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This code is revised by China National Chemical Engineering Group Corporation Ltd., The 13th Construction Co., Ltd. of China National Chemical Engineering and National Chemical Construction Standardization Management Center Station as organized by the China Petroleum & Chemical Engineering Survey and Design Association in accordance with the requirements of Notice on printing the formulation and revision plan of first batch industry standards in 2009 (GONGXINTINGKE [2014], No. 104) issued by the Ministry of Industry and Information Technology and the document (ZHONGSHIHUAXIEZHIFA [2009] No. 136) of the China Petroleum and Chemical Industry Association.
This code replaces HG 20203-2000 General specification for installation and acceptance of chemical machinery as of its implementation date.
After extensive investigation and careful summarization of practical experience, with reference to relevant international and foreign advanced standards and based on widely soliciting opinions, the drafting group of this code revised this code.
This code consists of 8 clauses and 11 annexes, with the main contents including general provisions, terms and symbols, construction preparation, machine installation, cleaning and assembling, installation for auxiliary equipment and piping, single unit test run and hand over technical documents.
The following main changes have been made with respect to HG 20203-2000:
1. The terms and symbols are added;
2. The installation without pad plate and with spiral jackscrew is added in 4.2;
3. The 5.3 “Assembling of coupling” is added;
4. 6.2 “Piping installation for oil system and other system” and 6.4 “Degreasing, anti-corrosion and heat insulation” are added in clause 6;
5. The original "Annex E Mixture ratio of concrete for grouting" is deleted;
6. The "Annex E Cleaning and washing for fittings and piping” is added;
7. The clause 7 “Pre-test run work” is revised as “Single unit test run”, with the contents adjusted;
8. The names and contents of other clauses are also adjusted, modified and supplemented.
This code was proposed by and is under the jurisdiction of China Petroleum & Chemical Engineering Survey and Design Association.
Code for construction and acceptance of chemical machine installation engineering
(General purpose requirement)
1 General provisions
1.0.1 This code is formulated in order to improve the construction level of chemical machine installation engineering, strengthen the quality control in the construction process, and ensure the construction quality and safety.
1.0.2 This code is applicable to the construction and acceptance of general purpose requirements for the on-site assembly or integral installation of compressors, fans, chemical pumps, centrifuges, stirrers, filters, dryers and refrigerators.
1.0.3 The installed machines, parts and components, and main materials shall meet the requirements of the design documents.
1.0.4 For chemical machine, during the construction, the implementation shall comply with the design documents.
1.0.5 For the construction and acceptance of chemical machine installation engineering, this code shall be implemented and the requirements of current relevant standards of the nation shall be met.
2 Terms and symbols
2.1 Terms
2.1.1
machine
machinery equipped with driving device and mainly composed of moving action components
2.1.2
equipment
machinery mainly composed of static action component
2.1.3
set
machinery combination of several different machines, auxiliary equipment and detection and automatic control system to complete the same task
2.1.4
datum (point, line and level)
point, line and plane determined as the standard position of the starting point for measuring and adjusting the position of one or several relative points, lines and planes when the machine is installed and tested
2.1.5
datum size
size given by the design document, which is a reference size used to determine the deviation limiting size
2.1.6
deviation
algebraic difference obtained by subtracting the datum size from an actual size or limiting size
2.1.7
tolerance deviation
limit range of allowable deviation for the two limits between which the size change is allowed, which is determined in order to meet certain use requirements while determining the datum size
2.1.8
centring deviation
deviation of the adjusted axis relative to the reference axis at the axial and radial positions
2.1.9
radial displacement
offset of the adjusted axis relative to the reference axis at the radial position
2.1.10
axial inclination
degree of inclination of the adjusted axis relative to the reference axis
2.1.11
levelness
degree of inclination of a plane relative to horizontal plane
2.1.12
verticality
degree of inclination of a straight line relative to a plumb line
2.1.13
primary grouting for anchor bolt hole
grouting for the holes reserved for anchor bolts after initial leveling and aligning are carried out for the machine and considered acceptable
2.1.14
secondary grouting for anchor bolt hole
grouting between the foundation and the base surface of the machine after leveling and aligning are carried out as required for the machine and considered acceptable
2.1.15
utility engineering
auxiliary engineering for oil, water, gas and steam systems in chemical plants
2.1.16
single unit test run
test run of the machine body, including no-load and load test run
2.1.17
hand over
handover work carried out by the construction organization to the development organization (or the general contractor) after all the construction tasks (a small amount of tail items that do not affect the test run are allowed) for unit engineering or partial devices are completed according to the scope specified in the design drawings and technical documents, the single unit test run is considered acceptable and it is inspected and confirmed by the supervision organization
2.2 Symbols
θ, ψ——plane angle;
L——length;
b——width;
h——height;
R——radius;
D——diameter;
A——area;
m——mass;
F, W——force and weight;
M, T——moment, torque and couple moment;
p——pressure, intensity of pressure;
t——Celsius temperature;
n——rotating speed;
n1——number of groups;
C——safety coefficient or clearance value;
α——linear expansion coefficient of materials;
Δt——difference between working temperature and ambient temperature.
