脱硫烟风道制作施工方案(英文版)

Table of Content 1. Purpose and scope……………………………………………………2 2. Reference basis……………………………………………………….2 3. General………………………………………………………………..3 4. Procedure……………………………………………………………...3 5. Quality assurance measure ………………………………………….. 9 6. Safety assurance measure……………………………………………..10 7. Equipment and tool……………………………………………………12 8. Construction schedule…………………………………………………13 9. Organizational structure…………………………………….…………14 10.0 Risk Control Program of Occupational Health and Safety（RCP）…15 11.0 Layout drawing …………………………………………… …………18 1.0 Purpose and Scope This WPP is to provide technical guide for the fabrication and erection of flue gas duct of SWFGD system and to ensure the construction quality and construction staff safety. a). Inlet duct of FGD booster fan Flow: Boiler ID fan outlet →FGD booster fan inlet Principle: provide driving force for untreated gas from ID fan outlet entering into booster fan which in turn force flue gas to FGD Absorber. Design parameter:  design pressure: -1300Pa，2000Pa, design temperature: 150℃ b). Duct from booster fan outlet to GGH inlet Flow: booster fan→ GGH inlet Design parameter: design pressure:-1300Pa，4500Pa design temperature 150℃ c). Duct from GGH to Absorber inlet Flow: GGH outlet → Absorber inelt Design parameter:  design pressure: 10372pa,  design temperature: 106℃ d). Duct from Absorber outlet to stack Flow： Absorber→stack→atmosphere Principle: Force the flue gas treated by SWFGD to atmosphere via stack Design parameter: Design pressure: -1300Pa    Design temperature: 150℃ e)  Bypass duct from IDfan outlet to stack Flow: IDfan outlet → stack→atmosphere Design parameter: Design pressure: -1300Pa    Design temperature: 150℃ f) Sealing air duct Flow: seal fan→seal air duct→damper Principle: to provide seal air for dampers. Design parameter: design pressure: 6000Pa design temperature: 180℃ for raw gas side , 50℃ for clean gas side. 2.0 References --General Descriptions of Drawings and List of Drawings (drawing No.: F4281S-P0101) --List of Insulation/Lagging and Painting (drawing No.: F4281S-P0104) --List of Lining (drawing No.: F4281S-P0105) --Layout Drawings of Absorber Area (drawing No.: F4281S-P0202) -- Drawings of gas equipments Unit 1 (Drawing No.: F4281S-P0401) -- Layout drawings of raw gas duct (before GGH) unit 1 (Drawing No.: F4281S-P0402) -- Layout drawings of raw clean duct (between Stack and GGH) unit 1 (Drawing No.: F4281S-P0404) -- Layout drawings of damper sealing pipe unit1 (drawing NO.: F4281S-P0406) -- Layout drawings of CEMS unit1 (drawing No.: F4281S- P0407) -- Drawings of gas equipments Unit 2 (Drawing No.: F4281S-P0501) -- Layout drawings of raw gas duct (before GGH) unit 2 (Drawing No.: F4281S-P0502) -- Layout drawings of clean duct (between Stack and GGH) unit2 (Drawing No.: F4281S-P0504) -- Layout drawings of damper sealing pipe unit2 (drawing NO.: F4281S-P0506) -- Layout drawings of CEMS unit2 (drawing No.: F4281S- P0507) --EPC contract 3.0 General FGD flue gas duct system is composed of duct before GGH, duct between GGH and Absorber (untreated flue gas form GGH outlet to Absorber inlet) , GGH outlet duct (flue gas treated by SWFGD ),bypass duct (for bypassing SWFGD) and damper sealing air duct. 4.0 Procedure 4.1 Fabrication procedure Duct fabrication procedure: flooring steel plate→ setting out→ cutting →assembly → welding→ quality inspection →painting Fabrication procedure of supports and hangers: cutting→assembly→welding→quality inspection→painting 4.2 Fabrication The assembly work will be done at specified place as per drawing. 4.3 Duct fabrication 4.3.1 Fabrication and assembly of rectangle joint, duct, elbow and tee 4.3.1.1 The material shall be assembled as per drawing. 4.3.1.2 The oil, iron rust etc. shall be removed before welding, and welding slag, spattering shall be cleaned after welding. The welding joint shall be complete, without defects like crack, pore, etc. 4.3.1.3 Supporting pipe and reinforcing ring shall be welded against the duct in accordance with requirements of design drawings to avoid deformation of duct. 4.3.1.4 Fitting up of pipes should be done as per drawing, and at the same time the installation allowance shall be considered. The welding for butt-weld joint shall be complete, without defects like crack, pore, etc. In addition, the welding slag shall be cleaned after welding. 4.3.1.5 Strengthening measures shall be taken to the component that of big size and poor rigidity during assembling for the convenience of erection. 4.3.2 Technical requirement during fabricating and assembling 4.3.2.1 All the fabrication work shall be done as per drawing requirements.  