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StoragetankprefabricationprocedureforEO/EGComplex
1.0Prefabricationchartmethod
1.1预制准备
1.2罐底预制罐底板罐底垫板地脚螺栓支架包装运输
1.2罐顶预制罐顶板罐顶垫板罐顶工字钢罐顶环板罐顶筒体罐顶筋板包装运输
1.3罐壁预制罐壁板罐壁筋板罐壁加强板罐壁连接板罐壁挡板包装运输
1.4其它附件预制罐体管口罐体补强圈雷达液位计RadarliquidometerNozzlejointpipeNozzleentermaterialpipeNozzlebracketPackagingandTransportation
1.5TankroofplantandhandrailPrepareprefabricationPlantSupporterBalusterpackagetransportationremark1.The50tcraneisusedforarrivematerialunload、beoutofluckandload/unloadofheavypackagingbox.2.AllCSmaterialmustbedealedwithfacesandblastedbeforeuse.3.HandrailofbalusteronlyrollinfabricationfieldlengthdonotensuredAccordingfactrequirementtocutwhenfieldinstallation.4.BlockwaistandfeetboardofbalusteradoptflatsteelrolledinfabricationfieldonlylengthdonotensuredAccordingfactrequirementtocutwhenfieldinstallation.5.UpwardsprocedureiscurrencyprocedureofEO-EGtankfarmstoragetankfabricationdifferentstoragetankfabricationprocedureaccordingtoeachstructurecharacteristic.
2.0PlanelayoffabricationfieldPlanelayoffabricationfieldseefollowing“planelaydrawingoffabricationfield”.
3.0Machineandequipmentresourceplanplasmacuttingmachine1set;digitallycontrolledcuttingmachine1set;Oxygen-ethinecuttingtool2sets;Oxygenbottle4sets;Ethinebottle4sets;Edgeplaner1set;Manualgrindingmachine4sets;rollingmachine1set;drillpress1set;argonweldingmachine1set;Handcraftarcweldingmachine4sets;Travelingcrane2sets;10Tlorry1set;25Tcrane1set;50Tcrane1set
4.0ManpowerplanManager6people;Reveter15people;Electricweldingworker6people;Gasweldingworker2people;Electrician1people;Liftingworker2people;Decorator4people;Forceworker8people
5.0Storagetankfabricationschedule作业方法作业程序按照储罐构件预制流程和加工量进行设备布置、安装固定绘制完的排板图报JGC/SEI审批设备布置安装设备安装固定后接通电源,进行调试、试运行,保证正常使用设备调试根据实际供货板材规格进行排版,绘制排版图绘制储罐排板图储罐排板图报审按照相关材料的检查验收标准进行检查或复验材料到场检查复验罐底板材料领取按照经审批后的排板图在板材上排板画线罐底板排板画线排版画线后经QA/QC主管人员检查确认罐底板画线检查确认在每块已画线的罐底板的右下角标出底板号、材质证号等罐底板编号标识用等离子或数控切割机进行切割下料罐底板切割下料用固定式坡口机刨削加工罐底板坡口罐底板坡口加工坡口加工质量检查领取时填写材料领取记录由SFCC和JGC/SEI的QA/QC主管人员检查确认罐底垫板画线用剪板机进行切割下料罐底垫板下料切割固定焊50mm间断300mm短垫板与罐底板点焊按设计图样进行画线用等离子切割机进行切割下料罐底DEG入