儲(chǔ)罐預(yù)制方案zxy

1、Storage tank prefabrication procedure for EO/EG Complex1.0 Prefabrication chart & method作業(yè)方法作業(yè)程序 1.1 預(yù)制準(zhǔn)備按照儲(chǔ)罐構(gòu)件預(yù)制流程和加工量進(jìn)行設(shè)備布置、安裝固定。繪制完的排板圖報(bào)JGC/SEI審批。設(shè)備布置安裝設(shè)備安裝固定后接通電源，進(jìn)行調(diào)試、試運(yùn)行，保證正常使用。設(shè)備調(diào)試根據(jù)實(shí)際供貨板材規(guī)格進(jìn)行排版，繪制排版圖。繪制儲(chǔ)罐排板圖儲(chǔ)罐排板圖報(bào)審按照相關(guān)材料的檢查驗(yàn)收標(biāo)準(zhǔn)進(jìn)行檢查或復(fù)驗(yàn)。材料到場(chǎng)檢查復(fù)驗(yàn)1.2 罐底預(yù)制l 罐底板罐底板材料領(lǐng)取按照經(jīng)審批后的排板圖在板材上排板畫線。罐底板排板畫

2、線排版畫線后經(jīng)QA/QC主管人員檢查確認(rèn)。罐底板畫線檢查確認(rèn)在每塊已畫線的罐底板的右下角標(biāo)出底板號(hào)、材質(zhì)證號(hào)等。罐底板編號(hào)標(biāo)識(shí)用等離子或數(shù)控切割機(jī)進(jìn)行切割下料。罐底板切割下料用固定式坡口機(jī)刨削加工罐底板坡口。罐底板坡口加工坡口加工質(zhì)量檢查領(lǐng)取時(shí)填寫材料領(lǐng)取記錄。由SFCC和JGC/SEI的QA/QC主管人員檢查確認(rèn)。l 罐底墊板罐底墊板畫線用剪板機(jī)進(jìn)行切割下料。罐底墊板下料切割固定焊50mm,間斷300mm。短墊板與罐底板點(diǎn)焊按設(shè)計(jì)圖樣進(jìn)行畫線。用等離子切割機(jī)進(jìn)行切割下料。罐底DEG入口接管畫線、切割下料用手工氬弧焊打底、手工電弧焊蓋面。罐底DEG入口接管組對(duì)、焊接用X光機(jī)進(jìn)行射線探傷，II級(jí)

3、合格。由SFCC和JGC/SEI的QA/QC主管人員檢查確認(rèn)。罐底板用等離子切割機(jī)開孔，用手工電弧焊焊接。由SFCC和JGC/SEI的QA/QC主管人員檢查確認(rèn)。罐底DEG入口接管與罐底板組焊質(zhì)量檢查罐底DEG入口接管射線探傷罐底DEG入口接管檢查確認(rèn)罐底DEG入口接管與罐底板組焊（CS罐底板下面防腐）CS需要罐底板防腐。SS罐底板不需要防腐。防腐材料為瀝青漆。由SFCC和JGC/SEI的QA/QC主管人員檢查確認(rèn)。(CS防腐質(zhì)量檢查)l 地腳螺栓支架在預(yù)制平臺(tái)上根據(jù)設(shè)計(jì)圖樣按1:1的比例放樣并制作樣板。地腳螺栓蓋板放樣用樣板在鋼板上畫出罐底蓋板的輪廓線。地腳螺栓蓋板畫線罐底蓋板放樣用剪板機(jī)切

4、割下料。地腳螺栓蓋板切割下料用鉆床將罐底蓋板鉆孔。地腳螺栓蓋板鉆孔由SFCC的QA/QC主管人員檢查確認(rèn)。地腳螺栓蓋板尺寸檢查地腳螺栓筋板放樣用樣板在鋼板上畫出罐底蓋板的輪廓線。在預(yù)制平臺(tái)上根據(jù)設(shè)計(jì)圖樣按1:1的比例放樣并制作樣板。用樣板在鋼板上畫出罐底地腳螺栓筋板的輪廓線。地腳螺栓筋板畫線用剪板機(jī)切割下料。地腳螺栓筋板切割下料由SFCC的QA/QC主管人員檢查確認(rèn)。地腳螺栓筋板尺寸檢查罐底筋板放樣罐底筋板畫線罐底筋板切割下料罐底筋板切割下料地腳螺栓墊板畫線在鋼板上畫出地腳螺栓墊板的輪廓線。用樣板在鋼板上畫出罐底蓋板的輪廓線。用剪板機(jī)切割下料。地腳螺栓墊板切割下料用鉆床將地腳螺栓墊板鉆孔。地腳

