内蒙古博源联合化工有限公司 1000kt/a天然气制甲醇项目主装置
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框架和管架钢结构施工方案
编 制：唐建军
审 核：贺 嵘
批 准：周宗华
中国化学工程第十一建设公司
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中国化学工程第十一建设公司
内蒙古博源联合化工有限公司 1000kt/a天然气制甲醇项目主装置
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目 录
1 2 3 4 5 6 7 8
编制说明 ·······························································································································································44 编制依据 ·······························································································································································44 施工准备 ·······························································································································································44 防腐 ··········································································································································································44 预制 ··········································································································································································44 吊装组对 ·······························································································································································44 施工技术要求·····················································································································································45 质量控制 ·······························································································································································45 8.1 8.2 9 10
主要工序控制点 ··································································································· 45 钢结构验收 ··········································································································· 46
质量保证措施·····················································································································································46 安全文明施工技术措施··························································································································46
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中国化学工程第十一建设公司
内蒙古博源联合化工有限公司 1000kt/a天然气制甲醇项目主装置
44
框架和管架钢结构施工方案
1 编制说明
因无钢管架、钢框架的图纸资料，根据我单位施工经验编制，仅用于投标。
2 编制依据
《钢结构工程施工及验收规范》（GB50205-2001）；
内蒙古博源联合化工有限公司1000kt/a天然气制甲醇项目招标文件。
3 施工准备
建立钢结构预制场，准备好下料、焊接、钻孔、防腐、运输吊装的机具材料。 进行钢结构施工之前，应做好包括基础复验﹑技术交底﹑材料复检﹑劳动力﹑工机具等的准备工作。
4 防腐
防腐工作应在下完料组对前进行，只刷一遍底漆，待结构施工完成之后再进行彻底的防腐工作。
5 预制
预制工作应在平整的钢平台上进行，所有板材的切割应用剪板机（厚度≤12mm
的钢板）或用氧-乙炔焰切割（厚度>12mm的钢板），钢材的切割断面应用砂轮机打磨平整，将同一截面上的管架按照尺寸预制成型（包括柱子的高度，跨度等主要尺寸），尽量减少高空作业。长度不够的梁﹑柱在对接时，应采用45度斜对接方式，以增加构件的强度。采用直接方式的应根据需要增设补强板，并校核其强度。
管架和框架在地面预制成片后组对成整跨桁架，焊接检验，完成防腐工作后整体吊装。
6 吊装组对
经检验合格的半成品构件（预制件）用吊车吊装找正，并且应立即安装联接梁，组
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中国化学工程第十一建设公司
内蒙古博源联合化工有限公司 1000kt/a天然气制甲醇项目主装置
45
装成片，以减少危险程度。 3.2.5焊缝检验：
包括外观和无损检验（无损检验指使用超声波探伤）。无损检验的焊缝主要指需要熔透焊接的H型钢翼板和腹板的对接以及H型钢翼板的T形对接处。凡在地面上预制的焊缝需要做无损检验的，均应在地面上检验。
7 施工技术要求
1）钢结构焊接采用CO2保护焊和手工电弧焊，使用J422（E4303）焊条，焊条应按照规定烘干保温，焊工使用保温筒盛装焊条，随用随取。
2）钢构件在吊装找正前应进行检查，其变形﹑缺陷应先校正，校正后的尺寸偏差不得超出允许值。
3）柱脚底板的安装使用无垫铁安装法。
4）钢柱安装时，应待灌浆层达到设计强度后方可安装柱子，安装柱子之后应立即安装联接梁，按照规定的焊接工艺焊接，不允许点焊，花焊。
5）钢格板及其他附属设施的安装应在管廊结构基本完成后再安装。 6）钢材涂装前的表面应无泥沙，浮锈，油污等杂物。
7）油漆涂层应均匀，无流挂，起皱，每道底漆与面漆的干膜厚度为45~55mm，涂装完好后的干膜总厚度为200±20 mm。
8）涂装完好的钢结构表面应无明显的颜色差异，无金属表面暴露在外。
8 质量控制
8.1 主要工序控制点
序号 1 2 3 4 5 名称 施工前技术准备 施工前其他准备 结构预制 结构焊接 结构安装 内容 图纸会审,施工方案的审批 基础,材料合要求,技术交底,三单一卡齐备 下料尺寸,组对合要求 材料焊工合格证,焊缝检验 各定位线正确,标记明显 备注 45
中国化学工程第十一建设公司
内蒙古博源联合化工有限公司 1000kt/a天然气制甲醇项目主装置
46
6 结构防腐 涂料,涂层合要求 8.2 钢结构验收
所有需要熔透焊的焊缝均必须进行100%超声波探伤。焊缝评定标准依据JB4730-94合格等级II级。
所有构件的外形尺寸和安装尺寸偏差应符合规范的质量指标。
钢结构施工完成之后，施工班组要有自检记录，专职质检员要按照规定检查钢结构的偏差值，严格控制工程的质量。
9 质量保证措施
原材料使用前应复检，包括其外形尺寸﹑材质合格证﹑产品合格证﹑材料代用单等。
施工前技术人员必须向施工人员进行技术交底，下发工程质量单。施工人员应作好自检记录。
按照图纸技术要求施工，所有中心线﹑标高线等定位线应用白色油漆标记明显，严格控制结构的尺寸及定位线的偏差值在允许的范围之内。
施工时所使用的计量器具必须经检验合格，并有专职检验员所发的“计量准用”证。 电焊工必须持有与施焊项目相符的焊工合格证才能施焊。焊接前必须有经过焊接质保工程师下达的焊接工艺卡。施焊时应严格按照工艺卡中规定的顺序施焊，防止焊接变形。
10安全文明施工技术措施
1）施工人员应懂得常见突发事故的处理救治措施。
2）进入现场，所有人员必须系戴好安全帽，高处作业必须系挂好安全带。 3）现场施工注意安全用电，所有电动工机具应装好漏电保护器并使其工作在正常状态，以防止触电事故的发生。
4）防腐用油漆应存放在阴凉干燥处，并禁止使用明火，在作业场所和存放库周围必须设置好消防器材，以杜绝火灾事故的发生。
5）钢结构吊装时一定要用溜绳控制构件的摆动方向，在吊车作业区内禁止无关人
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中国化学工程第十一建设公司
内蒙古博源联合化工有限公司 1000kt/a天然气制甲醇项目主装置
47
员入内。吊车臂下严禁站人。
6）各工种施工人员应严格按照本工种操作规程进行作业，不得违章代岗作业。 7）雨雪天气施工时，应注意防滑，并做好钢材的防腐蚀工作。不得进行吊装等高处作业。
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中国化学工程第十一建设公司
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