4.3.2.2 Fabrication parts shall be with good appearance and the size thereof shall conform to the requirements of drawing. The ferric iron oxide, coating spattering shall be cleaned and no debris left inside of duct. 4.3.2.3 All the materials shall conform to the design requirements. 4.3.2.4 The location of reserved welding joint shall be easy for construction and welding. The welding shall be done as per drawing requirements. 4.3.2.5 The components shall possess enough rigidity, if not, temporary shoring shall be added. Temporary lifting points shall be firmly welded, with enough loading capacity. 4.3.2.6During duct fabrication and assembling, forced fitting up shall not be adopted. 4.3.2.7 The metal burr, welding slag and ferric iron oxide shall be cleaned after cutting. 4.3.2.8 Rust prevention treatment and paint coating shall be done to the fabricated component as per related requirements. 4.4 Duct installation Installation sequence: transportation of duct→ assembly on the ground (e.g. Straight duct & straight duct, straight duct & elbow, straight duct& flue gas damper) →installation of supports and hangers →rough adjustment of supports and hangers→ positioning of components→ components fitting up→ installation of accessories →adjustment of supports and hangers →overall check of duct→ inspection & acceptance Notes: Flue gas damper shall be installed with duct in parallel, the damper only need to be lifted to fit-up location and welded. Installation shall be in strict accordance with reference design drawings in order to assure the installation direction, elevation, level and center comply with design requirements. The following dampers are included in the construction scope of this document: FGD Inlet Isolation Damper (2 Set Electric Drive,6000*11000, Tandem Louver KKS:10/20HTA10AA001), FGD Outlet Isolation Damper (2 Set, Electric Drive,7000*8000,Tandem Louver KKS:10/20HTA20AA001), FGD Bypass Damper (2 Set, Pneumatic Drive,5500*12000,Single Louver, KKS:10/20HTA30AA001), GGH Bypass Damper (2 Set, Electric Drive, Single Louver, 1600*1600,KKS: 10/20HTA40AA001). 4.4.1 The internal debris shall be removed before installation of duct and the cleaning and protection work shall be done. 4.4.2 The steel structure elevation shall be the datum of duct installation, which shall also comply with the design requirement. 4.4.3 Enough expansion distance shall be reserved as per drawing requirements for the installation of expansion joints. In the course of installation, the joint wave shall not be damaged, and the same shall be protected after installation. 4.4.4 The sealant shall be added between flange and flue gas damper before their connecting and installation. 4.4.5 Before installation of flue gas damper, the flexibility of rotating part shall be checked, and full opening and full closing of flue gas damper shall be marked. 4.4.6 Installation of pipe supports and hangers shall conform to requirements of drawing. 4.4.7 Temporary reinforcement of expansion joints shall be removed only after completing erection and adjustment of supports and hangers. 4.4.8 The erection tolerances for duct should meet the requirements of DL/T5047-95: Length deviation: ≤2L/1000 and ≤10mm (L: The length of assembly) Length deviation：≤2L/1000 and ≤10mm (L: installation length) Width deviation: ≤2L/1000 and ≤10mm (L: The width of assembly) Width deviation：≤2L/1000 and ≤10mm (L: installation width) Center line deviation of duct≤30mm center deviation≤30mm 4.5 welding work 4.5.1Welding of duct Welding work of duct as follows: --welding of duct installation 4.5.2 Welding procedure 1. Submit the Certificate of welders and Quality Certification of electrodes to Owner/engineer before welding. Owner/engineer shall attend and witness the welders having the welding test. 2. Electrodes should be preheated. Welders get the right electrodes according to the material request of drawing and store them with insulation barrels temporarily. Welding engineers should tell welders the detail of welding technological requirements before working 3. Welders always weld according to the welding technological requirements of drawing. Welding engineers make record for the welders, welding scope and electrodes. Welding engineers and QC manager shall often do the visual inspection for the welding quality. Clear and paint the welding surface after welding engineers inspect and approve. 4.5.3 Welding inspection 100% penetrate test for all flue gas duct. The procedure of penetrate test is as follow: apply lime at one side of welding joint first, after the lime dries, apply kerosene at the other side, leakage can be found by visual inspection. 