篦冷机施工方案中英文rev1

1、Method Statement of Clinker Cooler ErectionWriter by： Safety Officer： Quality Controller： Technical Leader： Approve by： AVIC Pahang， Malaysia Department October，15th，2013目录一、篦冷机施工组织构成 1.Manpower Structure- 3 -二、篦冷机施工机具一览表2.tools table- 3 -三、篦冷机安装周计划3. Cooler erection plan- 4 -四、篦冷机施工技术方案Cooler const

2、ruction technique requirement - 6 -五、施工技术保证措施technique guarantees- 16 -六、 安全与文明施工保证措施safty guarantee. 18一、篦冷机施工组织构成 1.Manpower Structure窑头工段Sub-contractor工段长一人 工程师supervisor one班组长二人 技师team leaders two钳工五人 技工riveter five 焊工二人 技师welder two起重工一人 技师lifting worker one架子工一人 临时Worker oneTemporatory质安员一人 专

3、职quality controller one辅助工临时调配Auxiliary worker 工程技术部Mechanical Dept项目经理部project manager二、篦冷机施工机具一览表2.tools table序号SN名称Name型号Spec.单位Unit数量Num.备注Remarks1汽车吊mobile crane45T台12汽车吊mobile crane30T台14滑轮pulley 10T台35滑轮pulley5T台26螺旋千斤顶jacking screw10T台47螺旋千斤顶jacking screw5T台28手拉葫芦chain block5T台89交流电焊机AC weld

4、ing machineBX-30台310气割工具gas cutting machine套211水准仪level instrument台112经纬仪theodolite台1三、篦冷机安装周计划3. Cooler erection plan施工预计划：第一周基础校验、放线，预埋标板，砂堆制作，设备出库检查清洗说明：土建提供合格基础，场地平整达到要求，三方会检签证。First week：foundation inspection， embedded plates check， equipment package check第二三周下壳体、底梁、灰斗安装说明：三方会检签证。Second to thir

5、d week：downside casing, bottom beams, hoppers erection. Need inspection.第四六周传动装置安装，篦床安装调整。说明：三方会检签证。Forth to six week: driving device erection, grid bed erection and alignment. Need inspection.第七十周上壳体安装，破碎机安装，自动润滑装置安装。说明：三方会检签证。Seventh to tenth week: top casing erection, crusher erection, automatic

6、lubricating device erection. Need inspection.第十一周交筑炉。说明：会检签证。Eleventh week: handover to ramming work. Need inspection.篦冷机施工程序procedure基础验收及划线施工准备设备出库及检验篦冷机下壳体安装传动装置安装篦板安装上壳体及润滑系统安装破碎机安装试运转砌 筑1, preparatory work 2, foundation inspection and marking line; equipment package check3, bottom casing erecti

7、on4, driving device erection5, grid plate erection6, top casing and insulating system erection7, crusher erection8, ramming erection9, running test 四、篦冷机施工技术方案4. Cooler construction technique requirement 1、概述A. summarization往复推动篦式冷却机是回转窑的主要配套设备之一，其作用是降低熟料温度，改善熟料质量，提高熟料的易磨性，提高二次空气温度，改变火焰燃烧条件，节约能源。篦式冷

8、却机主要由以下几部分组成：下壳体、上壳体、篦床、篦床液压传动装置、篦床支撑装置、熟料破碎机、自动润滑装置及冷却风机组等。 reciprocating grate cooler is one of Rotarys major ancillary equipment, its role is to reduce the clinker temperature, improve the clinker quality, improve the grind ability of clinker, and improve secondary air temperature, change the fla

9、me conditions, save energy. Grate cooler mainly by the following components: the next shell, the shell, grate bed, grate bed hydraulic actuator, grate bed supporting device, clinker crusher, automatic lubrication system and cooling units such as wind.2、施工前准备a、施工人员熟悉图纸、安装说明书等技术文件。b、施工图会审。c、熟悉施工现场和设备堆

10、放场地。d、准备施工工机具、材料及施工电源。e、做好施工方案及技术交底（包括质量、安全措施）。B. pre-construction preparationa, officials familiar with the construction drawings, installation instructions and other technical documents.b, Check construction drawings.c, familiar with the construction site and equipment stack space.d, the construct

11、ion work to prepare equipment, materials and construction of power supply.e, well construction program and technical disclosure (including the quality, safety).3、基础验收及放线a、基础验收：基础验收必须认真进行，安排专人进行此项工作，会同厂方、监理及土建等有关部门，根据有关资料（工艺图、基础图、安装图、验收标准等）认真测量、记录，验收合格后，方可进行安装施工。设备基础各部分的偏差应符合如下要求：C. foundation check

12、and marking linesa, foundation check basis of acceptance must be carefully carried out, arrange to carry out this work, together with the factory, supervision and civil works and other relevant departments, according to the data (process diagram and foundation drawing, installation plans, acceptance

13、 criteria, etc.) carefully measuring, recording, post-acceptance before the installation works. equipment parts based on the deviation should meet the following requirements:序号SN名 称items允许偏差allowed deviation(mm)1基础外形尺寸size302基础坐标位置（纵、横中心线）coordinate（lengthways& transverse center lines）203基础上平面标高leve

