10万吨裂解炉施工方案

11.工程概况1.1工程简介10万吨/年裂解炉采用中国石化科技开发公司和鲁玛公司联合开发的SL-2型乙烯裂解炉技术,2台合一台。裂解炉结构紧凑，布置严整，炉体框架宽20280mm，长19600mm，高39700mm。炉体下部为辐射段，内装辐射段炉管，悬挂在辐射段上部的吊架上。每台炉底部设有36组燃烧器，侧墙上设有48组燃烧器和窥视孔，端墙上设有窥视孔和人孔。炉体上部为对流段，对流段内部装有七组水平放置的管束，从上往下看分别为：(1)UFP段(2)BFW段(3)LFP段(4)UMP段(5)USSH段(6)LSSH段(7)LMP段对流段端墙由弯头箱封闭，侧墙设有吹灰器，顶部有烟气收集器，烟气经烟道、引风机、烟囱排入大气中。每台炉顶部有一台汽包，急冷锅炉位于辐射段上部，辐射段正上方有六台TLE型急冷换热器，每台急冷换热器由一根上升管和一根下降管与汽包相连，用于废热回收，产生超高压饱和蒸汽。2台裂解炉主要安装工程量见表1-1。裂解炉炉体结构、辅助设备及附件工程量一览表表1-1序号项目规格数量重量(t)备注1钢结构9604802辐射段炉管Φ63.5×6.4/Φ121×6.425-35/35-45/30-3236×224组(120根/台)3对流管束160×27组管束4汽包Φ1650×12880×6435×25风机2台6TLE急冷换热器126台7底部燃烧器72套8侧壁燃烧器96套9看火孔120套10锚固件2台11消喑器2台21.2工程特点裂解炉结构布局紧凑，安装工程量大，施工工序复杂，施工工期短。钢结构、设备、衬里、配管和仪表电气等各专业交叉作业多。钢结构采用螺栓连接，安装精度要求高，作业难度大。对流段采用模块化施工，单组模块吨位大，吊装难度大。炉管系统操作温度高，材质复杂，有低合金钢、不锈钢和高镍合金等，焊接难度大。辐射段炉管直接受火焰加热，支吊架安装质量直接影响其工作寿命，因此辐射段炉管热膨胀平衡系统的安装要求尤其重要。水汽系统为高温高压管道，配管复杂，热应力大，管道支吊架安装要求严。2．施工方法和程序裂解炉施工工艺流程见图3.2-1，施工工序示意图见附图3图4.2.1－1裂解炉施工流程技术工艺文件编制焊接工艺评定试验焊工技能考试对流段墙板保温钉焊接对流段墙板地面衬里对流段模块组对辐射段炉管检验辐射段炉管支、吊架安装急冷锅炉检验集气室地面衬里集气室保温钉焊接汽包检验引风机检验外围系统工艺配管外围工艺系统试压外围工艺系统吹扫工艺系统气密水汽风氮气引进装置燃料气引进装置施工准备裂解炉基础验收、处理辐射段墙板安装辐射段主框架结构安装辐射段平台、梯子安装过渡段钢结构安装对流段模块吊装、找正对流段框架结构安装废热锅炉支撑梁安装辐射段炉管吊装就位急冷锅炉吊装就位烟道安装对流段平台梯子安装、结构完善汽包吊装就位引风机、烟囱吊装就位汽包、风机找正上升管/下降管支、吊架安装上升下降管组焊、检验过热蒸汽管支、吊架安装过热蒸气管组焊、检验热处理硬度检验蒸汽系统水压试验物料系统气压试验系统防腐、保温炉管系统终平衡水汽系统化学清洗烘炉蒸汽吹扫、安全阀调试螺栓热紧烘炉后筑炉质量检查裂解炉工程机械完工施工人员、机具准备辐射段墙板保温钉焊接钢结构预制急冷锅炉找正辐射段炉管调整辐射段炉管组焊、检验横跨管组焊、检验辐射段炉顶板、底板安装辐射段门类安装辐射段、过渡段衬里炉底燃烧器安装人孔封闭风机试运4L2w11施工方案编制/Constructionschemepreparationh2semi-productinspection基础对角线偏差/FoundationDiagonaldeviation弹簧吊架、TLE换热器、汽包等附助设备检验/Fittinginspectionforspringhangers,TLEheatexchangersandsteamdrums钢结构构件外形尺寸检查/Outlinedimensioncheckforsteelstructurecomponents炉管外观检查及焊缝无损探伤检验/Visualinspectionforfurnacetabes.材料、半成品合格证及有关技术资料确认/Confirmationformaterials,Semi-finishedproductscertificateandrelativetechnicalinformation监检点/Detectinypoint基础顶表面标高/Elevationforfoundationtopsurface基础轴线总间距/Totalsparelengthforfoundationaxis12相邻基础轴线间距离/Spacelengthforadjacentfoundationaxises螺栓中心对基础轴线偏差/Deviationbetweenboltcenterandfoundationaxis螺栓垂直度/Boltsverfionlity1110201918螺栓有效高度/Eppectiveheightofbolts89螺栓间距离7监检点/Defectingpoints161715exhaustboiler4施工机具准备焊接工艺评定和焊工技能考试/Qualificationofweldingprocedueandqualificationtestofwelders.