仪表施工方案方案

编号：15-06部-Stepan-SHF-601The50,000t/apolyesterpolyolprojectofStepan(Nanjing)ChemicalCo.,Ltd.斯泰潘（南京）5万吨/年聚酯多元醇项目仪表施工方案InstrumentConstructionPlan编制Prepareby：安全Securityby：审核Reviewby：批准Approveby：NanjingChemicalConstructionCo.,Lid南京南化建设有限公司13.Mar.20152of54目录Contents第一章工程概况GENERAL……………………………………….……3第二章：编制依据CHAPTER2-REFERENCE..................................3第三章：仪表实物工作量CHAPTER3-INSTRUMENTQUANTITYOFWORK..................................................................................................3第四章：施工的主要程序CHAPTER4-MAINCONSTRUCTIONPROCEDURE............................................................................................4第五章：主要施工方法和技术要求CHAPTER5-CONSTRUCTIONTECHNICALREQUIRESANDQUALITYSTANDARD...................7第六章：质量控制和检、试验计划CHAPTER6-QUALITYCONTROLANDINSPECTIONTESTPLAN.....................................29第七章：主要施工机具CHAPTER7--MANPOWER.......................34第八章：劳动力组织CHAPTER8-LABORORGANIZATION…...34第九章：施工进度计划CHAPTER9-CONSTRUCTIONPROGRESSSCHEDULE……………………………………………………………..35第十章：安全保证措施、JHA及文明施工CHAPTERFIVESAFETYASSURANCESYSTEM,JHAANDHOUSEKEEPING....................373of54第一章：工程概况Chapter1-General本工程为斯泰潘（南京）化学有限公司新建5万吨/年聚酯多元醇项目，工程范围主要包括：行政办公和电控楼，空压站、门卫和称重，焚烧炉，冷却水系统，消防泵房，事故水池，工艺装置区，仓储区等。ThisisanexpansionprojectofBASF-YPCCompanyLimited,themanagementteamisIET,TARworkinvolvedinarea1mainlyincludesexistinginstrumentexchanges,remove,andresetting,newinstrumentinstallation,cabletraylayingandcablepulling.仪表种类主要有：控制阀、开关阀、流量计、差压变送器、压力变送器、温度变送器、、分析仪表、气体检测仪等仪表。Variousinstrumentscoveredlikecontrolvalve,on-offvalve,integratedflowmeter,DPtransmitter,pressureandtemperaturetransmitter,forkliquidlevelswitchandtoxicgasdetector.第二章：编制依据Chapter2-Reference招标文件《自动化仪表工程施工及质量验收规范》GB50093-2013Chineseinstrumentconstructionworkcode.《石油化工仪表工程施工技术规程》SH3521-2007Petrochemicalinstrumentconstructionworkcode.《电气和仪表回路检验规范》GB/T25921-2010《自控安装图册》HG/T21581-2010《电气装置安装工程爆炸和火灾危险环境施工及验收规范》GB50257-96《建筑工程施工现场供用电安全规范》（GB50194-93）；PowerSupplyandUtilitySafetyRegulationsonConstructionEngineeringSiteGB50194-93《建设工程安全管理条例》第三章：仪表实物工作量Chapter3-Instrumentquantityofwork名称单位数量名称单位数量温度仪表台36调节阀台18压力变送器台24过程开关台86差压变送器台2分析仪表台5差压液位变送器台15有毒气体检测仪台2液位仪表台16仪表电缆米39666流量仪表台29桥架米2122开关阀台51仪表管路米11474of54施工前准备preparationbeforeconstruction盘柜及底座制作安装cabinetfabricationandinstallation第四章：施工的主要程序Chapter4-Mainconstructionprocedure1.