塔架施工方案.docx

文件编号：GU3-方案-M-010Erection 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 录contents一.工程概述 Summary-3 二方案编制依据Compilation basis -3 三吊装机具的选择The choice of Lifting instrument-6 四质量安全保证体系流程图 The flow chart of quality safety guarantee system-11 五施工工艺过程 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水泥厂是一条日产4500吨的水泥熟料生产线。窑尾预热器塔架是整个熟料生产线的关键部位，因其系统复杂，安装高度高，构件数量多，单件重量重而成为安装难度最大的一个子项之一。预热器塔架采用钢结构和预热器相结合的安装方式，其中钢结构的的作用是支撑整个预热器系统，提供生产操作，检修操作的平台。整个钢结构主体系统共7层，高96.4m（15m-111.4m），构件共9根H型钢，各层平面有连接梁，上铺花纹钢板，钢结构总重约2500吨。预热器在熟料生产中主要起生料预热和物料分解的作用，整个系统分别由五级旋风筒、分解炉、三次风管、喂料室等组成，设备安装分别从喂料室开始至C1旋风筒结束。预热器系统还配备有提升机、喂料机、风机、收尘器，电梯等辅助设备。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 编制依据Compilation basis1. HOLCIM(ECUADOR)GU3水泥厂烧成窑尾工艺布置图。 HOLCIM(ECUADOR)GU3 PROJECT PREHEATER TOWER GENERAL ARRANGEMENT DRAWING45工 艺 布 置 图General arrangement drawing2. HOLCIM(ECUADOR)GU3水泥厂窑尾塔架钢结构制作、安装图。 HOLCIM(ECUADOR)GU3 preheater tower steel structure fabrication, installation drawings3. HOLCIM(ECUADOR)GU3水泥厂预热器制作、安装图。HOLCIM(ECUADOR)GU3 preheater fabrication, installation drawings4. 钢结构施工验收规范Steel construction and acceptance。5. 机械设备安装验收规范Mechanical equipment installation acceptance。三.吊装机具的选择The choice of Lifting instrument：窑尾预热器塔架的安装主要包括预热器的地面组对工作和钢结构预热器的高空安装工作。钢结构、预热器的安装工作由于构件安装高度高，整个安装面积大，如使用大型可移动吊车将存在吊装高度不够，吊装性能小的问题，并且施工速度也很慢。所以我们将采用STT403-24T型塔吊。地面预热器的组对将使用一台50吨吊车。下面是STT403-24T塔吊的性能表和预热器塔塔吊的布置图。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塔吊吊装性能表STT403-24T Tower crane performance tableSTT403-24T塔吊载荷信息表STT403-24T Tower crane load chart 塔 吊 布 置 图 Preheater tower crane layout通过对预热器塔钢结构重量的计算，前两层钢结构的单件重量达20吨。结合塔吊的吊装性能标和塔吊的布置图可以看出：使用STT403-24T塔吊进行预热器塔的安装施工满足不了施工要求，固需要250吨吊车配合吊装。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 质量安全保证体系流程图主管经理Mananger：Zhouyougen质量安全：Quantity and safety：BowenshuaiDucumentation：Zhangqing Tech director：Zhu ziwuSupervisor：Xue zhiminXiang xianlunLiftingZhangjieChenlabaoDocumentation record and storageSAFETT SUPERVISOR：YANGHAICHAOthe bridge work execute（50 workers）五.施工工艺过程 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 rulerElectric wrench4515C1 cyclone erectionStart:08/03/06End:11/03/061.upper weight: 39.5 ton3.cone weight: 18.7 ton1. Assemble the cone and the upper sections on the ground.2. Hoist each section in turn.Tower craneArc welderChain blockTheodoliteLength rulerElectric wrench4010C2-C1 cyclone erectionStart:10/03/06End:11/03/061. bend weight: 12.4 ton2.tubeweight: 6.8 tons1. Assemble the tube section and bend section on the ground.2. Lift each section in turn.Tower craneArc welderChain blockTheodoliteLength rulerElectric wrench4010Bucket elevator erectionStart:22/11/05End:24/03/06Bucket elevator total weight:53tonlevel:0120.2m1. Lifting the shell from the bottom up.2.Lifting the drive unit3. Lifting the belt.4.erection the bucketTower craneArc welderChain blockTheodoliteLength rulerElectric wrench4010Steel chimney erectionStart:05/03/06End:14/03/06Tower craneArc welderChain blockTheodoliteLength rulerElectric wrench4013六安全及文明施工 由于整个窑尾工程的安装工作绝大部分处于高空作业，因此安全工作非常由为重要。 所有施工人员必须经过安全操作规程教育并经考试合格后方可上岗。 1.所有施工人员必须身体健康，并作定期体检。 2.施工小组设置专门的安全员，每天检查安全的防护。 3.操作前，都应对脚手架、踏板安全网等进行检查，看是否牢固。 4.吊装作业区内应设置警戒线。 5.大重量设备件或结构件吊装时应进行能力计算，并在吊装前仔细检查