大型储罐制作及安装作业指导书

大型储罐制作及安装作业指导书

Fabrication and Erection of Tank Work Instruction

1 PURPOSE目的

To provide specification and requirement for oil/water tank fabrication.This instruction can act as a direction in making and erecting tanksto ensure the project to complete on time and with good quality.

在于制订罐、水箱制作的规范及要求，作为以后制作及安装的指导，确保工程高质量的按期完工。

2 PROJECT SUMMARIZATION工程概述

2.1 PROJECT ITEMS工程项目

PROJECT ITEMS SCHEDULE

2.2Butt joint (fully melt) will be adopted for annular plates and lap joint for bottom center plates ; butt joint (welding line fully melt) be adopted for shell plates, and lap joint for tank roof, butt joint for every plate part. Roof form is dome roof with rib.

罐底板边缘板采用对接接头（全部熔透），中幅板采取搭接接头；罐壁板采用对接接头（全熔透焊缝）；罐顶板采取搭接接头,每一等分板间采用对接接头。罐顶的结构形式全为带肋拱顶。

2.3The reeling, sand blasting, painting ofsteel plates shall be finished in workshop. Erection, including process of assembly, weld, inspection, testing, thermal insulation and antisepsis, will be done at jobsite erecting location.

钢板的卷制、喷砂、涂漆在车间完成。储罐在现场的安装位置进行安装，现场安装包括组对、焊接、检验、试验、保温、防腐等工序。

3 PROCESS FLOW工艺流程

Process flow chart of oil-tank fabrication and erection:

油罐制作安装工艺流程图：

3.1Workshop prefabrication process flow chart:车间预制的工艺流程图：

Drawings joint checkup--------Received material inspection--------Construction technology

deliver----------laying off and groove process--------- Reeling--------- Sand Blasting---------- Painting and Numbering--------Transported to jobsite

图纸会审-------进厂检验-------施工技术交底------下料及坡口加工--------卷板------喷砂-------涂漆并编号-------运输到现场

3.2Jobsite erection process flow chart:现场安装流程图：

construction preparation---- acceptance of foundation------laying bottom plates-----weld of bottom center plates-----assembly and weld of top plate----- assembly and weld of curb angle----assembly of temporary column for dome roof----assembly and weld of roof plates----assembly and weld of ribs for roof-----erection of hoisting vertical column-----hoisting shell plates----assembly and weld of the subsequent course-----finished weld inspection-----fillet weld shell plates to bottom

plates-----weld shell plates to annular plates----vacuum side leaking of seams on the bottom plates ----acceptance of geometric dimension-----erection of fittings-----erection of stair

platform-----filling water testing----anticorrosion and thermal insulation----acceptance of the finished construction

施工准备-----基础验收-----铺设底板-----中幅板焊接-----最上层壁板装配、焊接------包边角钢组对、焊接-----临时拱顶支柱组装-----罐顶板装配、焊接-----罐顶肋板装配、焊接-----提升立柱安装------提升壁板------装配、焊接下一层壁板-----依次提升组焊其他各层壁板------罐壁焊缝检验------最下层壁板和底板的角焊缝焊接------中幅板与边缘板焊接-----底板焊缝真空测漏

-----罐体几何尺寸验收-----附件安装-----梯子平台安装-----充水试验-----防腐、保温-----竣工验收

4 ERECTIING PROCESS REQUIREMENT安装工序要求

4.1 CONSTRUCTION PREPARATION施工准备

4.1.1Drawings shall be checked up by related personnel. Particular attention shall be paid to checking the general dimension and junctions dimension of tanks. Learn the usage and basic working principle of oil/water tank. Make clear technical standard &requirement and primary construction workload according to the acceptance specification. In the event any misunderstanding or mistake on the drawings is discovered, the problem shall be reported and solved before construction.

