Technical specifications and standards for equipment relocation (Part I)

1、 Disassembly principles and general requirements:

1.1 from small to large, from easy to difficult, from high altitude to ground, from periphery to main engine. The equipment that must be disassembled shall be divided as few as possible, and at the same time, it shall meet the transportation requirements. Finally, the accuracy and performance of the equipment after reinstallation shall be the same as that before disassembly. In order to strengthen the post responsibility, the division of labor responsibility system is adopted, and the person who disassembles and installs it.

1.2 before disassembly, first cut off and remove the power supply, water source, air source, etc. of the equipment.

1.3 vent lubricating oil, coolant, cleaning fluid, etc.

1.4 destructive disassembly and assembly (such as gas cutting) shall be avoided during disassembly. If necessary, contact the power equipment department for comments.

1.5 all wires and cables shall not be cut off, and the removed wire ends shall have labels. For some wire ends without labels, they shall be supplemented first and then removed. The wire number shall not be lost. Before wire removal, three comparisons (internal wire number, terminal board number and external wire number) shall be carried out to confirm that they are correct, and then they can be removed, otherwise the wire number shall be adjusted.

1.6 ensure the absolute safety of the equipment during disassembly.

1.7 during hoisting, the equipment shall not be bumped. Appropriate lifting points shall be selected to hoist slowly and gently. Protective measures shall be taken at the contact between steel wire rope and equipment.

1.8 when transporting equipment with forklift, the equipment shall be bound firmly and tightly to avoid falling down the slope or under vibration.

1.9 when assembling and disassembling the combined equipment, the removed bolts, nuts and locating pins shall be screwed back and inserted into the original position immediately after being oiled to avoid confusion and loss.

1.10 some movable parts on the equipment, such as slide. The power head shall lower the center of gravity and lock it after being padded with wood.

1.11 there are many hydraulic pipelines of the equipment. Before each head is removed, a signboard with installation number must be hung. Some parts shall be marked with positioning line. The two ends of the removed pipes shall be sealed immediately with plugs to avoid pollution and damage to the threads.

1.12 the dismantled equipment shall be stored in the designated place.

1.13 do not pull out the plug-in board (control board and integrated block) in the electrical cabinet of the equipment, and seal it with adhesive tape for reinforcement.

1.14 make disassembly records and submit them to relevant personnel.

2、 Disassembly process flow:

2.1 construction preparation

2.1.1 carry out technical disclosure for all construction personnel, and disclose the construction process requirements, quality requirements, construction precautions, etc. for the specific construction personnel of each single project. All construction personnel participating in the construction shall be familiar with the site, drawings, specifications and regulations, so that everyone knows well and does not operate blindly.

2.1.2 equipment inspection includes the following contents:

A. Inspect the appearance of the equipment

B. Confirm the technical parameters and action status of the equipment

C. Check the installation accuracy of the equipment

D. Mapping the mutual position and operation position between equipment, and draw relevant sketches

Detailed records shall be made for the above inspections as the basis for installation.

2.2 marking

In order to facilitate the smooth progress of demolition, restoration and installation, the equipment demolition adopts a unified marking method, that is, the method of digital marking. The demolition of electrical equipment basically adopts the same method, and some marks are added according to the complexity of electrical equipment.

The limit stop, travel switch and contactless switch of each line (equipment) shall not be removed as far as possible if conditions permit, so as to reduce the adjustment after installation. If they must be removed, the relative position and distance between the probe position and the transmitting workpiece (or stop) must be strictly measured, the installation position shall be marked, recorded and sketched.

For the equipment of each line, the relevant positioning dimensions shall be calibrated according to the situation that there may be lack of data during future installation, and the sketch shall be drawn and the specific data shall be recorded in order to reset the installation.

All kinds of disassembly symbols and signs must be firm, and the positioning marks and dimension measuring points must be positioned to avoid damage and ambiguity due to transportation and other reasons, which will affect the installation.

Recording is the guarantee for the smooth progress of installation in the future, and special personnel must be responsible for it.