5、螺栓墊板鉆孔由SFCC的QA/QC主管人員檢查確認(rèn)。地腳螺栓墊板尺寸檢查在預(yù)制平臺(tái)上根據(jù)設(shè)計(jì)圖樣按1:1的比例放樣并制作樣板。地腳螺栓支架墊板制作樣板罐底筋板畫線用樣板在鋼板上畫出罐壁地腳螺栓支架墊板的輪廓線。地腳螺栓支架墊板畫線罐底筋板切割下料用剪板機(jī)切割下料。由SFCC的QA/QC主管人員檢查確認(rèn)。預(yù)制場(chǎng)設(shè)備布置罐底筋板切割下料地腳螺栓支架墊板切割下料地腳螺栓支架墊板尺寸檢查按照?qǐng)D樣尺寸分段畫出罐基礎(chǔ)防雨罩的輪廓線。罐基礎(chǔ)防雨罩畫線用等離子或數(shù)控切割機(jī)進(jìn)行切割下料。罐基礎(chǔ)防雨罩切割下料l 包裝運(yùn)輸罐底預(yù)制件運(yùn)往現(xiàn)場(chǎng)罐底預(yù)制件包裝用10T卡車將預(yù)制件運(yùn)往EO-EG現(xiàn)場(chǎng)。按照罐底預(yù)制件編號(hào)順序

6、分組包裝。 1.2 罐頂預(yù)制l 罐頂板 制作罐頂板支撐胎架領(lǐng)取時(shí)填寫材料領(lǐng)取記錄。罐頂板材料領(lǐng)取在每塊已畫線的罐頂板的右下角標(biāo)出板號(hào)、材質(zhì)證號(hào)等。排版畫線后經(jīng)QA/QC主管人員檢查確認(rèn)。按照經(jīng)審批后的排板圖在板材上排版畫線。罐頂板畫線檢查確認(rèn)罐頂板排板畫線用等離子或數(shù)控切割機(jī)進(jìn)行切割下料。用手持砂輪機(jī)打磨切割面。由SFCC和JGC/SEI的QA/QC主管人員檢查確認(rèn)。用滾板機(jī)將罐頂板滾弧成型。由SFCC和JGC/SEI的QA/QC主管人員檢查確認(rèn)。滾弧成型形狀尺寸檢查 罐頂板滾弧成型 下料形狀尺寸檢查 罐頂板切割面打磨罐頂板下料切割罐頂板編號(hào)標(biāo)識(shí)用鋼管、型鋼和鋼板制作罐頂板支撐胎架。l 罐頂墊

7、板按圖樣尺寸畫線，用等離子或數(shù)控切割機(jī)進(jìn)行切割下料。用滾板機(jī)將罐頂墊板滾弧成型。罐頂墊板滾弧成型罐頂墊板下料切割用行車或汽車吊（8t）將罐頂板放在支撐胎具上。在支撐胎具上將罐頂墊板與罐頂板焊接在一起。將罐頂板放在支撐胎具上罐頂墊板與罐頂板焊接l 罐頂工字鋼罐頂工字鋼畫線用火焰割具進(jìn)行切割下料。用型鋼煨彎?rùn)C(jī)將罐頂工字鋼煨成圓弧型（外委加工）。用手持砂輪機(jī)修磨罐頂工字鋼端口。罐頂工字鋼修磨端口由SFCC和JGC/SEI的QA/QC主管人員檢查確認(rèn)。罐頂工字鋼形狀檢查罐頂工字鋼切割下料罐頂工字鋼滾弧成型按照?qǐng)D樣展開弧長(zhǎng)畫罐頂工字鋼切割線。按照?qǐng)D樣展開弧長(zhǎng)畫錐頂切割線。用等離子或數(shù)控切割機(jī)切割下料。用

8、壓力機(jī)或千斤頂將下料的鋼板壓制成型。罐頂?shù)腻F頂號(hào)料畫線罐頂?shù)腻F頂切割下料罐頂?shù)腻F頂制作l 罐頂環(huán)板用刨邊機(jī)加工環(huán)板坡口。按照?qǐng)D樣展開直徑畫罐頂環(huán)板圓周切割線。用火焰割具和數(shù)控機(jī)床進(jìn)行切割下料。用壓力機(jī)床將罐頂環(huán)板壓制成型（外委加工）。由SFCC和JGC/SEI的QA/QC主管人員檢查確認(rèn)。罐頂環(huán)板成型檢查罐頂環(huán)板加工坡口罐頂環(huán)板沖壓成型罐頂環(huán)板切割下料罐頂環(huán)板號(hào)料畫線l 罐頂筒體用數(shù)控機(jī)床進(jìn)行切割下料。按照?qǐng)D樣展開周長(zhǎng)畫罐頂筒體切割線。用刨床加工筒體板對(duì)接處的坡口。用滾板機(jī)將筒體板滾圓成型。罐頂筒體板滾圓成型罐頂筒體加工坡口罐頂筒體切割下料罐頂筒體號(hào)料畫線罐頂筒體成型焊接用手工電弧焊焊接滾制成

