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
2、columns 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 instal
3、lation 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 com
4、pliance 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
5、 Vessel, 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
6、Installation 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 Work
7、s GB50235-1997Non-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 fr
8、om settlement 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
9、 liquid 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
10、 waterproof 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-i
11、nsulating 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 thickne
12、ss not below300mm, 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:
13、 Impermeability 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,
14、its surface shall 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 tha
15、n 5/1000, and the 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 vesse
16、l and valve)4.1 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 ve
17、ssel having 2 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 provi
18、ded with sealing 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 instal
19、lation.4.1.3 Outside 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 subj
20、ected to separate 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
21、conditions, in 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 Outs
22、ide the guarantee 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 g
23、as-tight test 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
24、 during the period 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 clo
25、se without any 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 requ
26、irement. For the 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 position
27、er shall be subjected 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 require
28、ments specified 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, ads
29、orber and filter)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 component
30、s which were degreased 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 tetrachlo
31、ride solvent. 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 org
32、anic solvent because 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 clean
33、ing temperature 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 visual
34、ly andqualitatively 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-infla
35、mmable detergents 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.
36、 Installation of 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 kep
37、t in a same horizontal 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
38、:adjust the level 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
39、 interval 150mm 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
40、 the installation 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 allFig. 36.6 Before the installation of the cold box without foundation frame, the bottom plate of cold boxshall be subjec
41、ted to secondary 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 mor
42、tar) is used in 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 on
43、to the foundation 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
44、 be collected 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 n
45、eat and above 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 ofverti
46、cality of total 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
47、and wrapped with 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 bra
48、ce.Brace（支撑） rubber sleeve（橡皮套）Fig. 57.2 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 shi
49、mming 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 (of the effective section of trays of lower column, excluding the main condensing evaporator) shall not exceed 0.5/1000. After correction of the verticality, the pad sheets shall be prevented from shift through welding with frame face of lower column.7.3 Installation of upper column:7.3.1 Assembly and welding of upper column and main condenser.7.3.1.1 Use the pneumatic (or