2.3 disassembly record

2.3.1 before disassembly, we should check the appearance, relative position, installation accuracy and process of each equipment as the basis for future acceptance. We can also take its machined parts as samples during commissioning as the standard of processing accuracy after equipment installation. For some equipment with advanced control methods, such as PLC controlled equipment, we should consider from shutdown, disassembly, packaging, transportation In the long-term process of reinstallation, debugging and operation, the internal program is lost, and backup shall be made in time.

2.3.2 before disassembly, the equipment label is a very important and detailed work. It is necessary to do this work well for equipment disassembly. During disassembly, it shall be numbered according to the unified label method to ensure smooth installation in the future. In addition, in addition to numbering the disassembled equipment, positioning marks shall be made for some parts of the equipment, such as the process block of the equipment, The position of the head limit switch, the installation position of various sensors, the original position of the safety device and safety valve, as well as some circular and symmetrical installation parts, may change the position during disassembly. During disassembly, make positioning marks, and the position can be easily restored during installation, so as to reduce unnecessary adjustment and errors.

2.3.3 according to the general disassembly principle and combined with the actual situation of each equipment, determine the number of main disassembled parts, the overall dimension and estimated weight of each part. Before disassembly, draw the relevant dimensions of each part, draw the necessary pipeline system diagram, and take protective measures for the running guide rail, power head and various sensing and detection elements.

2.3.4 removal of pipelines and lines

During disassembly, the branch pipe shall be removed first, then the main pipe, and finally the support. The pipeline within the overall dimensions of other equipment disassembly parts shall not be disassembled. When connecting the hose to the equipment, the hose shall be bound to the equipment after the connection with the pipe is disassembled. During disassembly, special attention shall be paid to the following points:

A. Draw the necessary pipeline system diagram of each production line

B. Since there are many pipe heads to be disassembled, installation label plates must be hung on both sides of the disassembled pipe joint, and the disassembled pipe joint shall be wrapped to prevent damage to the screw thread and dirt from entering.

C. The sealing gasket of the pipe joint shall not be lost and can be wrapped in the pipe joint together.

D. The removed pipes shall be bound according to the type of medium contained, hung with packing marks and sent to the designated place.

2.3.5 disassembly

Determine whether the process equipment is disassembled according to the specific conditions and transportation requirements. Pay attention to the following points during disassembly:

A. Draw the necessary layout plan of process equipment.

B. Detailed inspection and disassembly and disassembly records shall be made during disassembly.

2.3.6 disassembly of electrical system

The following points shall be paid attention to when removing the electrical system of each processing line (equipment):

A. Before disassembly, be familiar with the relative position of each electrical equipment and understand the cable direction and its numbering significance.

B. Draw the mutual position of each electrical equipment. Before removing the bridge, draw a three-dimensional drawing, then mark the installation number on the drawing, and then mark the installation number on the cable bridge. After marking, it can be removed.

C. Considering the safety, convenience and reliability of mechanical and electrical disassembly, the cable disassembly shall be carried out from each power head according to the position of the junction box.

D. Before disassembly, all wires of the corresponding terminals shall be numbered according to the wire number, and can be disassembled only after careful verification.

E. The junction box with ultra-high position shall be removed from the column and fixed at the corresponding position, but the cable shall not be stressed.

2.4 cleaning

After the equipment and pipe fittings are disassembled, they shall be cleaned and rustproof in time. For the specific operation method, see "equipment cleaning" in the mechanical equipment installation scheme.

3、 Safety technical measures for equipment demolition construction:

In order to ensure the safety of demolition construction, the following requirements and measures must be met:

3.1 be familiar with the environment and understand the operation position of water, gas and power control. The operation can only be carried out after the shutdown state is clear during disassembly.

3.2 the construction shall be carried out in strict accordance with the electrical safety regulations. The stop must be hung with a sign board of "no switching on" and technical measures to prevent mistransmission of power.

3.3 correctly use on-site tools and machines to understand their performance.

3.4 strictly abide by fire prevention regulations. When open fire operation is required, fire prevention measures must be taken and supervised by a specially assigned person. Open fire operation shall be strictly prohibited around inflammables and explosives.