9、型的罐頂筒體縱縫。l 罐頂筋板按照?qǐng)D樣展開弧長(zhǎng)畫罐筋板切割線，用火焰割具切割。用滾板機(jī)將筋板滾弧成型。罐頂筋板滾弧成型罐頂筋板號(hào)線下料l 包裝運(yùn)輸按照罐頂預(yù)制件編號(hào)順序分組包裝。罐頂預(yù)制件運(yùn)往現(xiàn)場(chǎng)罐頂預(yù)制件包裝用10T卡車將罐頂預(yù)制件運(yùn)往EO-EG現(xiàn)場(chǎng)。1.3 罐壁預(yù)制l 罐壁板頂圈壁板對(duì)口處削?。ㄈ绻枰┯门龠厵C(jī)將頂圈壁板對(duì)口處削薄。用刨邊機(jī)加工罐壁板坡口。由SFCC和JGC/SEI的QA/QC主管人員檢查確認(rèn)。用等離子或數(shù)控切割機(jī)進(jìn)行切割下料。在每塊已畫線的罐壁板的右下角標(biāo)出板號(hào)、材質(zhì)證號(hào)等。排板畫線后經(jīng)SFCC的QA/QC主管人員檢查確認(rèn)。按照經(jīng)審批后的排板圖在板材上排板畫線。領(lǐng)取時(shí)填

10、寫材料領(lǐng)取記錄。用鋼管、型鋼和鋼板制作罐壁板支撐胎架。罐壁板材料領(lǐng)取罐壁板編號(hào)標(biāo)識(shí)罐壁板畫線檢查確認(rèn)罐壁板排板畫線罐壁板下料切割制作罐壁板支撐胎架罐壁板坡口加工坡口加工質(zhì)量檢查用滾板機(jī)將罐壁板滾壓成設(shè)計(jì)圖樣規(guī)定的圓弧形。罐壁板滾弧成型由SFCC和JGC/SEI的QA/QC主管人員檢查確認(rèn)。罐壁板滾弧成型質(zhì)量檢查l 罐壁筋板用鐵皮制作罐壁筋板樣板。在預(yù)制平臺(tái)上根據(jù)設(shè)計(jì)圖樣按1:1的比例放樣。罐壁筋板放樣制作罐壁筋板樣板用樣板在鋼板上畫出罐壁筋板的輪廓線。用剪板機(jī)切割下料。由SFCC的QA/QC主管人員檢查確認(rèn)。罐壁筋板樣板檢查確認(rèn)罐壁筋板畫線罐壁筋板切割下料罐壁筋板形狀尺寸檢查由SFCC的QA/

11、QC主管人員檢查確認(rèn)。l 罐壁加強(qiáng)板按照?qǐng)D樣分段畫出加強(qiáng)板輪廓線。用等離子或數(shù)控切割機(jī)切割下料。用手持砂輪機(jī)在切割處打磨。罐壁加強(qiáng)板下料切割罐壁加強(qiáng)板切割處打磨罐壁加強(qiáng)板畫線用刨邊機(jī)加工坡口。加工加強(qiáng)板對(duì)接處坡口l 罐壁連接板用樣板在鋼板上畫出罐壁連接板的輪廓線。用等離子或數(shù)控切割機(jī)切割下料。用刨邊機(jī)或手持砂輪機(jī)加工坡口。用滾板機(jī)將罐壁連接板分段滾弧成型。由SFCC和JGC/SEI的QA/QC主管人員檢查確認(rèn)。罐壁連接板放樣罐壁連接板畫線罐壁連接板分段切割下料罐壁連接板對(duì)接處坡口加工罐壁連接板分段滾弧成型罐壁連接板成型尺寸檢查在預(yù)制平臺(tái)上根據(jù)設(shè)計(jì)圖樣按1:1的比例放樣并制作樣板。l 罐壁擋板按