口接管画线、切割下料用手工氩弧焊打底、手工电弧焊盖面罐底DEG入口接管组对、焊接用X光机进行射线探伤,II级合格由SFCC和JGC/SEI的QA/QC主管人员检查确认罐底板用等离子切割机开孔,用手工电弧焊焊接由SFCC和JGC/SEI的QA/QC主管人员检查确认罐底DEG入口接管与罐底板组焊质量检查罐底DEG入口接管射线探伤罐底DEG入口接管检查确认罐底DEG入口接管与罐底板组焊(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为沥青漆由SFCC和JGC/SEI的QA/QC主管人员检查确认CS防腐质量检查在预制平台上根据设计图样按1:1的比例放样并制作样板地脚螺栓盖板放样用样板在钢板上画出罐底盖板的轮廓线地脚螺栓盖板画线罐底盖板放样用剪板机切割下料地脚螺栓盖板切割下料用钻床将罐底盖板钻孔地脚螺栓盖板钻孔由SFCC的QA/QC主管人员检查确认地脚螺栓盖板尺寸检查地脚螺栓筋板放样用样板在钢板上画出罐底盖板的轮廓线在预制平台上根据设计图样按1:1的比例放样并制作样板用样板在钢板上画出罐底地脚螺栓筋板的轮廓线地脚螺栓筋板画线用剪板机切割下料地脚螺栓筋板切割下料由SFCC的QA/QC主管人员检查确认地脚螺栓筋板尺寸检查罐底筋板放样罐底筋板画线罐底筋板切割下料罐底筋板切割下料地脚螺栓垫板画线在钢板上画出地脚螺栓垫板的轮廓线用样板在钢板上画出罐底盖板的轮廓线用剪板机切割下料地脚螺栓垫板切割下料用钻床将地脚螺栓垫板钻孔地脚螺栓垫板钻孔由SFCC的QA/QC主管人员检查确认地脚螺栓垫板尺寸检查在预制平台上根据设计图样按1:1的比例放样并制作样板地脚螺栓支架垫板制作样板罐底筋板画线用样板在钢板上画出罐壁地脚螺栓支架垫板的轮廓线地脚螺栓支架垫板画线罐底筋板切割下料用剪板机切割下料由SFCC的QA/QC主管人员检查确认预制场设备布置罐底筋板切割下料地脚螺栓支架垫板切割下料地脚螺栓支架垫板尺寸检查按照图样尺寸分段画出罐基础防雨罩的轮廓线罐基础防雨罩画线用等离子或数控切割机进行切割下料罐基础防雨罩切割下料罐底预制件运往现场罐底预制件包装用10T卡车将预制件运往EO-EG现场按照罐底预制件编号顺序分组包装制作罐顶板支撑胎架领取时填写材料领取记录罐顶板材料领取在每块已画线的罐顶板的右下角标出板号、材质证号等排版画线后经QA/QC主管人员检查确认按照经审批后的排板图在板材上排版画线罐顶板画线检查确认罐顶板排板画线用等离子或数控切割机进行切割下料用手持砂轮机打磨切割面由SFCC和JGC/SEI的QA/QC主管人员检查确认用滚板机将罐顶板滚弧成型由SFCC和JGC/SEI的QA/QC主管人员检查确认滚弧成型形状尺寸检查罐顶板滚弧成型下料形状尺寸检查罐顶板切割面打磨罐顶板下料切割罐顶板编号标识用钢管、型钢和钢板制作罐顶板支撑胎架按图样尺寸画线,用等离子或数控切割机进行切割下料用滚板机将罐顶垫板滚弧成型罐顶垫板滚弧成型罐顶垫板下料切割用行车或汽车吊(8t)将罐顶板放在支撑胎具上在支撑胎具上将罐顶垫板与罐顶板焊接在一起将罐顶板放在支撑胎具上罐顶垫板与罐顶板焊接罐顶工字钢画线用火焰割具进行切割下料用型钢煨弯机将罐顶工字钢煨成圆弧型(外委加工)用手持砂轮机修磨罐顶工字钢端口罐顶工字钢修磨端口由SFCC和JGC/SEI的QA/QC主管人员检查确认罐顶工字钢形状检查罐顶工字钢切割下料罐顶工字钢滚弧成型按照图样展开弧长画罐顶工字钢切割线按照图样展开弧长画锥顶切割线用等离子或数控切割机切割下料用压力机或千斤顶将下料的钢板压制成型罐顶的锥顶号料画线罐顶的锥顶切割下料罐顶的锥顶制作用刨边机加工环板坡口按照图样展开直径画罐顶环板圆周切割线用火焰割具和数控机床进行切割下料用压力机床将罐顶环板压制成型(外委加工)由SFCC和JGC/SEI的QA/QC主管人员检查确认罐顶环板成型检查罐顶环板加工坡口罐顶环板冲压成型罐顶环板切割下料罐顶环板号料画线用数控机床进行切割下料按照图样展开周长画罐顶筒体切割线用刨床加工筒体板对接处的坡口用滚板机将筒体板滚圆成型罐顶筒体板滚圆成型罐顶筒体加工坡口罐顶筒体切割下料罐顶筒体号料画线罐顶筒体成型焊接用手工电弧焊焊接滚制成型的罐顶筒体纵缝按照图样展开弧长画罐筋板切割线,用火焰割具切割用滚板机将筋板滚弧成型罐顶筋板滚弧成型罐顶筋板号线下料按照罐顶预制件编号顺序分组包装罐顶预制件运往现场罐顶预制件包装用10T卡车将罐顶预制件运往EO-EG现场顶圈壁板对口处削薄(如果需要)用刨边机将顶圈壁板对口处削薄用刨边机加工罐壁板坡口由SFCC和JGC/SEI的QA/QC主管人员检查确认用等离子或数控切割机进行切割下料在每块已画线的罐壁板的右下角标出板号、材质证号等排板画线后经SFCC的QA/QC主管人员检查确认按照经审批后的排板图在板材上排板画线领取时填写材料领取记录用钢管、型钢和钢板制作罐壁板支撑胎架罐壁板材料领取罐壁板编号标识罐壁板画线检查确认罐壁板排板画线罐壁板下料切割制作罐