerbuildingwasqualifiedbyoverallinspection,aswellasthefieldandpathsforequipmenttransportationanddownloadingcarriedoutwithclean-up,planningandcompactiontobeready.

3.ErectionMethods,ProceduresandDetails

3.1Methods

Waterwallerectionscheduleproceedsindivisions,coordinatedwithpartialcombination.Thatis―thebuckstayswillbeliftedtotheircorrespondingelevationsinpriortocarryingonwaterwallhoisting;majorpartsofbuckstaysandwaterwallwillbehangedupfromthebottomoffurnaceandotherwaterwallwillbefilledinfromthetopoffurnaceaccordingtothesizeofframespaceoftopplate.Waterwalliserectedfromtoptobottom.Whenonelayerwasfinished,it’ssupposedtogoonbuttjointandcenteringatsoonanderectbuckstays,andthencomestothenextlayer.

3.2Procedures

3.3Contents

3.3.1EquipmentExamination

●Checktheamount,type,qualityandmaterialtomakesurewhethertheymeetwiththerequirementornot.Ifany,itmustberesolvedimmediately.

●Duetobeingdifferenttypesofcomponents,itisnecessarytocheckoutthecode,shipmentnumbertomakeaarrangement.Whentheboxisopened,itoughttobeverifiedandkeptwithrecords,aspershipmentlistanddrawing.

●Equipmentinthesameboxshouldbeconcentratedatthesameplaceandnumbered,othersmallercomponentscanbestoredinwarehouse.

●Allthecomponentsonthesameequipmentneedbecountedatonce,suchas,tubepanel,headers,firepeephole,doorholes,hangerrods,buckstay,steelmemberauxiliaries,etc.

●Allthealloydeviceswillbecarriedoutwithspectroanalysis,withmarksandrecordsasqualifiedthroughinspection,andstoreddividently.

●Defectsfoundintheexaminationofcomponents:

flattening,collision,crack,pinhole,etc;qualityandsizeofweldingjointdoesn’tmeetwiththerequirements;pipeholeandhandholeamountandqualitydoesn’tcomplywiththeregulations;disqualifiedpipeshape,bendingandlength,andunflatpipeopening;thebendingofheadersandbuckstays,etc,surpasstheallowablelimitation;unflatpanelwithexcessivebulksorgrooves;needbecorrected.

●Correctingmethods:

additionalweldingofjoint,polishingofpipeopening,replacingofpipes,hotbending,andsoon.

3.3.3HeaderClean-upandBallPassingTestonPipes

●Theremustbeballpassinginpriortothecombinationofwaterwalltubesandheaders,forwhich1~2minutes’blowingthroughcompressedairneedbeconductedtocleanupinternalashdepositandredundant.Andwatchwhetherfallingitemsexistsornot,asaresultofholedrilling.

●Steelballs（fortypes,refertothefollowing）andcompressedairwithapressureforceof4―6kg/cm2,willbeadopted.Andballpassingoughttobeundergoneinthesequencethatballlaidaftertubeblowing.

PassingBallDiameters（mm）

bendingradius

outsidepipediameter

D1≥60

32＜D1＜60

D1≤32

R≥3.5D1

0.85D0

0.80D0

0.70D0

2.5D1＜R＜3.5D1

0.85D0

0.80D0

0.70D0

1.8D1＜R＜2.5D1

0.75D0

0.75D0

0.70D0

1.4D1＜R＜1.8D1

0.70D0

0.70D0

0.70D0

R＜1.4D1

0.65D0

0.65D0

0.65D0

Note:

DO―insidediameterofpipe（asforinletpipe,D1isactualmeasureddata）/D1―outsidepipediameter/R―bendingradius

●Ballhanding-downwouldbedocumentedandmanaged.Thosetubesalreadypastwithballsshouldbemarkedandsealed,aswellasheaderssealedwithsteelsheetafterheaderclean-upconfirmedqualifiedaftersurveyfromQCpersonalsandconsultants.

●Relevantdocumentsneedbesignedafterballpassingisover,withoutlossofanyone.

●Itcanbeconsideredtouseasteelbrushandrebartoremovetherust,meditationremainant,glassrins,etc,insidetheheaderundernoeffectivenessbycompressedairclean-up.Forthosetubesfailedinballpassing,itwassurposedtofindoutthelocationsandreplacethetubesorshortones.

3.3.4WaterwallAssembly

●Toreducetheman-hourasworkinginh