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SPC现场电气设备安装及调试方案SPC Electric Equipment Field Installation and Commissioning method statement版本Rev.编制Prepared by审核Reviewed by批准Approved by认可Accepted by目 录1.目的2purpose22.工作范围2work scope23.编制依据2references24.施工准备2Preparation for construction24.1工机具准备2Preparation for machine and tools24.2应配备下列人员：3Preparation for personnel34.3技术准备3Preparation for technical34.4材料准备3Preparation for materials34.5人员准备3Preparation for construction person35.电气设备安装要求4installation requirment46.金属构件制作安装及控制箱、盒安装5metal component fabrication and installation, control box installation56.1操作柱的制作安装5operation post fabrication57.电动机检查6electromotor inspection67.1作业条件6work condition67.2作业方法6work method67.3电动机启动调试7start commissioning78.照明安装。12Illumination installation128.1导线的敷设12lead pulling128.2照明灯具作业方法和步骤12lighting appliance working method and steps129.交工验收要求12handover acceptance requirements1210.危险点分析13hazardous analysis131. 目的 purpose 本程序描述拜耳聚碳酸酯SPCII项目电气设备安装有关规定。为保证电气设备的正确安装及电动机能安全投入运行，促进施工管理和技术水平的提高。 This procedure describes the related provision on electrical equipment installation of Bayer Polymers SPCII project so as to ensure the correct installation, operation and promote the administration and technology skills. 2. 工作范围 work scope适用于拜耳聚碳酸酯SPCII项目，主要区域为B204、B244、B209；其中电机就地控制按钮共计51个；就地控制盘2个；电机就地控制转换开关54个；电动机检查及启动调试共计68台；照明安装 28盏。It is applied to the main area B204、B244、B209 of Bayer Polymers SPCII project, among which there are 51 electrical grounding control button; 2 grounding control panel;54electrical grounding control switch; 68 motor inspection and commissioning and 28 lighting installation. 3. 编制依据 referencesGBJ 50254-96 电气安装工程低压电器施工及验收规范； LV electrical apparatus construction and acceptance code for electrical installation engineering GBJ 50254-96GBJ 50255-96 电气安装工程电力变流设备施工及验收规范；Electric power variable current equipment construction and acceptance code for electrical installation engineering GBJ 50255-96GBJ 50256-96 电气安装工程起重机电气装置施工及验收规范；Lifting electric device construction and acceptance code for electrical installation engineering GBJ 50256-96GBJ 50257-96 电气安装工程爆炸和火灾危险环境电气装置施工及验收规范；Electrical equipment construction and acceptance code in explosive and fire enviroment for electrical installation engineering GBJ 50257-96GBJ 50303-2002 建筑电气工程施工质量验收规范；Code for construction and acceptance of electrical engineering GBJ 50303-20024. 施工准备 Preparation for construction4.1 工机具准备 Preparation for machine and tools电锤、手锤、电缆剪断钳、兆欧表、万用表、钳型电流表、切割机、磁力线坠、斜口钳、机械和液压工具、力矩扳手、电工刀。Electric hammer, hand hammer, cable cutting pliers, megohmmeter,multimeter, clamp-type ammeter,cutting machine, magnetic line cone, inclined mouth pliers, mechanical and hydraulic pressure tools, moment spanner, electricians knife.4.2 应配备下列人员：Preparation for personnel安全监督员、施工队长、班长、取得施工资格的工人。Safety officer, construction team leader, foreman, qualified certificate worker.4.3 技术准备Preparation for technical4.3.1 熟悉电机安装位置。 Familiarize with installation location4.3.2 核对电机及电缆规格、型号与电缆清册相符 Check the specification and model of motor and cable against cable checklist. 4.3.3 熟悉照明灯具的具体安装位置，电源电缆的敷设路径及端接位置。 Familiarize with the concrete installation location of lighting device, layout route of power cable and termination place. 4.3.4 核对图纸和清册，并与相关专业进行图纸会审。 Checking drawing and cable list, making a joint drawing check up with relevant professional.4.4 材料准备Preparation for materialsC型钢、槽钢、膨胀螺栓、螺栓等。 C steel, channel steel, expansion bolt, bolt and so on. 4.5 人员准备 Preparation for construction person序号No.