塔架施工方案

1、 文件編號：GU3-方案-M-010 Erection Program For the443-3P1preheater 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 DaDate：2013-11-20Verified by：Date：Approved by：Date：Version 0目

2、錄contents一.工程概述 Summary3二方案編制依據(jù)Compilation basis 3三吊裝機(jī)具的選擇The choice of Lifting instrument6 四質(zhì)量安全保證體系流程圖The flow chart of quality safety guarantee system11五施工工藝過程The construction process12六安全及文明施工Safe and civilized construction16一工程概述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)熱器塔架是整個熟料生產(chǎn)線的關(guān)鍵

3、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預(yù)熱器系統(tǒng)，提供生產(chǎn)操作，檢修操作的平臺。整個鋼結(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，整個系統(tǒng)分別由五級旋風(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 C

4、ement 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. Preheat

5、ertower 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 p

6、lanar 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, equip

7、ment 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.編制依據(jù)Compilation basisHOLCIM(ECUADOR)GU3水泥廠燒成窯尾工藝布置圖。 HOLCIM(ECUADOR)GU3 PROJECT PREHEATER TOWER G

8、ENERAL ARRANGEMENT DRAWING工藝布置圖General arrangement drawingHOLCIM(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 structurefabrication, installation drawingsHOLCIM(ECUADOR)GU3水泥廠預(yù)熱器制作、安裝圖。HOLCIM(ECUADOR)GU3 preheater fabrication, installation drawings鋼結(jié)構(gòu)施工驗(yàn)收規(guī)范Steel construction a

9、nd acceptance。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，整個安裝面積大，如使用大型可移動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)熱器的組對將使用一臺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

10、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 usingthe large mobile crane, the lifting will be not high enough and the le

11、ss 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S

12、TT403-24T Tower crane load chart 文件編號：GU3-方案-M-010塔吊布置圖 Preheater tower crane layout通過對預(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 weightcalculation, all steel single piece weighing not more than 12 to

13、ns. 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主管經(jīng)理Mananger：Zhouy

14、ougen質(zhì)量安全：Quantity and safety：BowenshuaiDucumentation：Zhangqing Tech director：Zhu ziwu質(zhì)量安全：Quantity and safety：BowenshuaiDucumentation：Zhangqing Tech director：Zhu ziwuSupervisor：Supervisor：Xue zhiminXiang xianlunLiftingZhangjieChenlabaoLiftingZhangjieChenlabaoDocumentation record and storageSAFETT S

15、UPERVISOR：YANGHAICHAOthe bridge workthe 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 par

16、ts 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):

17、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.

18、 +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 tSecondl

19、y 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):leng

20、th: 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

21、 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 lif

22、t 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):lengt

23、h: 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.+50.20

24、0 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 ton1. Assemble the the bottom, the middle an

25、d 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.

26、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 b

27、lockTheodoliteLength 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 blockTheodoliteLen

28、gth rulerElectric wrench4515C4 cyclone erectionStart:19/04/14End:25/04/141.topweight: 26.7 ton2.middle:weight: 20 ton3.bottom weight: 3.55 ton1. Assemble the cone the bottom, the middle and the upper sections on the ground.2. Lift each section in turn.Tower craneArc welderChain blockWater levelLengt

29、h rulerElectric wrench4510Gas duct from precalciner to C5 cycloneStart:26/04/14End:30/04/141. tube oneweight: 38.8 tons2.bendweight: 11.08 tons1. Assemble the bend section andDust one 2. Lift the tube one3.lift the dustone4.lift the bendTower craneArc welderChain blockTheodoliteLength rulerElectric

30、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

31、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 er

32、ectionStart: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.Up

33、per weight: 25.05 ton2.middle weight: 20.09 ton3.bottom weight: 4.35 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 wrench4510C4-C3 gas duct erectionStart:06/06/14End:10/06/141.Du

34、ctweight: 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:16mG

35、irder 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.Pip

36、e 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

37、, 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 grou

38、nd.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 er

39、ection.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 blockTh