现场平面布置/FieldPlatformpreparation561314半成品检验技术交底/TechnicalClarification32图纸会审/DrawingReview废热锅炉/Liftingthesecondpiecesideplateinpositionofradiationsection26吊装第二片辐射段侧墙板就位/Liftingandpositioningthefirstpiecesideplateofradiationsection/Settingoutandweldingforinsulatingbolts/preawangementatplateformforfurnacewallofradiationsution炉墙板和框架钢结构成片组对吊装第一片辐射段侧墙板就位25保温钉放线、焊接2422辐射段炉墙板在平台上放样23监检点/Defectingpoints21/Steelstracturepartsassemblyforthefraneoffurnacewall1718192021W汽包c施工准备12constructurepreparation34567foundationtreatment基础处理fhCaw2L1/LiftingandpositioningsideplateofradiationsectionLfA2A1h1Radiationsectionerection22辐射段安装S231514131211109816辐射段墙板成片安装26252428273029hl2l2l2l2l1l15/Liftingandpositioningthebeamofradiationsection/Physicaldimensionalignmentfortheframeandboxofradiationsection/Liftingandpositioningtheframeofradiationsection/Jointweldingforboxstractureofradiationsection/Theladderplatformandhandrailinstalltionforradiationsection/Boxassemblyatplatformforthefirststagesteelstructureofconrectionsection辐射段箱体结构节点焊接辐射段平台、栏杆和塔体安装对流段第一级钢结构在平台上箱形组对32313028吊装辐射段横梁就位29辐射段炉体和框架找正27吊装辐射段框架就位/Convctionsectionmodelerection对流段模块组装Convectionsectioninstallation31对流段安装323533343637Serviceequipmenterection/Physicaldimensiondignmentfortopsteelstructureofconrectionsection辐射段顶部钢结构节点焊接41/Jointweldingfortopsteelstructureofradiationsection/Physicaldimensioncheckforradiationsection对流段几何尺寸检查3740/Piecesliftingandoverheadassemblyfortopsteelstructureofconrectionsection/Liftingheatingtubesofthefirststageforconrectionsectioninposition吊装第一级对流段炉管就位35依次吊装第二、三、四级对流段炉管就位/Sequentiallingliftingheatingtubesofthesecond,thirdandfourthstageforconrectionsectioninposition36/Physicaldimensioncheck二、三、四级钢结构和炉管在平台上组对连接/Connectingstellstructureofthesecond,thirdandfourthstagewithfurnacetubesatplatform几何尺寸检查34333938辐射段顶部钢结构成片吊装、空中组对辐射段顶部钢结构几何尺寸找正/Physicaldimensioncheckforconrectionsection辐射段几何尺寸检查对流室串砖砌砖结构示意图convectionsectionbrickstructureview辐射段耐火砖砌筑对流段模块安装/Convctionsectionmodelerection②①③4238394041辅助设备安装444543insulaction464748筑炉LMPHSSH6吊装SLE换热器就位吊装IDF引风机就位吊装汽包就位吊装烟囱就位炉体附件安装监检点/Defectingpoints烟道与引风机连接辐射段耐火砖砌筑/Refractorybricklayingforradiationsectionwallwithsticksupportview对流室串砖砌砖结构示意图49refractoryfibresbricksupport4847托砖板4546434442耐火纤维炉墙板wall物料系统气压试验/Pneumatictestforfeedsystem61炉体配管：A.Y型管B.横跨管C.上升管、下降管D.跳跃管/Furnacebodypiping:A.cross-overpipeB.riseranddowncomerC.Y-pipe炉管焊接:A、焊条烘干B、焊口预热C、充氩D、TIG焊接/furacetubewelding:A.weldingelectrodedryingB.craterpreheatingC.ArgonpillingD.TIGwelding55无损检验:A、坡口PT探伤B、第一层焊缝PT探伤C、100%RT探伤/Non-destructivetest:A.PTtesting.B.PTtestingforweldseamofthefirstlayer.C.100%PTtesting焊缝焊后热处理/PWHT(postweldheattreament)forweldingline蒸汽发生系统水压试验/Hydraulictestforsteamoccursystem辐射段炉管调整/Furnacetubeinstallation安装A型、H型和弹簧吊架/HangeroftypeA&Handspringistallation过渡段衬里/Refractorybricklayingfortransitionsection烟