职务title姓名Name 责任Duty1施工队长Construction team leader宋建平Song jianping全面负责电气设备安装In for charge of E&I equipment installation2安全负责Safety officer谭克明Tan keming全面负责电仪安全In for charge of E&I safety of laying cable3工程师engineer吴跃年Wu yuenian负责电仪技术工作In charge of E&I Technical works4电气工程师Electrical engineer宋 强Song qiang负责电气技术工作In charge of E&I Technical works 5电工Electrician李长波Li changpo电气安装Electrical installation6电工Electrician苌新庄Chang xinzhuang电气安装Electrical installation7电工Electrician丁文戈Ding wenge电气安装Electrical installation8电工Electrician赖洪坤Lai hongkun电气安装Electrical installation9电工Electrician谭永建Tan yongjian电气安装Electrical installation10普工Electrician吴 波Wu po电气安装Electrical installation11普工labors姜正健Jiang zhengjian电气安装Electrical installation12普工labors张金龙Zhang jinlong电气安装Electrical installation13普工labors张志勇Zhang zhiyong电气安装Electrical installation14普工（6名）labors(six)电气安装Electrical installation5. 电气设备安装要求 installation requirment电气设备的安装必须遵照布置图纸中所规定的尺寸。当在图纸上没有标明设备的安装尺寸时，应将设备尽可能装在靠近图纸上显示的相对位置。Electrical equipment installation should observe the prescribed demension in drawing. The equipments should as far as possible locate nearby the place showed in the drawing when installation demension isnot marked.设备不得装在伸缩缝上。在钻固定于地面设备的膨胀螺栓孔时，要特别注意，不要将混凝土内的钢筋打断，因为这样可能影响建筑物结构的受力情况。 It is forbidden to install equipment on the flexiable seam. When drilling expansion bolt fixed on ground, pay attention not to break the concrete bar. 设备在搬运和运输过程中应尽量保持原始包装或至少保持塑料保护罩。Keep original packing or at least plastic cover during transit. 在安装期间注意保护盘面油漆不被破坏。安装结束后在盘面油漆被刮伤的部位补漆。所补油漆采用制造商随设备一起提供的油漆，其颜色的调配应尽可能与设备原色保持一致。Protect surface paint from damage during installation. After completion, repaint the scratched parts. The paint should be supplied by manufacturer with equipment and the color as far as possible keep the same. 6. 金属构件制作安装及控制箱、盒安装 metal component fabrication and installation, control box installation 6.1 操作柱的制作安装 operation post fabrication 6.1.1 操作柱选用10#镀锌槽钢，就地控制按钮及维修开关中心高度为1.4米；根据现场实际情况，有些电机的控制按钮和维修开关可安装在就近电机的柱子上；对于某些电机的操作柱可采用10mm厚钢板作为操作柱底板，用膨胀螺栓固定在地面上，对于一层的操作柱不允许直接安装在地面上，以防止操作柱被介子腐蚀，因此用C型钢固定10#镀锌槽钢在设备基础上，安装方式见下图：10# galvanized channel steel is used for operation post and the hight of grounding control button and maintenance switch is 1.4 meter. Depending on site condition, some control button and maintenance switch of motors can be installed in the post. For a certain number of posts, 10mm steel plate can be used as post base plate and be fixed on ground by expansion bolt. Its not allowed to install the first layer of operation post directly on the ground in case of particle corrosion. Hence, fix 10# gavalnized channel steel to equipment base by C steel. Refer to the following sketch of installation method: 7. 电动机检查 electromotor inspection 7.1 作业条件 work condition 7.1.1 电动机应符合国家现行技术标准的规定，并应有合格证件和出厂检验报告。The electromotor should be in line with national standards, with qualified certificate and check-out report in factory. 7.1.2 电动机在检查前，如果其与机械部分的联轴器已连上，应将联轴器脱开。 Disconnect the connecting axis if it is connected with mechanical component prior to check electromotor. 7.2 作业方法 work method 7.2.1 检查电动机外观应无损伤，并抄录铭牌。 Inspect the appearance of electromotor for intactness and write down the nameplate 7.2.2 盘动电动机转子应灵活，不得有碰卡声。 The rotor should be agile without “blocking” voice. 7.2.3 打开电缆接线盒，检查引出线鼻子焊接或压接应良好，编号齐全，裸露带电部分的电气距离应符合产品标准的规定。Unpack the cable junction box and check the educing lug to make sure welding good and serial number complete. The distance of naked section with power should be in compliance with product standards7.2.4 测量电动机绝缘。