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1、杭氧 工厂标准大型空分设备安装技术要求1. 适用范围1.1 This standard （规定） the requirements on installation of air separation plantdesigned and manufactured by Hangzhou Hangyang Holding Co., Ltd 简称 Hangyang).1.2 This Standard is applicable for site installation of Hangyang-designed-manufactured regular packed rectification c
2、olumns of the switchover process and molecular sieve purification absorption process (including boosting type) as well as the air separation plants of full-rectification 制氩process, oxygen (nitrogen) internal compression process and liquid air separation.1.3 This Standard is inapplicable for installa
3、tion of compressor, turbine expander, pump, thestorage system of liquefied gas, 稀有gas 提取equipment and corresponding 按照their corresponding installation standard or technical documentation.1.4 当时the special requirement on the drawing and technical documentations, theinstallation shall be in compliance
4、 with the drawing and technical documentation. The installation unit may prepare detail rules of installation according to the requirement of this standard.2. 规范性 引用documentationsRegulations of Safe and Technical Supervision for Pressure Vessel (issued by the Former 局 in 1999).Steel Pressure Vessel,
5、 GB150-1998Specifications of Aluminum Welded Vessel, JB/T4734-2002Technical Conditions of Oxygen Pipe for Air Separation Plant, JB/T 5902-2001.Technical Conditions of Installation and Welding for Aluminum Air Separation Plant,HTA5411-2001General Regulations of Construction and Acceptance of Installa
6、tion Works of Mechanical Equipment, GB50231-1998General Regulation of Construction and Acceptance of Installation Works of Refrigeration Equipment and Air Separation Plant GB50274-1998General Regulations of Construction and Acceptance of Installation Works of IndustrialMetallic Pipeline Works GB5023
7、5-1997Non-destruction Inspection for Pressure Vessel, JB4730Oil Removing and Cleaning for Metal Product, HT8009-88Slag Wool, HT7075-83Expanded Pearlite.HT7012-823. Foundation of Cold Box:3.1 The foundation of cold box of air separation column shall have sufficient strength and beprevented from settl
8、ement and inclination, and meanwhile the features of working under low temperature of the equipment placed on the foundation shall be well considered.3.2 The loads borne by the cold box foundation includes cold box, platform stair, valves, pipelines,column, vessels, and expanded pearlite and liquid
9、media.3.3 The surface temperature of cold box foundation is from +30 to 90 during normalrunning and even 190 in case of liquid leakage.3.4 The cold box foundation body consists of foundation body, water-stop plate, cold insulationcourse and surface course.3.4.1 The foundation body is made of waterpr
10、oof and frost-resistant concrete of animpermeability strength grade not below B12 and a frost-resistant strength grade not below MP75 and is pre-compressed with 1.5 times of the total weight of the equipment for 7 days to prevent the foundation from inclination. Fig. 1Surface course面层Cold-insulating
11、 course隔冷层waterproof mortar防水砂浆 foundation body基础本体, water-stop plate隔水板3.4.2 The water-stop plate shall be welded or complete piece of 0.5mm thick copper sheet or0.8-1.0 mm thick stainless steel sheet.3.4.3 The cold insulation course is made by expanded pearlite concrete of a thickness not below300
12、mm, compression strength not below 7.35MPaand heat conductivity not above0.2325W/Mk.3.4.4 The surface course is 50mm thick fine sand concrete (admixed with 0.5% waterproofagent) of an impermeability strength grade not below B12 and a frost-resistant strength grade not below MP75.Note: Impermeability
13、 strength grade B12 means that under 1.176MPa hydraulic pressure no seepage occurs in concrete test block. The frost-resisting grade MP75 means that after 75 cycles offreezing-thawing the drop of strength of the concrete test block is less than 25%.3.5 After completion of foundation, its surface sha
14、ll meet the following requirements:3.5.1 The surface shall be free of defects such as crack.3.5.2 The surface shall be clean without inclusion of inflammables such as wood board and felt.3.5.3 The surface flatness shall be less than 5/1000.3.5.4 The surface levelness shall be less than 5/1000, and t
15、he deviation of the entire length notabove 15mm. 3.6 After the qualification of foundation, the installation central line of vessel shall be set outaccording to the vessel layout, and the orientation of nose marked.4. Pressure test and gas-tight test for the single unit (pressure vessel and valve)4.
16、1 The test before positioning and installation of the pressure vessel4.1.1 Each passage of the pressure vessel was filled with 0.02MPa sealing nitrogen beforedelivery and before positioning the sealing nitrogen pressure shall be measured with grade 1.5 pressure gauge. In case of the vessel having 2
17、or more passages, the pressure in a passage shall be measured and the sealing nitrogen completely vented, and after 30 minutes the pressure of other passage is measured.4.1.2 In case that the inspection of sealing nitrogen of multi-passage vessel is suspicious or thevessel is not provided with seali
18、ng nitrogen, the pressure test shall be carried out to check for internal leakage. If the pressure vessel is within the guarantee period and has qualification certificate and its package keeps intact it is unnecessary to carry out separate pressure test and gas-tight test before installation.4.1.3 O
19、utside the guarantee period, though the pressure vessel has qualification certificate andits package keeps intact, the gas-tight test shall be performed before installation.4.1.4 If the pressure vessel has no qualification, or is damaged, or is locally modified in site, itshall be subjected to separ
20、ate strength test and gas-tight test before installation.4.1.5 No oxygen shall be used as the pressure-test gas.4.2 Valve inspection and adjustment before installation:4.2.1 If the valve is within the guarantee period and has qualification certificate and its sealingfaces keep at good conditions, in
21、 general, separate pressure test and gas-tight test is unnecessary before installation.4.2.2 If the valve is within the guarantee period and has qualification certificate, but its sealingfaces are rusted or damaged, after treatment it shall be subjected to the gas-tight test.4.2.3 Outside the guaran
22、tee period, though the valve has qualification certificate and its sealingfaces keep at good conditions, it shall be subjected to the gas-tight test.4.2.4 In case no qualification certificate or abnormal phenomenon (damage) of valve, it shall besubjected to separate strength test and gas-tight test
23、before installation.4.2.5 The valve which shall be degreased and disassemble-inspected at site shall be subjected toseparate gas-tight test before installation.4.2.6 The sealing faces of automatic valve may be subjected to gas-tight test under workingpressure (0.6MPa) for 3 minutes and during the pe
24、riod the leakage rate shall be less than0.1l/min. After 5 cycles of opening/closing, the valve shall still meet the requirements. The automatic valveQualified in this inspection shall be soaked in liquid nitrogen for 15 minutes and thereafter its flap shall be able to free open and close without any
25、 seizure. The vale of leakage exceeding the criteria shall be lapped.4.2.7 The safety valve shall be subjected to individual tripping test according to therequirements of summary sheet of presetting values provided by the complete set manufacturer and then leaded after meeting the requirement. For t
26、he safety valve of a fore check valve, it shall be fully opened and leaded.adjusting valve:4.2.8.1 The leakage rate shall be inspected under the manual and pneumatic model separately. Theleakage rate shall be in compliance with the relevant standard of manufacturer.4.2.8.2 The positioner shall be su
27、bjected to actuation test under the specified gas pressure andshall meet the requirement.4.2.8.3 Leakage inspection for the stuffing box and flange-sealing faces shall be conducted andthere shall be no leakage.4.2.8.4 The leakage rate of pneumatic butterfly valve shall meet the requirements specifie
28、d in thedrawing.4.3 Media for the test:4.3.1 Clean domestic water shall be used for hydraulic test and gas pressure test may beperformed for the vessels of complex structure or unsuitable for water as test media(rectification column, plate-fin heat exchanger, condensing evaporator, adsorber and filt
29、er)4.3.2 The dry oil free air or nitrogen is used in gas-tight test and cares shall be taken to preventfrom asphyxia in case of using nitrogen.5.1 Before installation, all the pressure vessels, valves, pipe and pipe accessories shall be clean, dryand free of oil stain.5.2 The components which were d
30、egreased in the manufacturer and yet not contaminated, shall notbe degreased before installation. However, if they are contaminated by grease, they shall be degreased.5.3 It is strictly not allowed to degrease the aluminum product (pressure vessel, valve and pipe) with carbon tetrachloride solvent.