3 Construction preparation
3.1 Technical preparation
3.1.1 Drawing joint review shall be completed before the construction of chemical machine installation engineering.
3.1.2 Construction technical scheme or technical measures for chemical machine installation engineering shall have been approved.
3.1.3 Before construction of chemical machine installation engineering, technical disclosure shall be carried out for the construction personnel.
3.2 Technical materials
3.2.1 Prior to the construction of chemical machine installation engineering, the following technical materials shall be available:
1 Installation engineering construction drawings and design documents.
2 Assembly drawings, main component drawings, vulnerable part drawings and instructions of machines and equipment.
3 Certificate of conformance issued by the machine and equipment manufacturers and inspection records of assembling, test and test run.
4 Packing list of machines and equipment.
5 Product quality certificate of the machine and equipment manufacturers shall include the following contents:
1) Quality certificate, certificate of conformance and valve pressure test certificate of random pipes, valves, pipe fittings and fasteners;
2) Quality certificate, certificate of conformance and manufacturing supervision and inspection certificate of random pressure vessels.
3.2.2 Construction tables for quality records and hand over technical documents shall be complete.
3.3 Unpacking inspection and keeping
3.3.1 For the inspection of imported machines, auxiliary equipment and materials, detailed inspection rules shall be compiled in accordance with the current professional standard HG 20234 General rules for inspection of imported equipment and materials for chemical industrial construction projects and accompanied technical documents, after which is approved can the inspection be carried out.
3.3.2 Unpacking acceptance of machines, equipment and materials shall be conducted with the participation of the development organization or the general contractor, the supervision organization and the installation organization; for large and complex machines and equipment, the unpacking inspection shall be conducted with the participation of the manufacturer beside the aforesaid interested parties, with the following requirements met:
1 The packing condition, box number, name, specification, model and quantity of packaging boxes of machines, equipment and materials shall be verified.
2 The technical documents and special tools of the machine shall be complete.
3 The appearance of machines and auxiliary equipment, parts, components and accessories shall be checked, and the type, specification, model and quantity of parts, components and accessories shall be verified.
4 The inspection records shall be signed after inspection.
3.3.3 The inspection records of the auxiliary equipment belonging to the pressure vessel shall be complete.
3.3.4 After the machines, equipment and materials are accepted by all parties, they shall be kept and maintained in accordance with the following requirements:
1 The warehouse or workshop for storing machines and accompanying accessories shall be dry, ventilated and anti-corrosive.
2 Machines placed in open-air shall meet the following requirements:
1) The machine shall be lifted by padding, placed stably and neatly.
2) Temporary covering measures should be taken;
3) The inlet and outlet shall be sealed.
3 Where there are special maintenance requirements specified in the accompanied technical documents, the machine shall be subjected to special maintenance as required.
4 The surface of the packaging box shall be in good condition. In case of any damage, it shall be repaired in time.
5 Fire-fighting equipment shall be available at the storage site.
3.3.5 Electrical and instrument equipment and accessories matched with the machine shall be accepted by personnel from various disciplines.
3.4 Requiring conditions of construction site
3.4.1 The following conditions shall be provided before machine installation:
1 The main civil works have been completed, the foundation is ready for installation, and the underground works near the foundation have been completed.
2 The site has been leveled and sundries cleaned up.
3 Transport and fire fighting roads for construction have been unblocked.
4 Water, power, steam, compressed air, lighting and communication systems for construction are complete.
5 The lifting and transporting machinery are ready for use.
6 Storage warehouses for parts, components and materials are ready for use.
7 The detection instruments and test equipment used for the installation of the machine have been fully prepared.
8 Fire fighting equipment has been fully prepared.
3.4.2 Where the environment on the construction site does not meet the construction requirements, protective measures shall be taken.
3.5 Acceptance and treatment for foundation
3.5.1 Before the foundation is used, the handover shall be carried out and the following data shall be provided:
1 Foundation construction records, foundation acceptance reports and foundation defect treatment records.
2 Concrete test block strength test report.
3 Foundation handover certificate.
3.5.2 The elevation datum line as well as the vertical and horizontal center lines on the foundation as well as the coordinate axes on the building shall be distinct.