4.6 Insulation 4.6.1 Technology flow Installation of insulation layer Installation of hooked nails Construction preparation Installation of outer casing Acceptance& acceptance 4.6.2 The insulation work shall be done after painting work is inspected and accepted for duct. 4.6.3 Insulation materials must comply with the design requirements. The unqualified insulation materials are not allowed to use. 4.6.4 Tight splicing and firm binding of insulation materials shall be done. 4.6.5 The insulation material and thickness of insulation shall strictly comply with the design requirements. 4.6.6 Insulation materials must be kept properly, piled orderly; and avoid moisture and pressing environment. 4.7 Painting 4.7.1 Painting procedure 1. Paint coating procedure 1.1 Contractor submit the product specification and qualification certificate of paint approved by Owner/Engineer. 1.2 Surface treatment Before painting, the removal of rust, welding slug, spatters, grease, encrustation of equipment surface (to be painted) shall be done. The manual tools or power tools will be used for rust removal. After surface treatment, there are no visible grease, no fouling, no scale, and no iron rust on the equipment surface. 2. Painting condition The inclement weather (such as freezing temperature, high humidity, frost. etc) shall be avoided for painting work. The weather condition for painting work shall be:  no raining, ambient humidity not more than 85%, and more than 5℃ on the surface temperature of steel structure with no frost and dew. 3. Do’s and don’ts 3.1 The quantity of paints shall be as per the use quantity on that day. The mix proportion of paints shall strictly comply with the requirements of specification, and paints shall be stirred evenly after mixing. 3.2 The paint shall be applied evenly, and the thickness of paints shall be basically identical. 3.3 The barriers shall be arranged for some painting areas for avoidance of polluting other equipment. After completion of the painting work on that day, the painting barrel and painting brush shall be put back at the storage place, and the unfinished paint shall be sealed. 3.4 The paint shall be applied under condition of sound ventilation. The skin contact with paint shall be avoided. If the paint spatters on the skin, it shall be rinsed by proper cleanser and water immediately; If the paint spatters into the eyes, they shall be rinsed by water and cured by doctor immediately. 3.5 Storage of paint: Paint shall be stored in dry, cool and sound ventilation place and shall avoided heat source and fire source. The container for paint shall keep sealed. 4.7.2 Coating specification According to design drawing (F4281S-P0104-101), coating shall comply with requirements as follows: No. Location/surface Surface preparation Coat No. of coat Specification Per coat DFT microns(min) 1 Outside of ductwork & stiffeners(w/insulation) Sa 2.5 Primer 2 Organic silicon high temperature resistant aluminum powder paint 25μm 2 Inside of ductwork & internal bracings Sa 2.5 Shop primer 1 Organic zinc primer or other epoxy anticorrosive paint 50μm               5.0 Quality Assurance Measures 5.1 Quality control points and control measures during construction 5.1.1During construction, acceptance system shall be implemented and problems found shall be corrected in time. 5.1.2 Inspection to the following control points shall be enhanced: 5.1.2.1 The size of the flue gas ducts shall be checked that whether it meets requirements before welding with reinforcing bars, the flue gas ducts shall be reinforced when necessary. 5.1.2.2 Defects like welding miss, pore, crack, sand hole are not permitted at the weld joint of flue gas ducts. 5.1.2.3 The iron rust and oil contamination at welding part shall be removed and cleared with steel brush or electric steel brush before pipe welding. 5.1.2.4 During compensator erection, attention shall be paid that the medium flowing direction shall be the same with the marked direction of compensator. 5.1.2.5 After flue gas damper erection, blades of dampers must be adjusted to make sure that their actual location is same to their indicators outside of the dampers. There must be a only correct KKS code with the flue gas damper. 5.2 Major quality defects treatment procedure of duct installation. 5.2.1 Repair procedure Procedure as follows: a) Cleaning b) Preparation of the joint to the repaired. c) Selection of the welding process and electrode, painting after welding. Care should be taken to ensure that the temperature of the weld is held at the required level in order to prevent cracking. 6.0 Safety Assurance Measures 6.0.1 Project construction can only be commenced after the clarification of safety technologies and construction technologies are accepted by construction personnel. 