塔架施工方案.doc

Erection Program For the 443-3P1preheater towerName of the document：The Erection program of the 443-3P1 preheater towerNo. of the document：GU3-方案-M-010Editing department：The Engineering department of CBMIEdited by：Liu Li Da Date：2013-11-20Verified by： Date：Approved by： Date： Version 0目 錄contents一.工程概述 Summary-3 二方案編制依據(jù)Compilation basis -3 三吊裝機(jī)具的選擇The choice of Lifting instrument-6 四質(zhì)量安全保證體系流程圖 The flow chart of quality safety guarantee system-11 五施工工藝過程 The construction process-12六安全及文明施工Safe and civilized construction-16一工程概述Summary:HOLCIM(ECUADOR)GU3水泥廠是一條日產(chǎn)4500噸的水泥熟料生產(chǎn)線。窯尾預(yù)熱器塔架是整個(gè)熟料生產(chǎn)線的關(guān)鍵部位，因其系統(tǒng)復(fù)雜，安裝高度高，構(gòu)件數(shù)量多，單件重量重而成為安裝難度最大的一個(gè)子項(xiàng)之一。預(yù)熱器塔架采用鋼結(jié)構(gòu)和預(yù)熱器相結(jié)合的安裝方式，其中鋼結(jié)構(gòu)的的作用是支撐整個(gè)預(yù)熱器系統(tǒng)，提供生產(chǎn)操作，檢修操作的平臺(tái)。整個(gè)鋼結(jié)構(gòu)主體系統(tǒng)共7層，高96.4m（15m-111.4m），構(gòu)件共9根H型鋼，各層平面有連接梁，上鋪花紋鋼板，鋼結(jié)構(gòu)總重約2500噸。預(yù)熱器在熟料生產(chǎn)中主要起生料預(yù)熱和物料分解的作用，整個(gè)系統(tǒng)分別由五級(jí)旋風(fēng)筒、分解爐、三次風(fēng)管、喂料室等組成，設(shè)備安裝分別從喂料室開始至C1旋風(fēng)筒結(jié)束。預(yù)熱器系統(tǒng)還配備有提升機(jī)、喂料機(jī)、風(fēng)機(jī)、收塵器，電梯等輔助設(shè)備。HOLCIM (ECUADOR) GU3 Cement is a 4500 t/d clinker cement production line. Preheater tower is the key component of clinker production line, because of its complexity, the installation height is high, the number of multi-component, one-piece heavy weight and become difficult to install one of the largest one child. Preheater tower using a combination of steel and installation, which is the role of steel structures to support the entire preheater system, providing production operations, maintenance operations platform. Entire steel body system of 7 storey, 96.4m (15m-111.4m), member of 9 H-beam, the beam is connected planar layers, upper tread plate, steel structure weighing about 2,500 tons. Preheater in the clinker production mainly from the decomposition of raw material preheating and the role of the entire system respectively, by five cyclone, calciner, tertiary air duct, feed room and other components, equipment installation separately from the feed chamber begins - C1 cyclone ends. Preheater system is also equipped with bucket elevator, feeder, fan, dust collector, elevators and other auxiliary equipments.二 編制依據(jù)Compilation basis1. HOLCIM(ECUADOR)GU3水泥廠燒成窯尾工藝布置圖。 HOLCIM(ECUADOR)GU3 PROJECT PREHEATER TOWER GENERAL ARRANGEMENT DRAWING44 / 44工 藝 布 置 圖General arrangement drawing2. HOLCIM(ECUADOR)GU3水泥廠窯尾塔架鋼結(jié)構(gòu)制作、安裝圖。 HOLCIM(ECUADOR)GU3 preheater tower steel structure fabrication, installation drawings3. HOLCIM(ECUADOR)GU3水泥廠預(yù)熱器制作、安裝圖。HOLCIM(ECUADOR)GU3 preheater fabrication, installation drawings4. 鋼結(jié)構(gòu)施工驗(yàn)收規(guī)范Steel construction and acceptance。5. 機(jī)械設(shè)備安裝驗(yàn)收規(guī)范Mechanical equipment installation acceptance。三.吊裝機(jī)具的選擇The choice of Lifting instrument：窯尾預(yù)熱器塔架的安裝主要包括預(yù)熱器的地面組對(duì)工作和鋼結(jié)構(gòu)預(yù)熱器的高空安裝工作。鋼結(jié)構(gòu)、預(yù)熱器的安裝工作由于構(gòu)件安裝高度高，整個(gè)安裝面積大，如使用大型可移動(dòng)吊車將存在吊裝高度不夠，吊裝性能小的問題，并且施工速度也很慢。所以我們將采用STT403-24T型塔吊。地面預(yù)熱器的組對(duì)將使用一臺(tái)50噸吊車。下面是STT403-24T塔吊的性能表和預(yù)熱器塔塔吊的布置圖。Preheater tower installation includes preheater ground group work and steel preheater aerial installation work. Steel structure and the installation of the preheater components mounting height is high, the entire installation area, if using the large mobile crane, the lifting will be not high enough and the less lifting capacity, and the construction speed is very slow. So we will use STT403-24T type crane. Ground preheater group will use a 50-ton crane. Here is STT403-24T crane performance tables and preheater tower crane layout.STT403-24T塔吊吊裝性能表STT403-24T Tower crane performance tableSTT403-24T塔吊載荷信息表STT403-24T Tower crane load chart 塔 吊 布 置 圖 Preheater tower crane layout通過對(duì)預(yù)熱器塔鋼結(jié)構(gòu)重量的計(jì)算，前兩層鋼結(jié)構(gòu)的單件重量達(dá)20噸。結(jié)合塔吊的吊裝性能標(biāo)和塔吊的布置圖可以看出：使用STT403-24T塔吊進(jìn)行預(yù)熱器塔的安裝施工滿足不了施工要求，固需要250噸吊車配合吊裝。