低压电动机绝缘电阻应不小于0.5兆欧。吸收比不小于1.2，100KW以上的电机应测量电机绕组的直流电阻，恢复电缆接线盒。Measure the insulation of electromotor. Insulation resistance of LV electromotor should not be less than 0.5 megohm, the absorption ratio no less than 1.2. The DC resistance of winding should be measured for electromotor above 100KW and recover cable junction box. 7.2.5 当检查电机有下列情况之一时，应作抽芯检查。Core inspection should be performed when facing one of the following condition: l 出厂日期超过了制造厂的保证期限，当制造厂无保证期限时，出厂日期已超过一年。l Date of leaving factory is beyond the promised period of manufacturer or is more than one year when missing guaranteed date. l 经安装检查或电气试验，质量可疑时。l Through installation inspection or electric test, the quality is suspicious l 试运转电机有异常情况时。l Abnormity when commissioning electromotor 7.2.6 电机接线前需测量绕组的绝缘电阻；Insulation resistance of winding needs to be checked prior to connection7.3 电动机启动调试 start commissioning 7.3.1 作业准备仪器仪表配备instrument preparation 序号名 称规 格数量1兆欧表megohmmeter 1000V/1000兆欧1只2兆欧表megohmmeter500V/500兆欧1只3钳形电流表 forcipiform ammeter100A(最大范围)1只4钳形电流表 forcipiform ammeter50A(最大范围)2只5数字万用表 digital multimeterDT-890B3 块6指针式万用表 figurelike multimeterMF-151 块7对讲机 walkie-talkie4只8直阻仪 DC ohmmeterZGS200/3A1台7.3.2 作业条件 work condition l 设备材料、铭牌、资料、合格证等齐全。Get material, nameplate, qualified certificate ready. l 电动机及机械设备周围土建应全部完工无杂物，道路畅通。Civil work around electromotor and mechanical equipment should be finished without any obstaclesl 消防及通讯器材应配备齐全。Enough fire fighting and communication equipmentl 电动机周围应无积水，且干燥。 No seeper around electromotor and keep dry7.3.3 作业方法及工艺要求 working method and process requirementu 电动机启动前应检查下列项目：the following items should be checked prior to start: l 电动机及一、二次回路绝缘试验应合格。电机动力电缆及控制电缆的绝缘测试记录已报审。 l Electromotor and fist, secondary loop insulation test should be qualified. Insulation test record of Eletromotor power cable and control cable has submitted for approval l 电动机接线应正确，电缆要进行核对，保证正确无误。l The electromotor connection should be correct and the cable requires to be checked to make sure inerrability. l 电动机外壳的接地线应明显可靠。 l Obvious and stable grounding wire outside electromotorl 引线与电缆连接应坚固，电缆连接螺栓、绝缘包扎良好。l Solid connection between outcoming line and cable with good enswathement of connecting bolts and insulationl 电动机的绝缘电阻最少应达到下列数值，低压电机应不小于0.5兆欧（常温下）。 l The insulated resistance of electromotor should at least reaches the following number: LV electromotor should no less than 0.5 megohm (nomal temperature) l 电机转子转动应灵活，无碰卡现象，带机械启动应检查机械部分无卡住现象。 l The rotor running should smooth without any obstacles l 热继电器规格、整定值应与电机容量相匹配。l The specification and fixed value of heat relay should match with capacityl 电机的保护、控制、测量、信号等回路的应调试完毕，动作应正常。l Finish commissioning of protection, control, measure and signal loop with normal action u 电机的第一次空载启动：first start without load 电机空载运行时间宜为二小时。没有条件进行第一次空载启动，只能带负载启动的电机，应要求机械有关专业人员在场，经机械专业人员确认后，方可进行第一次启动。不能反转的电机试车前必须做转向试验，以保证电源接线的正确性。若为远方操作的电机，操作者应与就地人员联系好后方可启动，发现异常可立即停机。u 2 hours running without load is prefered. The mechnical professionals must be onsite and after confirmance by them, the first start-up with load can commence. Electromotor which cannot reverse must carry out turning test to ensure the correctness of power supply connection. If it is remote control, operator should well communicate with local workers and afterwards start up, stop promptly when any abnormity found. u 电动机初次启动，应符合下列要求：first start-up should meet the following requirements: l 电机的旋转方向应符合机械要求，无异常声音。l The rotation orientation of electromotor should be in accordance with mechanical requirements wihout any abnormal sound. l 工作电流不应超过允许值。