主要施工程序流程图预埋管、件安装embeddedpipe,fittingsinstallation电缆保护管安装Cableprotectionpipeinstallation管线上仪表拆除、隔离阀关闭DismantlethepipelineInstrument,isolationvalveclosed现场仪表二次安装Secondaryfieldinstrumentationinstallation配合单体试车singlecommissioning设计交底designdisclosure电缆敷设cablelaying系统联校systemjointcalibration导压管、气源管、伴热管安装Impulsecontrol,airsupplypipe,heatingpipeinstallation试压、试漏Pressuretesting,leaktesting现场仪表安装siteinstrumentinstallation校、接线calibration,wiring桥架、就地盘柜接线箱安装tray,cabinetwiringboxonsiteinstallation配合工艺一次部件安装Withtheinstallationprocessoncepart支托架立柱预制安装Supportbracketcolumninstallationofprefabricated交工验收acceptance仪表单校Instrumentsinglecalibration领、检设备材料receive,checkequipmentandmaterials仪表导压管试压Instrumentguidepressurepipepressuretest图纸会审jointreviewofdrawings5of542．.准备工作Preparation1）组织施工有关人员进行交底，充分做好施工图会审工作，及时解决图纸中发现的问题，从而为施工阶段争取时间。OrganizetechnicalclarificationandDWGreview,problemsexistinginDWGsshallbequicklysolvedtogainmoretimeforTAR.2）根据设计图和有关资料编制好设备材料表和有关施工资料，熟悉设计的规范、标准、设计图纸以及有关的操作说明等资料。PreparemateriallistandrelatedconstructiondocumentsasperdesignedDWGandrelativedocuments.Befamiliarwithcodes,standards,DWGsandguidelines.3）熟悉施工有关的资料及图纸，了解现有仪表的原理及接线柜位置。BeacknowledgeablewithconstructionrelateddocumentsandDWGs,beclearwithexistinginstrumentphilosophyandjunctionboxlocation.4）对施工班、组进行全面系统的技术交底，上岗人员能熟悉图纸，明确施工任务和施工要点，规范及特殊要求。Technicalclarificationtoconstructionteamshallbecompleteandsystematic,makesureconstructionpersonnelarefamiliarwitDWGs,workcontentandrequirements.5）及时了解设备、材料到货情况，设备到货时，一定要根据厂家提供的装箱单、技术资料，会同业主、监理单位开箱检验，核实仪表设备材料的规格，型号及数量是否符合设计要求，并做好记录，并在干燥清洁的条件下妥善保管。Beclearwithmaterialandequipmentstatus,open-boxinspectionjointlywithIETandBYCasperpackinglistandtechnicaldocumentsprovidedbymanufacturer,checkifequipmentandmaterialspecification,typeandquantityaresatisfied,andrecordmade,allequipmentsandmaterialsreceivedshallbewellkept.6）准备好干燥清洁的房间，作为调校室，环境应符合要求。班组要检查机具是否完好，检验期是否有效，校验仪表的等级是否符合要求。Acleanroomwillbepreparedtobeascalibrationroomwhichshallcomplywithenvironmentalrequirements.Machinesandtoolsshallbecheckedwithcompletenessandexpiresbythegroupandinstrumentshallbecheckedwithitsgrades.7)施工机具的准备。Preparationonconstructionmachinesandtools(1)根据图纸及工作量准备各种施工工具；PreparevariousconstructionmachinesandtoolsasperDWGandworkquantity.6of54(2)现场严禁使用活动扳手，需要按照仪表规格书、安装图、管道ISOMETRICS图准备同规格的套筒、梅花、开口扳手等。Movablewrenchisnotallowedtobeusedonsite,sleevesandopen-endwrenchshallbepreparedasperthespecificationprovidedinspecification,hook-ups,andpipeisometrics.2．施工前期1）仪表安装受装置作业、工艺设备、工艺管道、土建等专业的现场条件限制，不宜提前进行，但一些安装可在前期完成或部分完成。如：SiteconditionslimitadvanceconstructionofTARinstrumenterectionconsideringplantoperation,processequipment&piping,civil,however,someinstallationcanbefinishedatpre-TARorpartiallyfinished.(1)仪表单体调校，阀门