熟悉图纸，组织有关人员进行图纸会审。重点审核油罐及水箱的整体尺寸及连接点尺寸，弄

清油罐及水箱用途及基本工作原理，并且对照验收规范，弄清技术标准及要求和主要工程量，图纸设计不清或错误，应及时反映，落实清楚后方可施工。

4.1.2 Organize the related erecting personnel to provide technology delivery. Project summarization, time limit, primary construction workload, primary technology requirements, construction specifications and standards, construction process and methods, the problems to which particular attention shall be paid, key points of the drawings and quality controlling point and safety precautions shall be interpreted.

组织有关安装人员进行技术交底。交代工程概况、施工工期及主要工程量；交代主要技术要求和执行的规程规范及标准；交代施工顺序及施工方法，指出应注意的问题和有关处理方法；指出图纸中的关键之处，指出质量控制点；交代安全注意事项等。

4.1.3Compile tooling material plan and start to stock.编制工装材料计划并备料

4.1.4 Construction equipment & tools and field preparation:施工机具、施工场地准备：

4.1.5Preparation for tools,instruments, auxiliary facilities and safety protecting equipment: Tools and instruments of all types shall comply with the construction & safety requirement and gauges shall be inspected for acceptance. All of the safety facilities and equipment shall comply with appropriate specifications.

工器具量具辅助设施安全防护用品等的准备：各种工器具符合施工及安全要求；各种量具经检验合格；安全设施及安全用品符合安全规定。

4.2Design and fabrication of tooling system工装设计制作

4.2.1Design and fabrication of special equipment for hoisting tank walls

筒壁提升专用工具设计制作。

4.2.2Design and fabrication of special support for shell plates arrangement

壁板放置专用支架设计制作。

4.2.3Design and fabricationof special tooling system for settling tank walls reinforcing rings into place

筒壁加强环就位专用工装设计制作。

4.3 Materials inspection before entering the factory 材料入场检验

4.3.1 Carbon steel plates and sections shall conform to the accepted standards of the countriesin which the tanks are to be fabricated or the steel is to be rolled.

碳钢板和附件应符合储罐的制作和钢板卷制的国家验收标准。

4.3.2 The steel shall contain not more than 0.23% carbon, 0.05% sulphur and 0.05%phosphorus. 钢材中各成分含量C≤0.23%，S≤0.05%，P≤0.05%。

4.3.3 The steel shall have a guaranteed minimum ultimate tensile strength of at least 363

N/mm2and a maximum ultimate tensile strength of not more than 510 N/mm2. The steel shall havea guaranteed yield strength of at least 206 N/mm2. The steel shall have an elongation notless than 22%.

钢材应保证最小极限抗拉强度至少为363N/mm2且最大极限抗拉强度不超过510N/mm2，屈服强度至少为206 N/mm2，不小于22%的延展性。

4.3.4 Tank shell plates and bottom annular plates shall display adequate notch toughness, as shown below:

4.3.5 Mechanical testing机械测试

4.3.

5.1Mechanical testing is not required for roof and bottom plates for which the thickness isdetermined for practical reasons and not by stress considerations.

由于顶部和底部板的厚度由实践理论确定且不考虑压力，因此力学实验对顶部和底部板不要求。

4.3.

5.2For shell plates and for the bottom annular plates, tests shall be made on specimens takenfrom each plate thickness with a frequency of one test per 25 000 kg of steel or partthereof. 对于壳体板和底部环型板，用每25000kg的钢材做一个实验的频率对每一个厚度的板进行抽样实验。

4.3.6 Mill certificates shall show all the properties of materials guaranteed by its specification andany additional requirements.

工厂证明书表明了通过规范及一些附加要求而保证的材料的所有特性。

4.3.7 Structural bolts shall comply with GB 123, grade 8.8.

结构螺栓遵从GB123，8.8级

5罐体预制TANK PREFABRICATION

5.1 TEMPLET PREFABRICATION样板预制

5.1.1 The length of arc templet shall be more than 2.5m.

弧形样板长度应大于2.5m。

5.1.2 Onestraight templet shall be used to test the convex and concave curvature of tank bottom and wall,with length no less than 1m.