l Operating current shoulnot exceed the allowable valuel 检查电机温度不应超过产品技术规定。l Check for the electromotor temperature not above the technical descriptionl 有维修开关的电机在运行前把开关的位置由“OFF”转到“ON”位置l Eletromotor with maintenance switch should be turned from “ OFF” to “ON” prior to operation l 检查就地控制按钮的功能是否符合要求，此时变电所MCC应在试验位置。l check whether the function of control button satisfies the requirement, at that time substation MCC should be in testing position l 检查MCC抽屉各功能是否符合要求。l Inspect whether each function of MCC locker is up to the mustard. u 带负荷试运行 operation with loading 电机空载试运合格后，根据调试指挥部的要求，即可带负荷试运行，试运时应记录启动时间和负载电流。电机带负荷启动时，应注意如下事项：Perform operation with loading as per the commisioning headquarter after qualified operation without loading. And record start-up time and loading current. Notice the following items when operating with loading: l 交流电机的带负荷启动次数，应符合产品技术条件规定。l The start-up times of loading AC electromotor should accord with technical requirements. l 冷态时，可启动二次。每次间隔不得少于5min。l In cold state, it can be started two times. Each interval no less than 5min. l 热态时，可启动一次。当在处理事故以及电机启动时间不超过23S时，可再启动一次。l In hot state, it can start one time. It can start again when handling accident or the starting time is no more than 2 or 3S. l 电机启动宜逐台进行，应避免在同一条母线上同时启动两台较大容量的电动机。l The electromotor start-up should be one by one to avoid running two large-sized electromotor at the same time in one generatrix. u 工程验收 acceptance 工程完工后，应填写验收单，与质检人员一道进行验收鉴证。u The check and accept sheet should be filled in with QC after completion construction. u 作业流程图 flow chart开始start施工前准备Preparation prior to construction启动前准备Preparation prior to start-up空载启动试运Start-up operation without load运行情况是否正常Whether operation is normalN停机、检查处理stop, checking and handling Y2小时空转试运2-hour running without load带负载试运行Running with load验 收Accepted 结束completion8. 照明安装。Illumination installation 本工程的照明集中在B204及B209，B204的照明根据现场的实际情况增加少量的照明灯具，至灯具的桥架可采用100*50格珊桥架，电源电缆可沿原有一期施工的桥架敷设至配电箱，要求施工人员熟悉图纸，确定管路走向和安装用接线盒、灯具、开关及配电箱的位置， The illumination concentrates on B204 and B209. it requires a little more lamps and lanterns in B204 based on the site condition, to which should be 100*50 grid cable tray. Power cable pulls along the existed tray to switchbox. The construction worker must familiarize with drawing and know exactly the location of pipeline running, junction box, lamps and lanterns, switch and swtichbox. 8.1 导线的敷设 lead pulling 1. 检查电缆型号和规格是否符合设计要求。 Check the model and specification of cable as per design request. 2. 电缆敷设完毕后用500/1000欧姆表检查线路绝缘。Examine the insulation using 500/1000 ohmmeter when cable pulling is over3. 线路绝缘完好既可接线装灯及其它用电器。With good insulation, the lamp and other electrical apparatus can be connected. 8.2 照明灯具作业方法和步骤 lighting appliance working method and steps1. 灯具采用吊装、壁装、立杆安装,线路可从灯具的任意位置（一般在灯具的两端或中间）引进和引出，灯具可直接用膨胀螺栓或者按厂家要求在固定墙上、柱上、屋顶上。 Lighting appliances are installed as pendant lamp, wall lamp and post light which are fixed on the wall, post and ceiling with expansion bolt or as per the manufactures requirement. The wire line could come out and in at any place of lighting appliance (generally in the middle or the end).2. 作业过程中出现问题的处理方法。如用电器装好后，电路总开关和分支开关合不上，应检查火地线是否接错，导线绝缘有无破损。如日光灯不能发光或发光困难，灯管两头发亮或灯光闪耀，应检查线路是否断开，接线是否错误或灯座，灯脚接触不良等。Problem-handling methods during construction: check the fire grounding wire and lead insulation if the general switch and branch swtich can not close after installation. check whether the circuitry is disconnected or connection is wrong or bad lamp holder connection when the daylight lamp malfunction 9. 