6.0.2 Anyone who enters the site must wear safety helmet, slippers and shoes with pins are forbidden in the site, all the construction staff can’t drink alcohol or beer before working, the safety belt must be fixed at reliable place securely when working in high altitude, speed difference controller shall be adopted for places inconvenient to fix safety belt, ring rope shall be adopted at single beams. 6.0.3 Precautionary rope shall be equipped in construction area; unrelated people can’t stay or pass the construction area. 6.0.4 Guard rails or warning boards must be set at dangerous entrance/exit and cavern. 6.0.5 The excess material on the equipment must be cleared before lifting. 6.0.6 The crane hook shall not leave the equipment until it has been placed reliably. 6.0.7 Sufficient lighting must be provided for construction at night. 6.0.8 Lifting work can’t be done when the equipment weight is not known. 6.0.9.When the reinforcement of air duct has not been installed or the welding work has not been completed yet, the component cannot be lifted. 6.0.10 Protective goggles must be worn when polish the polishing machine; operation personnel shall not stand over against the tangential direction in order not to be damaged by splashed scraps. 6.0.11 Equipment shall be piled up in order and wooden sleeper shall be placed under to keep the equipment be stable and secure. 6.0.12 The equipment packages shall be moved to the pointed location, keep the site clean. 6.0.13 Snap rings used for lifting must match with the weight of lifted equipment to ensure enough safety factors. 6.0.14. Before use of all kinds of lifting tools and apparatuses, careful inspection shall be performed to each parts; corresponding regular inspection shall also be carried out. 6.0.15. Binding point for lifting shall not be changed without authorization. 6.0.16. Rubber sheet or iron sheet must be applied at contact point of steel wire rope and equipment edge when lifting equipment. 6.0.17.Number of workers must be counted before and after working in the air duct. 6.2.18. At least 2 people shall work together in the air duct, single person is not allowed to enter into and work in the air duct. 6.0.19. Designated person shall be responsible for lifting site to conduct in a uniform way and to achieve mutual cooperation. 6.0.20.Attentions shall be paid when objects are lifted; no person shall stand or pass under the lifted objects; it is prohibited to hit other objects; operation of lifting shall be slow when the objects are in place; head and hands of construction personnel shall not stretch out towards the contact face of the lifted objects. It is prohibited to walk on unfixed equipment. 6.0.21.When the objects are lifted 100mm off the ground, lifting shall be suspended for overall inspection and be continued after it is confirmed to be correct. 6.0.22. The excess materials shall be put away in order; the site shall be clean after construction completed. 6.0.23. During welding and cutting, fire proof measures shall be taken, after work done, the power and gas source shall be cut off. 7.0 Construction preparation 7.1. Human resource plan Type of duty Amount Management staff（including safety and quality management） 6 Bench worker 10 Lifting worker 3 Welder 8 Unskilled worker 12     7.2. Machinery preparation and location  S/N Name Description Unit Qty Remarks 1 Attached self -raising tower crane FZQ2000 set 1   2 Truck crane 50t set 1   3 Truck crane 25t set 1   4 Trailer 10t set 1               7.3. Tools and apparatus plan Description Specification Amount Remark Electric welding machine   8 sets Inclusive of wire Steel drum tape 50m 1 Qualified Steel tape 3.5m 10   Marking pen Red 4   Snap ring 8t 4   Snap ring 10t 10   Plumb bob 0.5kg 2   Monkey wrench   Several   Fire welding cutter   4 sets   Chain block 3T 8   Chain block 5T 8   Chain block 10T 2   Horizontal rubber pipe 30m 1           7.4. Safety control device Description Specification Amount Remark Safety net 3m×6m 10   Steel-cored circle rope φ11 L=3000 10   Horizontal safety rope   50m   Safety alert rope   100m   Wood gangway 2000×200×50 20 pieces   Safety belt   16   Automatic speed difference controller   6   Grinder   4pieces           S/N Construction Item Start date Finish date Remark 1 Fabrication of flue gas duct in front and behind GGH of #1 Unit 2014.03.05 2014.05.25   2 Erection of flue gas duct in front and behind GGH of #1 Unit 2014.04.15 2014.04.30   3 Fabrication of flue gas duct for Absorber outlet of #1 Unit 2014.04.15 2014.06.25   4 Erection of flue gas duct for Absorber outlet of #1 Unit 2014.05.15 