直线样板一个：用于检查罐底和罐壁的凸凹度，其长度不小于1米。

5.1.3 Templet shall be made of δ=0.75mm galvanized sheet iron.

样板用δ=0.75mm镀锌铁皮制成。

5.2TANKSBOTTOM PLATE PREFABRICATION罐底板预制

5.2.1 Alignment drawings shall be made according to the design requirements and actual specifications of steel plates before bottom plate prefabrication. Diameter of the plate should be amplified by 0.1%~0.2% of designed diameter (Cone curvature of bottom plate has been taken into consideration).

底板预制前应根据设计要求及实际钢板规格绘制排板图，排板直径宜按设计直径放大

0.1%~0.2%,以补偿底板的焊接收缩（此已考虑了底板的锥度）。

5.2.2According to the alignment drawings, a semiautomatic cutting machine shall be used for cutting plates.The cutting machine can also be used to make groove in arc annular plates.

按照排版图，用半自动切割机进行下料，对于弓形边缘板应用半自动切割机打坡口。

5.2.3 After finished cutting plates, hoist the bottom plate onto an conveyer belt for removing rust. 将下好的底板，吊至抛丸机传送带上，进入抛丸机抛丸除锈。

5.2.4 Blow away dust and iron powder on steel plates after being processed in an by using an

air-compressor.

利用空压机压力风，吹净抛丸后钢板上的尘土及铁粉。

5.2.5 Tank bottom shall be spray painted with zinc-rich epoxy primer by using theairless spray equipment. Dry film thickness shall be 25um.

利用无气喷吐机对罐底喷底漆，底漆为环氧富锌底漆，干膜厚度为25um。

5.2.6 Check of dry film thickness shall comply with GB 50205 CODE FOR ACCEPTANCE OF CONSTRUCTION QUALITY OF STEEL STRUCTURES.Dry film thickness shall be checked with dry film thickness meter. Each component for examining 5 places, everywhere is 3 average value of dry film thickness for mutually being apart from 50 mm measuring points.

干膜厚度的测量遵循GB 50205《钢结构工程施工质量验收规范》。利用干膜测厚仪检查油漆干膜厚度。每个构件检测5处，每处的数值为3个相距50mm测点涂层干漆厚度的平均值。

5.2.7 Painting shall not be permitted in the area of 50mm around the welding line on bottom plate. 底板的现场焊接焊缝周围50mm范围内不允许刷漆。

5.2.8 Bottom plates will be numbered according to alignment drawings after paint has been dried adequately. Numbering method is as following:

Tank number plus erection sequence number.

待油漆充分干燥后，按照排版图对底板进行编号，具体编号方式如下：

储罐编号+安装序号

5.2.9 Bottom plates shall be piled up and transported according to erection sequence after its numbering.

编号完毕后，按照安装顺序摆放、运输。

5.2.10 Inequable clearances shall be adopted for butt joints in arched annular plates. Outboard clearance shall be 6-7mm while inboard clearance shall be 8-12mm.

弓形边缘板的对接接头，宜采用不等间隙。外侧间隙宜为6~7mm；内侧间隙宜为8~12mm。

5.2.11 Width of bottom center plate shall not be less than 1000mm and length shall not be less than 2000mm.

中幅板的宽度不得小于1000mm；长度不得小于2000mm；

5.2.12 Distance between any two adjacent welding lines in bottom plates shall not be less than 200mm.

底板任意相邻焊缝之间的距离，不得小于200mm。

5.2.13 Deviation of dimension tolerance of arched annular plates shall be in accordance with requirements in the following form:

弓形边缘板的尺寸公差允许偏差，应符合下表的规定。

弓形边缘板尺寸允许公差