交工验收要求 handover acceptance requirements 在电气设备、线路的安装工作完成后，应对电气设备及系统安装的符合性进行检查即单回路系统试验，并进行交工验收。Carry out single loop test after completion of electrical equipment and system installation and accept it . 单回路系统试验依据设计规定的要求进行。在单回路系统试验阶段应完成以下工作：the following items should be finished at the stage of single loop system test as per the design requirements: 检查电气安装的部位及它们的型号规格、系统连接用的桥架和导线型号规格是否符合设计要求；Inspect the installation location, model, specification of electrical apparatus,tray and lead against design requirement检查电气安装方法、导线和敷设方法、电气设备的连接是否符合设计图纸和安装使用说明书的要求；Inspect the installation and connection method of electric equipment, lead pulling method against drawing and installation manual. 单回路系统试验完成后，填写单回路试验报告。Fill in report after completion of single loop system test. 以上工作全部完成后，电气设备的安装即可认为结束。Electrical equipment installation is concluded after all the above work done. 10. 危险点分析 hazardous analysis 1. 进入高温或附近有火源的区域，需设置隔离防护栏，准备好灭火工具。Isolation safety rail will be established and fire fighting apparatus will be needed when entering into hot temperature or fire source places.2.SPCII电气设备大部分是在生产与施工的环境下同时进行，务必要求所有进入生产区域现场施工的人员不得接触任何与施工无关的设备，并且严禁碰撞生产设备、管线；生产区域内施工时必须开作业票，办理工作许可证，无证严禁施工。Electric Equipment in SPCII area is under operation condition, it is required that all construction people do not touch any equipment unrelated to construction and knock on production equipment and pipe; job slip and work permit will be needed when working in the production area. It is forbidden to work if no work permits.3. 进入B204一期生产区作业施工时，该生产区域内介质都为有毒的液体、气体或粉末状物质，应在施工区域内拉上警戒线，并搭设防护栏；在规定的警戒线范围内施工。 Guard line and safety rail will be established and work in the stated range when construction can be done in first term of B204 area because this area is poisonous.4. 施工用电严禁将电线直接勾挂在闸刀上或直接插入插座内使用。Its forbidden to directly hang the wire of construction electricity on the brake or plug into receptacle for usage. 5. 电源线路不得接近热源或直接绑挂在金属构件上。Wiring route of power supply should not be clost to heat source or directly tie with the metal components. 6. 在光线不足及夜间工作的场所应有足够的照明，主要通道上应装设路灯。There should be enough illumination for places without sufficient lighting or night working area, and road lamp standing on the main routeway7. 进入施工现场请带好安全帽，上高必须系安全带。使用梯子需有人监护，梯子底部应有防滑措施，人字梯需有限制张开的绳索，且一张梯子上不得站两人。 Wear safety helmet prior to entering construction site and tie safety belt when climbing upwards. It demands guardians and slide-proof measures at the bottom when using ladder. trestle type ladder should be equiped with rope which restricts spread. and just one person one ladder. 8. 使用电动工具和电火焊器械必须按规程操作。operating electromotor tools and electrical, fire, welding instrument according to regulations. 9. 施工场所每天应清理整顿，做到工完料尽场地清。Clean up the construction site everyday to catch the saying that when the work finished the materials are used up and site clean. 10. 运输设备时，注意设备和人身安全，不要损坏设备的油漆，内部元件以及其表面的平整度。During transit, maintain both equipment and personnel safely and donot destroy the paint, inner element and the surface level of equipment. 11. 所有作业人员应严格执行电业安全工作规程中的有关规定。All workers should strictly observe and follow the provisions in safety construction codes of electrical industry 12. 电机试运时，应定时巡视，确保设备及人身安全。When motor trial operation, carry out regular patrol to ensure equipment and personnel safety13. 送电操作时，双方应取得联系，严格执行操作监护制度。 When power-on operation, carry out mutual communication and strictly implement operation guardianship system.
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