12、照?qǐng)D樣畫出罐壁擋板輪廓線。用剪板機(jī)切割下料。由SFCC的QA/QC主管人員檢查確認(rèn)。罐壁擋板畫線罐壁擋板切割下料罐壁擋板尺寸檢查l 包裝運(yùn)輸用10T卡車將罐壁預(yù)制件運(yùn)往EO-EG現(xiàn)場(chǎng)。按照罐壁預(yù)制件編號(hào)順序分組包裝。罐壁預(yù)制件運(yùn)往現(xiàn)場(chǎng)罐壁預(yù)制件包裝1.4 其它附件預(yù)制l 罐體管口領(lǐng)取時(shí)填寫材料領(lǐng)取記錄。領(lǐng)取罐體接管、法蘭按照?qǐng)D樣尺寸畫出罐體接管切割線。用等離子或數(shù)控切割機(jī)切割下料。罐體接管畫線罐體接管切割下料罐體接管切割下料罐體接管畫線用氬弧焊打底，手工電弧焊蓋面。法蘭與接管焊接罐體接管切割下料由SFCC和JGC/SEI的QA/QC主管人員檢查確認(rèn)。罐體接管尺寸檢查罐體接管尺寸檢查l 罐體補(bǔ)強(qiáng)

13、圈罐體補(bǔ)強(qiáng)圈加工信號(hào)孔罐體補(bǔ)強(qiáng)圈尺寸檢查罐體補(bǔ)強(qiáng)圈尺寸檢查罐體補(bǔ)強(qiáng)圈畫線罐體補(bǔ)強(qiáng)圈畫線罐體補(bǔ)強(qiáng)圈切割下料罐體補(bǔ)強(qiáng)圈切割下料罐體補(bǔ)強(qiáng)圈加工信號(hào)孔由SFCC的QA/QC主管人員檢查確認(rèn)。按照?qǐng)D樣畫出罐體補(bǔ)強(qiáng)圈輪廓線。用等離子或數(shù)控切割機(jī)切割下料。用鉆床加工罐體補(bǔ)強(qiáng)圈信號(hào)孔。l 雷達(dá)液位計(jì) Radar liquidometerAccording to draft dimension draw the incision line length.Joint pipe lineationCut and lay off with digitally controlled/ plasma cutting ma

14、chine Long hole machining with milling machine（machining out）。Joint pipe long hole machiningAccording to draft dimension draw the incision line length.Joint pipe block board lineationCut and lay off with digitally controlled/ plasma cutting machine According to draft dimension draw the incision line

15、 length.Cut and lay off with digitally controlled/ plasma cutting machine According design drawing on fabrication plant。Orientation bushing wimble part set sampleJoint pipe cut and lay off雷達(dá)液位計(jì)接管長(zhǎng)圓孔加工雷達(dá)液位計(jì)接管堵板畫線雷達(dá)液位計(jì)接管切割下料Weld with SMAW。Block board and joint pipe weld雷達(dá)液位計(jì)定位接管畫線Orientation bushing l

16、ineation雷達(dá)液位計(jì)定位接管切割下料Orientation bushing cut and lay off雷達(dá)液位計(jì)定位接管錐段放樣雷達(dá)液位計(jì)接管堵板切割下料Block board cut and lay off雷達(dá)液位計(jì)接管堵板與接管焊接According to draft dimension to draw outlineOrientation bushing wimble part lineationCut and lay off with digitally controlled/ plasma cutting machine Orientation bushing wimble

17、 part cut and lay offwimble part and bushing weldQA/Qc of SFCC governor inspectionOrientation bushing size inspectionAccording to draft dimension to draw outlineTank bottom orientation underlay lineationCut and lay off with digitally controlled/ plasma cutting machine Tank bottom orientation underla

18、y cut and lay offAccording to draft dimension draw the incision line length.Orientation bushing lug tendon lineationCut and lay off with plasma cutting machine Orientation bushing lug tendon cut and lay offAccording to draft dimension draw the incision line length.Cut and lay off with plasma cutting

19、 machine Orientation bushing Flat steel cut and lay offWeld with SMAW。Orientation bushing flat steel lineationl Nozzle joint pipeAccording to draft dimension draw the incision line length.Central pipe lineationCut and lay off with digitally controlled/ plasma cutting machine Central pipe cut and lay

20、 offDrilling hole with drill press。QA/Qc of SFCC and JGC/SEI governor inspectionCentral pipe size inspectionAccording to draft dimension draw the incision line length.Cut and lay off with digitally controlled/ plasma cutting machine Nozzle cut and lay offQA/Qc of SFCC and JGC/SEI governor inspection