壁板支撑胎架罐壁板坡口加工坡口加工质量检查用滚板机将罐壁板滚压成设计图样规定的圆弧形罐壁板滚弧成型由SFCC和JGC/SEI的QA/QC主管人员检查确认罐壁板滚弧成型质量检查用铁皮制作罐壁筋板样板在预制平台上根据设计图样按1:1的比例放样罐壁筋板放样制作罐壁筋板样板用样板在钢板上画出罐壁筋板的轮廓线用剪板机切割下料由SFCC的QA/QC主管人员检查确认罐壁筋板样板检查确认罐壁筋板画线罐壁筋板切割下料罐壁筋板形状尺寸检查由SFCC的QA/QC主管人员检查确认按照图样分段画出加强板轮廓线用等离子或数控切割机切割下料用手持砂轮机在切割处打磨罐壁加强板下料切割罐壁加强板切割处打磨罐壁加强板画线用刨边机加工坡口加工加强板对接处坡口用样板在钢板上画出罐壁连接板的轮廓线用等离子或数控切割机切割下料用刨边机或手持砂轮机加工坡口用滚板机将罐壁连接板分段滚弧成型由SFCC和JGC/SEI的QA/QC主管人员检查确认罐壁连接板放样罐壁连接板画线罐壁连接板分段切割下料罐壁连接板对接处坡口加工罐壁连接板分段滚弧成型罐壁连接板成型尺寸检查在预制平台上根据设计图样按1:1的比例放样并制作样板按照图样画出罐壁挡板轮廓线用剪板机切割下料由SFCC的QA/QC主管人员检查确认罐壁挡板画线罐壁挡板切割下料罐壁挡板尺寸检查用10T卡车将罐壁预制件运往EO-EG现场按照罐壁预制件编号顺序分组包装罐壁预制件运往现场罐壁预制件包装领取时填写材料领取记录领取罐体接管、法兰按照图样尺寸画出罐体接管切割线用等离子或数控切割机切割下料罐体接管画线罐体接管切割下料罐体接管切割下料罐体接管画线用氩弧焊打底,手工电弧焊盖面法兰与接管焊接罐体接管切割下料由SFCC和JGC/SEI的QA/QC主管人员检查确认罐体接管尺寸检查罐体接管尺寸检查罐体补强圈加工信号孔罐体补强圈尺寸检查罐体补强圈尺寸检查罐体补强圈画线罐体补强圈画线罐体补强圈切割下料罐体补强圈切割下料罐体补强圈加工信号孔由SFCC的QA/QC主管人员检查确认按照图样画出罐体补强圈轮廓线用等离子或数控切割机切割下料用钻床加工罐体补强圈信号孔Accordingtodraftdimensiondrawtheincisionlinelength.JointpipelineationCutandlayoffwithdigitallycontrolled/plasmacuttingmachineLongholemachiningwithmillingmachine(machiningout)JointpipelongholemachiningAccordingtodraftdimensiondrawtheincisionlinelength.JointpipeblockboardlineationCutandlayoffwithdigitallycontrolled/plasmacuttingmachineAccordingtodraftdimensiondrawtheincisionlinelength.Cutandlayoffwithdigitallycontrolled/plasmacuttingmachineAccordingdesigndrawingonfabricationplantOrientationbushingwimblepartsetsampleJointpipecutandlayoff雷达液位计接管长圆孔加工雷达液位计接管堵板画线雷达液位计接管切割下料WeldwithSMAWBlockboardandjointpipeweld雷达液位计定位接管画线Orientationbushinglineation雷达液位计定位接管切割下料Orientationbushingcutandlayoff雷达液位计定位接管锥段放样雷达液位计接管堵板切割下料Blockboardcutandlayoff雷达液位计接管堵板与接管焊接AccordingtodraftdimensiontodrawoutlineOrientationbushingwimblepartlineationCutandlayoffwithdigitallycontrolled/plasmacuttingmachineOrientationbushingwimblepartcutandlayoffwimblepartandbushingweldQA/QcofSFCCgovernorinspectionOrientationbushingsizeinspectionAccordingtodraftdimensiontodrawoutlineTankbottomorientationunderlaylineationCutandlayoffwithdigitallycontrolled/plasmacuttingmachineTankbottomorientationunderlaycutandlayoffAccordingtodraftdimensiondrawtheincisionlinelength.OrientationbushinglugtendonlineationCutandlayoffwithplasmacuttingmachineOrientationbushinglugtendoncutandlayoffAccordingtodraftdimensiondrawtheincisionlinelength.CutandlayoffwithplasmacuttingmachineOrientationbushingFlatsteelcutandlayoffWeldwithSMAWOrientationbushingflatsteellineationAccordingtodraftdimensiondrawtheincisionlinelength.CentralpipelineationCutandlayoffwithdigitallycontrolled/plasmacuttingmachineCentralpipecutandlayoffDrillingholewithdrillpressQA/QcofSFCCandJGC/SEIgovernorinspectionCentralpipesizeinspectionAccordingtodraftdimensiondrawtheincisionlinelength.Cutandlayoffwithdigitallycontrolled/plasmacuttingmachineNozzlecutandlayoffQA/QcofSFCCandJGC/SEIgovernorinspectionNozzlesizeinspectionWeldwithMMAWNozzleandcentralpipeweldFillinmaterialdrawnoteatdrawteejointandflangedrawAccordingtodraftdimensiondrawtheincisionlinelength.ShortpipelineationCentralpipedrillholeNozzlelineationCutandlayoffwithdigitallycontrolled/plasmacuttingmachineShortpipecutandlayoffCentralpipe、teejoint、shortpipeandinnerflangeweldWeldwithMMAWQA/QcofSFCCandJGC/SEIgovernorinspectionaspect、geometrysizeinspectionAccordingtodraftdimensiondrawtheincisionlinelength.NozzlepipelineationCutandlayoffwithplasmacuttingmachineNozzlepipecutandlayoffQA/QcofSFCCgovernorinspectionNozzlepipegeometrysizeinspectionFillinmaterialdrawnoteatdrawFlangedrawWeldwithMMAWNozzlepipeandflangeweldaspect、geometrysizeinspectionQA/QcofSFCCandJGC/SEIgovernorinspectionAccordingtodraftdimensiondrawtheincisionlinelength.NozzlebracketanglesteellineationCutandlayoffwithplasmacuttingmachineNozzlebracketanglesteelcutandlayoffAccordingtodraftdimensiondrawtheincisionlinelength.NozzlebracketlugtendonlineationCutandlayoffwithplasmacuttingmachineNozzlebracketlugtendoncutandlayoffAccordingtodraftdimensiontodrawunderlayplateoutlineNozzlebracketunderlaylineationCutandlayoffwithdigitallycontrolled/plasmacuttingmachineNozzlebracketunderlaycutandlayoffNozzlebracketunderlaydrillDrillU-typeboltholewithdrillpressWeldingwithMMAWNozzlebracketunderlayandangleiron、lugtendonweldQA/QcofSFCCandJGC/SEIgovernorinspectionaspect、geometrysizeinspection按照其它预制件编号顺序分组包装Othercomponets`spackage用10T卡车将其它预制件运往EO-EG现场OtherprefabricationpartsaretransportedtofieldFillinrecordwhendrawthematerial.DrawmaterialsMaterialsandblastandpaintAllCSmaterialneedsandblastthenpainttwotimes.PlantedgeangleironlineationAccordingtodraftdimensiondrawtheincisionlineatplantangleironlength.UseblazeincisetoollayingoffmaterialFlatedgeangleironinciseandlayingoffmaterialUseplaterollershapetheplatedgeangleironFlatedgeangleironrollandshapedQA/QcofSFCCgovernorinspectionandaffirmFlatedgeangleironrollandshapedinspection平台边缘角钢成型检查Onflatroofformeron1:1prorataaccordingtodesignFlatplankandmakeformerFabricateflatplankandmakeformerUsesheetirontomakeflatplankandformerUseformertodrawsubsectionoutlineFlatplankanddrawsubsectionUsenumericalcontrolincisemachinetolayoffFlatplanksubsectioninciseandlayoffmaterialQA/QcofSFCCgovernorinspectionandaffirmFlatplankdimensioninspectionAccordingtodraftdimensiontodrawunderlayplateoutlineUnderlayplatedrawUsecuttingmachinetoinciseandlayoffUnderlayplatesinciseandlayoffQA/QcofSFCCgovernorinspectionandaffirmUnderlaydimensioninspectionDrawribplatesfigureaccordingtodraftRibplatesdrawUsecuttingmachinetoinciseandlayoffRibplatesinciseandlayoffRibplatessizeinspectionQA/QcofSFCCgovernorinspectionandaffirmSupportangleirondrawAccordingtodraftdimensiondrawtheincisionlineatsupportangleironlength.UseblazecuttintoollayingoffmaterialSupportangleironcutandlayoffQA/QcofSFCCgovernorinspection.SupportangleironsizeinspectionWithMMAWWeldingofSupportangleironunderlayplateandribplateQA/QcofSFCCgovernorinspection.aspect、geometrysizeinspectionAccordingtodraftdimensiondrawtheincisionlineatstandpolelength.StandpoledrawUseblazecuttintoollayingoffmaterialStandpolecutandlayoffQA/QcofSFCCgovernorinspection.Standpolesizeinspectionhandrail、blockwaistandfeetboardrollUseplaterollershapetheplatedgeangleironhandrail、blockwaistandfeetboardrollinspectionQA/QcofSFCCgovernorinspection.Tanktiproof、balusterfabricationcomponentspackageWith10tlorryTanktiproof、balusterfabricationcomponentscarriedoutfield。