3.5.3 Where the design has settlement test observation requirements on the foundation, the elevation records of settlement observation points shall be verified, and the settlement observation time and settlement amount shall meet the relevant requirements of the current professional standard JGJ/T 8 Code for deformation measurement of building and structure.
3.5.4 The foundation surface shall be free from such defects as cracks, honeycombs, cavities and rib leakage.
3.5.5 The foundation size and position shall be remeasured, with the tolerance deviation meeting those specified in Table 3.5.5.
Table 3.5.5 Tolerance deviation of foundation size and position
In mm
Item Tolerance deviation
Coordinate location (vertical and horizontal axes) 20
Elevation of different planes 0
-20
Overall size of plane ±20
Overall sizes of the upper plane of the convex plate 0
-20
Recess size +20
0
Levelness of the upper plane of the foundation (including the part of floor where equipment is installed) 5mm/m, with a total length of 10
Verticality 5mm/m, with a total height of 10
Embedded anchor bolt Elevation (top) +20
0
Center distance (measured at root and top) ±2
Reserved anchor bolt hole Central position 10
Depth +20
0
Verticality of hole wall 10
Anchor-plate anchor bolt hole Elevation +20
0
Central position 5
Levelness of the anchor plate 2
Embedded casing pipe Verticality of casing pipe 5mm/m, with a total height of 10
3.5.6 The foundation treatment before installation shall meet the following requirements:
1 The foundation for secondary grouting for anchor bolt hole shall have a pitted surface. The depth of pitting should be greater than 10mm, and the density should be 3~5 points per 100mm×100mm; there shall be no oil stain or loose layer on the foundation surface.
2 The foundation surface from the place where the pad plate is placed to the periphery of about 30mm shall be leveled, with the tolerance deviation of levelness preferably being 2mm/m.
3 Gravel, mud, accumulated water and other sundries in bolt holes shall be removed.
4 Machine installation
4.1 Installation with pad plate
4.1.1 The layout of the pad plate group shall meet the following requirements:
1 One group shall be placed on each side of the anchor bolt. Where the spacing between the anchor bolts is less than 300mm, one group of pad plate may be placed on the same side of each anchor bolt.
2 The pad plate group on both sides of anchor bolts with anchor plates shall be placed on both sides of reserved holes.
3 The spacing between two adjacent pad plate groups should not be greater than 500mm.
4.1.2 The calculation and selection of the minimum area of the pad plate group shall meet the following requirements.
1 The minimum area of the pad plate group may be calculated using Formula (4.1.2-1):
(4.1.2-1)
where,
A——the pad plate area, mm2;
C——the safety coefficient, which may be 1.5~3;
W1——the load imposed by the weight of the machine on the pad plate group, N;
W2——the load generated on the pad plate group after the anchor bolt is tightened, N;
p——the compressive strength per unit area of foundation and floor concrete, which may be the concrete design strength, MPa.
Foreword iii
1 General provisions
2 Terms and symbols
2.1 Terms
2.2 Symbols
3 Construction preparation
3.1 Technical preparation
3.2 Technical materials
3.3 Unpacking inspection and keeping
3.4 Requiring conditions of construction site
3.5 Acceptance and treatment for foundation
4 Machine installation
4.1 Installation with pad plate
4.2 Installation without pad plate
4.3 Anchor bolt
4.4 Locating, leveling and aligning
4.5 Grouting
5 Cleaning and assembling
5.1 General requirement
5.2 Assembling for bolt, key and locating pin
5.3 Assembling of coupling
5.4 Assembling of rolling bearing
5.5 Assembling of sliding bearing
5.6 Assembling of interference fitting
5.7 Assembling of sealing element
5.8 Assembling of driving belt, chain and gear
6 Installation for auxiliary equipment and piping
6.1 Installation of auxiliary equipment
6.2 Piping installation for oil system and other systems
6.3 Jointing for piping and machine
6.4 Degreasing, anti-corrosion and heat insulation
7 Single unit test run
7.1 Conditions required for test run
7.2 Preparation for test run
7.3 Single unit test run
8 Hand over technical documents
Annex A Setting pad plate with pressure grouting or seating mortar method
Annex B Installation without pad plate
Annex C Twisting moment and axial tensile force for anchor bolt
Annex D Operating method for centring and aligning for coupling
Annex E Cleaning and washing for fittings and piping
Annex F Methods of surface treatment in common use and quality requirement
Annex G Seizure resistance agents in common use
Annex H Calculating method for bolt rigidity, rigidity of connected fittings and fastening moment
Annex J Assembling method for interference fit and transition fit
Annex K Adjustment for tensile force of triangular belt
Annex L Mixture ratio for acid cleaning solution of piping
Explanation of wording in this code
List of quoted standards