21、Nozzle size inspectionWeld with MMAW。Nozzle and central pipe weldFill in material draw note at draw。tee joint and flange drawAccording to draft dimension draw the incision line length.Short pipe lineationCentral pipe drill holeNozzle lineation Cut and lay off with digitally controlled/ plasma cuttin

22、g machine Short pipe cut and lay offCentral pipe、tee joint、short pipe and inner flange weldWeld with MMAWQA/Qc of SFCC and JGC/SEI governor inspectionaspect、geometry size inspection l Nozzle enter material pipeAccording to draft dimension draw the incision line length.Nozzle pipe lineationCut and la

23、y off with plasma cutting machineNozzle pipe cut and lay offQA/Qc of SFCC governor inspectionNozzle pipe geometry size inspectionFill in material draw note at draw。Flange drawWeld with MMAWNozzle pipe and flange weldaspect、geometry size inspectionQA/Qc of SFCC and JGC/SEI governor inspectionl Nozzle

24、 bracketAccording to draft dimension draw the incision line length.Nozzle bracket angle steel lineationCut and lay off with plasma cutting machineNozzle bracket angle steel cut and lay offAccording to draft dimension draw the incision line length.Nozzle bracket lug tendon lineationCut and lay off wi

25、th plasma cutting machine Nozzle bracket lug tendon cut and lay off According to draft dimension to draw underlay plate outlineNozzle bracket underlay lineationCut and lay off with digitally controlled/ plasma cutting machine Nozzle bracket underlay cut and lay offNozzle bracket underlay drillDrill

26、U-type bolt hole with drill press。Welding with MMAW Nozzle bracket underlay and angle iron、lug tendon weldQA/Qc of SFCC and JGC/SEI governor inspectionaspect、geometry size inspectionl Packaging and Transportation按照其它預(yù)制件編號(hào)順序分組包裝。Other componetss package用10T卡車將其它預(yù)制件運(yùn)往EO-EG現(xiàn)場(chǎng)。Other prefabrication parts

27、 are transported to field1.5 Tank roof plant and handrail l Prepare prefabricationFill in record when draw the material.Draw materialsMaterial sandblast and paintAll CS material need sandblast,then paint two times.l PlantPlant edge angle iron lineationAccording to draft dimension draw the incision l

28、ine at plant angle iron length.Use blaze incise tool laying off materialFlat edge angle iron incise and laying off materialUse plate roller shape the plat edge angle ironFlat edge angle iron roll and shapedQA/Qc of SFCC governor inspection and affirmFlat edge angle iron roll and shaped inspection平臺(tái)邊

29、緣角鋼成型檢查On flat roof former on 1:1pro rata according to designFlat plank and make formerFabricate flat plank and make formerUse sheet iron to make flat plank and formerUse former to draw subsection outline Flat plank and draw subsectionUse numerical control incise machine to lay off Flat plank subsec

30、tion incise and lay off materialQA/Qc of SFCC governor inspection and affirmFlat plank dimension inspection l SupporterAccording to draft dimension to draw underlay plate outlineUnderlay plate drawUse cutting machine to incise and lay offUnderlay plates incise and lay offQA/Qc of SFCC governor inspe

31、ction and affirmUnderlay dimension inspectionDraw rib plates figure according to draft。Rib plates drawUse cutting machine to incise and lay offRib plates incise and lay offRib plates size inspectionQA/Qc of SFCC governor inspection and affirmSupport angle iron drawAccording to draft dimension draw t

32、he incision line at support angle iron length.Use blaze cuttin tool laying off materialSupport angle iron cut and lay offQA/Qc of SFCC governor inspection.Support angle iron size inspectionWith MMAWWelding of Support angle iron, underlay plate and rib plateQA/Qc of SFCC governor inspection.aspect、ge

33、ometry size inspectionl Baluster According to draft dimension draw the incision line at stand pole length.Stand pole drawUse blaze cuttin tool laying off materialStand pole cut and lay offQA/Qc of SFCC governor inspection.Stand pole size inspectionhandrail、block waist and feet board rollUse plate ro

34、ller shape the plat edge angle ironhandrail、block waist and feet board roll inspectionQA/Qc of SFCC governor inspection.l package & transportationTank tip roof、baluster fabrication components packageWith 10t lorryTank tip roof、baluster fabrication components carried out fieldremark：1 The 50t crane is used for arrive material unload、be out of luck and load/unload of heavy packaging box.2 All CS material must be dealed with face sand blasted before use.3 Handrail of baluster only roll in fabrication field, length do not ensured, According fact requirement to