3.5 cross operation shall be avoided as far as possible. For high-altitude operation, safety belt must be carried, and the suspension of safety belt must meet the requirements of safety regulations.

3.6 when disassembling equipment, you must be familiar with relevant drawings and equipment first, and blind operation is prohibited.

3.7 during equipment disassembly and lifting, attention must be paid not to damage the plant and facilities.

3.8 the site shall be equipped with full-time security inspectors to timely check and eliminate unsafe factors.

3.9 civilized construction shall be achieved, and the site and waste shall be cleaned in time.

4、 Installation of equipment:

4.1 equipment installation process

4.1.1 the equipment shall be lifted, transported, unpacked, counted, inspected and handed over with the box from the storage place to the installation position;

4.1.2 foundation inspection, cleaning and installation equipment preparation;

4.1.3 hoisting, positioning and primary alignment of equipment;

4.1.4 grouting, curing and secondary alignment of anchor bolts;

4.1.5 pipeline connection;

4.1.6 hydraulic system installation and pipeline connection;

4.1.7 lubrication system installation and pipeline connection;

4.1.8 air duct connection;

4.1.9 installation of control cabinet and operation cabinet;

4.1.1 0 electrical instrument and control system installation, wiring and bridge laying;

4.1.11 installation of control liaison interface with upper and lower auxiliary machines;

4.1.12 lubricating grease filling of lubricating parts (including reducer, etc.);

4.1.1.3 equipment scrubbing and site cleaning;

4.1.14 cooperate with equipment no-load commissioning, comprehensive inspection, rectification, installation stage acceptance, load linkage commissioning and final acceptance;

4.1.1.5 system cleaning, equipment scrubbing, comprehensive inspection, no-load commissioning and load commissioning;

4.2 main construction scheme for equipment installation

4.2.1 mobilization transportation

(1) Select appropriate cranes and flatcars according to the quality of single equipment provided in the equipment list;

(2) Lifting and falling objects shall be stable

(3) The following items shall be recorded in the inspection before equipment disassembly, including appearance, photo records, equipment name, model and specification, equipment technical documents, data and special tools; Whether the equipment has non-destructive parts and whether the surface is damaged and rusted; Other conditions to be recorded.

(4) The equipment, its parts and special tools shall be kept properly without deformation, damage, corrosion or loss.

(5) Equipment technical documents, data and marks shall be used as the basis for construction and installation.

4.2.2 foundation acceptance

(1) Check the quality requirements according to the foundation construction drawings and equipment technical documents provided by the design institute.

(2) Conduct acceptance together with the construction representative, and make acceptance records, which shall be signed and approved by both parties.

4.2.3 foundation setting out

(1) 600 PMO shall provide the axis or edge line or elevation line of relevant buildings as the installation datum line.

(2) Measure the equipment central axis or equipment edge line according to the datum line.

(3) For equipment connected, connected or parallel to each other, the axis or edge line shall be measured at one time.

4.2.4 equipment positioning and alignment

(1) The allowable deviation between the plane position of the equipment and the foundation axis or edge line is ± 5mm.

(2) The equipment shall be lifted by forklift or tire truck crane. When forklift is used, it shall be bound with protective rope. When truck crane is used, it shall use equipment lifting point or sling. The contact between sling and equipment shall be provided with protective cushion to prevent surface damage.

4.2.5 anchor bolts

(1) If the equipment is fixed with anchor bolts, follow the instructions in this section.

(2) When testing the equipment foundation, the reserved anchor bolt holes shall be rechecked at the same time. If the anchor bolt holes are not reserved, the 600 Project Office representative shall confirm and adopt other methods such as manual hole drilling or changing to expansion anchor bolts.

(3) The embedded anchor bolt hole shall be free of oil, gravel, soil, ponding, etc., and the size shall be free of deviation.

(4) Fine crushed stone concrete is used for anchor bolt hole grouting, and the grade is one higher than that of foundation concrete.

(5) The anchor bolts shall be tightened when the concrete in the reserved hole reaches more than 75% of the design strength, and the tightening force of each bolt shall be uniform.