31、Tetrachloroethylene or trichloroethylene solvent isrecommended for degreasing. The solvent shall be free of oil and grease and decomposedsolution shall not be used. The organic solution is unsuitable for rubber, plastic or organic-coated component and cares shall be taken in use of organic solvent b
32、ecause of their toxicity and inflammability.Besides the above solvent, degreasing may be conducted with other methods such as lye-cleaning. The lye of an excessively high concentration would corrode metals, especially Al-Mg alloys. For these alloy the lye shall have pH 10 and the cleaning temperatur
33、e shall be kept within70-80. After leaning with lye, they shall be rinsed with cleaning water till no residual lye and then dried. The degreased pipes shall be welded in 24 hours and prevented from secondary contamination. The pipes may be checked for being completely degreased visually andqualitati
34、vely with UV lamp or with other methods.5.4 Before installation, the carbon steel oxygen pipelines outside the cold box, valves and all the parts contacting oxygen shall be thoroughly derusted and degreased through t blasting (only with quartz), pickling or other high effect non-inflammable detergen
35、ts and derusted and degreasednitrogen at a velocity above 20m/s till no rust, dust or other dirt.5.6 It is strictly not allowed to sweep the pipe with oxygen;5.7 The residual oil content of the part surface contacting oxygen and the residue oil under runningshall not exceed125mg/m2.6. Installation o
36、f cold box:6.1 The frame of cold box foundation includes frame type and non-frame type and the level error offrame types frame top surface shall not exceed 1/1000. Each sectional steel of the frame shall be positioned vertically and each bottom plate of non-frame cold box shall be kept in a same hor
37、izontal plane with level error not above 1/1000.6.2 During installation of cold box plates the adjacent faces may be pre-spliced into integral orangle piece on ground and the error of the diagonal length and the verticality of four sides of each piece shall meet stipulation in Table 2:adjust the lev
38、el of top end face of the box plate and the width of the shimmed sheet shall be equal to that of the corresponding shaped steel.6.4 The nuts and bolts between the skeletons shall be spot-welded. The inner side of shaped steel between the skeletons shall be discontinuously welded at an interval 150mm
39、 and weld of 50mm and the outer side continuously welded (Fig. 2). The continuous weld of outsides of the entire cold box shall meet the gas-tight requirement of cold box. Spot-weld （电焊） Inside cold box（冷箱Full-sized weld （满焊）Discontinuous weld（间断焊）, Continuous weld（连续焊）Fig. 26.5 After the installati
40、on of lower plate of the cold box and qualification in re-correction thefoundation frame may be grouted and during grouting the concrete shall be vibrated to fill all Fig. 36.6 Before the installation of the cold box without foundation frame, the bottom plate of cold boxshall be subjected to seconda
41、ry grouting under the prerequisite of the level error in a same plane not above 1/1000. After complete drying of the secondary grouted course, the cold box may be installed as in 6.3.6.7 General requirements for the secondary grouting:6.7.1 The fine broken stone concrete (or cement mortar) is used i
42、n the grouting, and its strengthgrade shall be at least one grade higher than that of the foundation concrete.6.7.2 before grouting, the bottom surface of the frame or the bottom plate shall be clean andcleared off oil stain and soil.6.7.3 The grouted course shall be closely adhered onto the foundat
43、ion face and the rubbish inthe holes of floor bolts shall be removed before grouting. The area of the foundation face to be adhered with the grouted course shall be roughened and the oil-stained concrete shall be chiseled off. They shall be allover cleaned with water and no water shall be collected
44、in the recesses.6.7.4 During grouting the concrete shall be compacted and during compacting the frame orbottom plate, and pads or floor bolts shall not be collided, or the installation precision would be impaired.6.7.5 the grout course of the outer margin of frame shall be smooth and neat and above
45、the bedface of the bottom plate or frame. The grouted course shall have a slope to avoid entrance of water and oil and emission of sealing gas (Fig. 4). Frame type Non-frame typeFig. 46.8 The error of verticality of cold box installation is less than 1.5/1000 and the total error ofverticality of tot
46、al cold box height is not more than 20mm, or meet the requirement of theThe sealing plate and pure nitrogen outlet pipe cap in upper section of the upper column andthe crude argon outlet pipe cap of the condenser in crude argon column II shall be cut onground, cleared off aluminum dust and wrapped w
47、ith white fabric or plastic film before being lifted and positioned. During lifting aluminum pressure vessel and aluminum pipe, the protective measures shall be taken to prevent their surface from damage, such as covering rubber sleeve onto the rigging or separating the rigging with brace. Brace（支撑）
48、 rubber sleeve（橡皮套）Fig. 5 7.2 The lower column (assembled with condenser) shall be lifted and installed with theaccompanied lifting eye and the positioned column checked for correct verticality with plumb line around the column. In correct verticality, if any, may be corrected through shimming thin steel sheet beneath the base and the width of the said sheet shall be basically equal to that of the frame face. The allowable tolerance of verticality