Through the preheater tower steel structure weight calculation, all steel single piece weighing not more than 12 tons. Combined with crane and crane lifting performance standard layout can be seen: Use STT403-24T preheater tower crane for installation and construction fully meet the construction requirements四Flow Sheet for Guarantee System of Quality and Safety 質(zhì)量安全保證體系流程圖主管經(jīng)理Mananger：Zhouyougen質(zhì)量安全：Quantity and safety：BowenshuaiDucumentation：Zhangqing Tech director：Zhu ziwuSupervisor：Xue zhiminXiang xianlunLiftingZhangjieChenlabaoDocumentation record and storageSAFETT SUPERVISOR：YANGHAICHAOthe bridge work execute（50 workers）五.施工工藝過程 The construction processitemtimeactivitymethodtoolsNumber of workersNumber of people aroundFeed-end chamber erectionStart:25/12/13End:10/01/14Size(m)Width:5.15mHeight:8.6mLength:2.55mWeight:16.9ton1. Assemble all the parts on the ground.2.lifting feed-end chamber 3.Stairs erectionTower craneArc welderChain blockLength ruler4515itemtimeactivitymethodtoolsNumber of workersNumber of people around+16.000-27.000m column and frame girder erectionStart:10/01/14End:25/01/14Column max.size(m):Length:12.4mGirder max size(m):length: 11mSingle part weight: 5.5ton1.Nine columns erection2.Frame girder erection.Tower crane，Arc welder，Chain block，Theodolite，Length ruler，Electric wrench4515+27.000m sub-girder and platform erectionStart:26/01/14End:31/01/14Sub-girder size(m):Length: 10mSingle part weight: 5ton1.Pipe erection2. +27.000m plan sub-girder erection3.+27.000m platform erection4.Stairs erectionTower craneArc welderChain blockTheodoliteLength rulerElectric wrench4515bottom section Precalciner erectionStart:01/02/14End:02/02/14Size(m)diameter:4.616-6.416mLength:16.174mWeight:20.05tonFirst lift weight:7.5 tSecondly lift weight:14.05 t1. Assemble two parts according to sketch map on the ground.2.lifting first lift3.lifting secondly liftTower craneArc welderChain blockLength ruler4510+27.000-41.600m column and frame girder erectionStart:03/02/14End:13/02/14Column max.size(m):Length:14.6mGirder max size(m):length: 11mSingle part weight: 8 ton1.Nine columns erection2. Frame girder erection.Tower craneArc welderChain blockTheodoliteLength rulerElectric wrench4015+41.600m sub-girder and platform erectionStart:14/02/14End:20/02/14Sub-girder size(m):Length: 11mSingle part weight: 4 ton1.Pipe erection2. +41.600 plan sub-girder erection3.+41.600m platform erection4. Stairs erectionTower craneArc welderChain blockTheodoliteLength rulerElectric wrench4515middle section Precalciner erectionStart:21/02/14End:28/02/14Size(m)diameter:5.646-6.416mLength:8.57mWeight:20.05 tonThirdly lift weight:8.5 tonFourthly lift weight:11.55 ton 1. Assemble two parts according to sketch map on the ground.2.lifting thirdly lift3.lifting fourthly liftTower craneArc welderChain blockLength ruler4515+41.600-50.200m column and frame girder erectionStart:01/03/14End:10/03/14Column max.size(m):Length:8.6mGirder max size(m):length: 11mSingle part weight: 7 ton1.Nine columns erection2. Frame girder erection.Tower craneArc welderChain blockTheodoliteLength rulerElectric wrench4515+50.200m sub-girder and platform erectionStart:11/03/14End:20/03/14Sub-girder size(m):Length: 10.95mSingle part weight: 4 ton1.Pipe erection2.+50.200 plan sub-girder erection3.+50.200m platform erection4. Stairs erectionTower craneArc welderChain blockTheodoliteLength rulerElectric wrench4515C5 cyclone erectionStart:21/03/14End:27/03/141.Upper:weight: 30 ton2.middle:weight: 20.2 ton3.bottom weight: 5 ton 1. Assemble the the bottom, the middle and the upper sections on the ground.2. Lift each section in turn.Tower craneArc welderChain blockWater levelLength rulerElectric wrench4510top section Precalciner erectionStart:28/03/14End:31/03/14Size(m)diameter:5-6.4mLength:8.6mWeight:19.40 ton1.Assemble parts according to sketch map on the ground.2.lifting top partsTower craneArc welderChain blockLength ruler4510+50.2m +66.0m sub-girder and platform erectionStart:01/04/14End:09/04/14Sub-girder size(m):Length: 17mSingle part weight: 8 ton1.Pipe erection2. +50.2+66m plan sub-girder erection3.