4.2.6 sizing block or adjustable screw, fine leveling

(1) The fine leveling of the equipment shall be realized by sizing block or adjustable screw or other methods, and the leveling method shall be determined according to the technical documents of the equipment.

(2) The sizing block shall be selected according to the shape of the equipment bottom and the number of anchor bolts, and the sizing block specification shall be standard specification.

(3) Pairs of inclined sizing blocks shall be used, which shall be firmly welded with tack welding after leveling and before grouting.

(4) Each sizing block shall be placed neatly and evenly with good contact. After the equipment is leveled, each group of sizing blocks shall be pressed tightly. Use a 0.05mm feeler gauge to check the gap between sizing blocks and between sizing blocks and the base surface. The total amount inserted on both sides of the same section of sizing blocks shall not exceed 1 / 3 of the length (width) of sizing blocks.

(5) In the foundation surface, the part where the sizing block is placed shall be chiseled flat.

(6) The equipment adopts adjusting screw. Under the adjusting screw, the foundation surface shall be firmly placed with support plate (100 * 100), the foundation surface under the support plate shall be chiseled flat, and the thickness of the support plate shall be greater than the screw diameter.

(7) During fine leveling of the equipment, the measuring datum plane, line and point according to the technical documents of the equipment shall be used as the detection surface to fine level the equipment to meet the technical requirements of the equipment.

(8) After the fine leveling of the equipment, the non shrinkage concrete shall be used for secondary grouting. When the strength of the grouting layer reaches 75%, the accuracy of the equipment shall be retested and adjusted until it is qualified.

(9) When the temperature is lower than 4 ℃, protective measures shall be taken for the grouting layer.

4.2.7 equipment cleaning

(1) Recheck and clean the fitting size, fitting surface and sliding surface of parts and components to be assembled, the fitting surface and sliding surface of the overall equipment, and the installation and inspection datum plane.

(2) When the equipment requiring disassembly and transportation is disassembled and cleaned, assembly records and marks shall be made.

(3) Clean the non painted surface of the arrived equipment, apply protective layer, and scrub it with solvent oil, kerosene and ethanol.

(4) If there is rust on the assembly surface and moving joint surface, derusting treatment shall be carried out, which shall be wiped with abrasive cloth or fine oilstone with particle size of 150-240 stained with mechanical oil, or polished with fine grinding paste.

(5) After cleaning, the surface shall show metallic luster. After the important joint surface and guide rail surface are wiped with white cloth, the white cloth shall be free of foreign matter pollution.

(6) During assembly, the cleaned joint surface shall be coated with clean mechanical oil. For the installation of equipment with a long construction period, the exposed moving surface and guide rail surface shall be provided with rust prevention measures in time, except for applying yellow dry oil or mechanical oil.

4.3 main technical requirements for equipment installation

4.3.1 equipment process piping

(1) Equipment process piping refers to the connection of external cold water, circulating water and gas pipelines of the equipment.

(3) Selection of pipe materials: when DN is less than 50mm, galvanized steel pipe shall be used for screw connection; when DN is greater than 50mm, welded steel pipe shall be used for welding connection.

(4) The processing accuracy of threaded connecting pipe and pipe thread shall comply with international pipe thread regulations. The thread shall be clean, regular, without broken wire, firmly connected and without welding interface.

(5) When welding steel pipes, the welded junction shall be straight, and the weld surface shall be free of nodules, slag inclusions and pores. If there are requirements for weld flaw detection, weld flaw detection shall be carried out.

(6) The installation method of pipe support (hanger and bracket) shall be determined and approved on site, and the support spacing shall meet the specifications.

(7) The gradient of the air flow pipeline is inclined downward along the gas flow direction, and the gradient value is greater than 10 / 1000mm. The return pipeline of the lubricating oil and emulsion system is inclined towards the oil tank, and the gradient value is greater than 12.5-25 / 1000mm.

(8) The model, specification, compressive strength and tightness test results of valves in the pipeline shall meet the technical requirements and construction specifications, the position and inlet and outlet direction shall be correct, the connection shall be firm and tight, and the opening shall be flexible.

(9) For the connection between the equipment with large vibration and the pipeline, the vibration avoidance hose shall be installed at the connection.