2014.06.30   5 Erection of dampers for flue gas duct of #1 Unit. 2014.05.20 2014.05.25   6 Fabrication of duct for damper seal air duct of #1 Unit 2014.05.15 2014.06.25   7 Erection of duct for damper seal air duct of #1 Unit 2014.05.25 2014.06.10   8 Fabrication of flue gas duct in front and behind GGH of #2 Unit 2014.06.05 2014.07.25   9 Erection of flue gas duct in front and behind GGH of #2 Unit 2014.07.15 2014.08.30   10 Fabrication of flue gas duct for Absorber outlet of #2 Unit 2014.07.15 2014.08.25   11 Erection of flue gas duct for Absorber outlet of #2 Unit 2014.08.15 2014.09.30   12 Erection of dampers for flue gas duct of #2 Unit. 2014.08.20 2014.08.25   13 Fabrication of duct for damper seal air duct of #2 Unit 2014.09.15 2014.10.25   14 Erection of duct for damper seal air duct of #2 Unit 2014.10.25 2014.11.10             8.0 Construction Schedule 9.0 Organizational Structure Quality supervision          Safety supervision Site management      Technical management 10.0 Risk Control Program of Occupational Health and Safety（RCP） Construction Company: Hunan Provincial Thermal Power Construction Co.                                      Construction Item: Installation of flue gas duct in FGD System S/N Construction activity Hazard factor Goal Control measures Control method Control time Measure operator Sign Supervisor Sign Remark 1 Dressing Workers do not wear safety helmet, poor safety consciousness No injury 1. Constructors shall wear working suit, insulation shoes and gloves. 2. Wear safety helmet before enter construction site. A A A T T Z Constructor   Safety supervisor     2 Work aloft Incomplete scaffold, safety belts are not fixed as required. No falling accidents 1. Safety belts shall be anchored on a reliable position. S T Constructor   Safety supervisor     3 Use of machine and tools Other injuries No injury 1. Check the machine and tool before use. 2. Temporary power supply shall be constructed by professional personnel. All electric tools shall be equipped with power socket with leakage protector 3. Power line cannot be anchored on knife switch or inserted into power socket. 4.Electric tools shall be of good earthling connection 5. Wear safety goggles when using grinding machine. A A A A A A A P P T T T T T Constructor   Safety supervisor     4 Use of crowbar Falling from high place, crowbar bounce harm No injury accident Supporting point shall be firm and solid when using crowbar. A T Constructor   Safety supervisor     5 Fire weld cutting Joint of fire welding are not bound firmly, and without backfire prevention unit No fire accident Gas supply pipe shall be without crack. Clean any explosives within 5m of welding or cutting area. W T Constructor   Safety supervisor     6 Electric and fire welding Eye hurt   Wear safety goggles when using electric or fire welding. A D Constructor   Safety supervisor     7 Chain pulley Brake malfunction or improper operation No injury Chain pulley shall be inspected before use. Temporary lifting points shall be welded by professional welder. A T Constructor   Safety supervisor     8 Equipment jacking Use jack exceeding its lifting capacity No personal injury or equipment damage Lifting jack shall be placed on plane, solid area and be perpendicular with loading face. No one can stand in front of safety cock when using hydraulic jack. A T Constructor   Safety supervisor     9 Lifting work Personal injury No personal injury 1. Lifting point shall be welded firmly. Check the welding joint before lifting. 2. Steel wire rope shall be bound firmly and cannot be used overload. 3. Unrelated person cannot stay at or pass lifting area. A A A P T T Constructor   Safety supervisor     10 Welding Electric shock, electric arc burn, fire accident No electric shock, fire accident 1. Wear special working suit, insulation shoes when doing welding works. 2. Earthling of welding machine shall be solid and reliable. 3. Power shall be cut off when welding or cutting work completed. 4. After welding, please make sure that no fire around, and cut off lighting and power of welding machine before leaving. 5. After welding & cutting works, power source must be cut off, and make sure that no fire risks before leaving. A A A A A T T T T T Constructor   Safety supervisor                             Note：Control method：W：witness：                H：stop work for inspection：                S：continuous monitoring：                A：reminding：                R：Record confirmation Control frequency：P：Prior to construction；D：At least once a day；Z：Once a week（4Z Once a month,12Z：Once a quarter）；T：in process of continuous activity or resume work after interruption. 11. 0  Layout drawing