+60.8m platform erectionTower craneArc welderChain blockTheodoliteLength rulerElectric wrench4515+66.000m sub-girder and platform erectionStart:10/04/14End:18/04/14Sub-girder size(m):Length: 11mSingle part weight: 4 ton1.Pipe erection2.+66m plan sub-girder erection3.+66m platform erection4. Stairs erectionTower craneArc welderChain blockTheodoliteLength rulerElectric wrench4515C4 cyclone erectionStart:19/04/14End:25/04/141.topweight: 26.7 ton2.middle:weight: 20 ton3.bottom weight: 3.55 ton 1. Assemble the cone the bottom, the middle and the upper sections on the ground.2. Lift each section in turn.Tower craneArc welderChain blockWater levelLength rulerElectric wrench4510Gas duct from precalciner to C5 cycloneStart:26/04/14End:30/04/141. tube one weight: 38.8 tons2.bend weight: 11.08 tons1. Assemble the bend section and Dust one 2. Lift the tube one3.lift the dust one4.lift the bendTower craneArc welderChain blockTheodoliteLength rulerElectric wrench4510C5-C4 gas duct erectionStart:01/05/14End:05/05/141. Tubeweight: 9.09 tons2.BendWeight：10.5tons1. Assemble the tube section and bend section on the ground.2. Lift each section in turn.Tower craneArc welderChain blockTheodoliteLength rulerElectric wrench4510+66-82.4m column and frame girder erectionStart:06/05/14End:18/05/14Column max.size(m):Length:16.4mGirder max size(m):length: 11mSingle part weight: 6 ton1.Nine columns erection2. Frame girder erection.3.+70.9m platform erectionTower craneArc welderChain blockTheodoliteLength rulerElectric wrench4515+82.4m sub-girder and platform erectionStart:19/05/14End:31/05/14Sub-girder size(m):Length: 11mSingle part weight: 5 ton1.Pipe erection2. +82.4 plan sub-girder erection3.+82.4m platform erection4.Stairs erectionTower craneArc welderChain blockTheodoliteLength rulerElectric wrench4515C3 cyclone erectionStart:01/06/14End:05/06/141.Upper weight: 25.05 ton2.middle weight: 20.09 ton3.bottom weight: 4.35 ton 1. Assemble the bottom, the middle and the upper sections on the ground.2. Lift each section in turn.Tower craneArc welderChain blockWater levelLength rulerElectric wrench4510C4-C3 gas duct erectionStart:06/06/14End:10/06/141.Ductweight: 11ton2.Bendweight:10 ton1. Assemble the gas duct section and bend section on the ground.2. Lift each section in turn.Tower craneArc welderChain blockTheodoliteLength rulerElectric wrench4510+82.4-98.4m column and frame girder erectionStart:11/06/14End:19/06/14Column max.size(m):Length:16mGirder max size(m):length: 11mSingle part weight: 6 ton1.Nine columns erection2. Frame girder erection.Tower craneArc welderChain blockTheodoliteLength rulerElectric wrench4515+98.4m sub-girder and platform erectionStart:20/06/14End:27/06/14Sub-girder size(m):Length: 11mSingle part weight: 5 ton1.Pipe erection2. +98.4m plan sub-girder erection3.+98.4m platform erection4.Stairs erectionTower craneArc welderChain blockTheodoliteLength rulerElectric wrench4515C2 cyclone erectionStart:28/06/14End:29/06/141.upper weight: 23.7 ton2.middleweight: 20.6 ton3.bottom weight: 4.24 ton1. Assemble the bottom, the middle and the upper sections on the ground.2. Lift each section in turn.Tower craneArc welderChain blockWater levelLength rulerElectric wrench4510C3-C2 gas duct erectionStart:30/06/14End:02/07/141.Ductweight: 10.3ton2.bendweight: 9 ton1. Assemble the bottom section and top section on the ground.2. Lift each section in turn.Tower craneArc welderChain blockTheodoliteLength rulerElectric wrench4510+98.4-111.4m column and frame girder erectionStart:03/07/14End:10/07/14Column max.size(m):Length:13mGirder max size(m):length: 11mSingle part weight: 5ton1.Nine columns erection2. Frame girder erection.Tower craneArc welderChain blockTheodoliteLength rulerElectric wrench4515+111.4m sub-girder and platform erectionStart:11/07/14End:20/07/14Sub-girder size(m):Length: 11mSingle part weight: 5 ton1.Pipe erection2. +102.55 plan sub-girder erection3.+102.55m platform erection4.Stairs erectionTower craneArc welderChain blockTheodoliteLength rule