14、l0 -204中心线间的距离distance between center lines1.05地脚孔中心位置center position of pocket106地脚孔深度depth of pocket+20 07地脚孔垂直度verticality of pocket5/1000b、基础放线：用经纬仪或线坠等将窑体的轴线引到冷却机基础上。即划出一条窑纵向中心线的延长线。以窑头托轮的横向中心线为基准，将回转窑窑口圈热态工作点引到在冷却机基础上已画出的窑的纵向中心线上。并在此点划出与托轮横向中心线相平行的线。以划出的纵线为基准，划出冷却机的纵向中心线，允许偏差1.5mm。以划出的横向线为基础划出

15、冷却机的横向中心线及冷却机进料端第一根柱子的横向中心线，其允差1.5mm。b, foundation lines mark fall with a theodolite or a line such as the axis of the kiln to the cooler based on the lead. That is to draw a vertical centerline of the extension line of the kiln. Kiln wheel to the horizontal center line as the base, the rotary kiln

16、thermal operating point lead lap to the cooling machine has been drawn based on the longitudinal center line of the kiln. And on this point to draw center line with the wheel horizontal parallel lines. to draw a vertical line as the base, draw cooler longitudinal centerline, to allow deviation of 1.

17、5mm. to draw the horizontal line is drawn based on the horizontal center line of the cooling machine and cooling machine feeding the first columns of the lateral end of the center line, its tolerance 1.5mm.4、设备出库和检查根据设备图和装箱清单仔细检查设备零部件的数量和质量，认真填写设备开箱检查记录。D Equipment package checkAccording to maps and

18、 packing equipment, equipment parts list carefully check the quantity and quality, carefully fill in the equipment out of the box inspection records.5、篦冷机机体安装a、侧框架安装：篦冷机基础经核对无误后，按如下工序进行安装。 放置第一段固定侧框架和底板（梁）于基础上。放置第二段固定侧框架和底板（梁）于基础上。放置第三段固定侧框架和底板（梁）于基础上。根据侧框架的安装布置及部件图对侧框架进行找正。垂直度偏差为1mm/m。相对标高允差1mm。水平度

19、允差0.1mm/m。同段的两片框架跨距应符合图纸要求，允差2mm，对角线允差3mm。找正合格后地脚灌浆、养生，当强度达设计强度的75%后，即可进行下步施工。ECooler body erectiona, Side Framework installed:Cooler base is verified by the following procedure to install. Place the first paragraph of the framework of the fixed side and bottom (beam) at the foundation. Place the se

20、cond paragraph of the fixed side of the frame and floor (beams) on the basis of. placed third paragraph of the fixed side of the frame and floor (beams) on the basis of. According to the installation side of the frame layout and framework components map to find is the opposite. Perpendicularity devi

21、ation of 1mm / m. Relative elevation of tolerance 1mm. Degree tolerance level 0.1mm / m.The framework of the same span of paragraph 2 should be consistent with drawings, tolerance 2mm, diagonal tolerance 3mm.Alignment of the feet after passing the filling, and health, when the strength of up to 75%

22、of design strength, you can proceed to the next step construction.b、底板安装：安装漏料锁风装置的漏斗及格栅。按图纸要求的位置依次将底板通过走线、倒链吊装到位，并按图施焊。 安装前端墙板，把紧螺栓，并连续焊接到侧框架和底板支承梁上。 安装下隔墙板，把紧螺栓并连续焊接到侧框架上，同时和底板或支承槽钢焊接。b, floor installation: installation materials to the lock device of the funnel and the wind grid. position by drawi

23、ng in turn will take the line through the floor, hoisting chain back in place, press the Map on welding. Install the front wall, put the bolt, and continuously welded to the side of the frame and the floor supporting beam. Install a partition wall, the bolts tight and continuous welded to the side o

24、f the frame at the same time and channel bottom or supporting welding.c、托轮支架安装：复查、调整侧框架的铅垂度及两片顶梁的跨距与对角线。依次将托轮支架吊装到位。 将托轮支架通过角钢焊在侧框架立柱上。c, roller bracket installation: review, adjust the side frame of the verticality and two roof beams and diagonal stride. in turn lifting the wheel bracket in place.

25、The roller bracket by welding angle iron framework in the column on the side.d、安装托轮组：同一段托轮组应在同一直线上，允差0.5mm。托轮组应与篦冷机中心线对称，允差0.5mm。同段托轮组相互平行，对角线允差2mm。d, install the wheel group: group with a wheel should be along the same line, tolerance 0.5mm. wheel group should be cooler center line of symmetry, tol

26、erance 0.5mm. paragraph supporting rollers with parallel, diagonal tolerance 2mm.e、安装传动装置：按图纸设计的位置将传动轴轴安装到位。 轴的水平度、允差0.2/1000。液压系统安装：i安装时先卸下密封装置，将壳体内连接板和密封装置的其他装置的其他部件分开并固定在壳体内侧，然后将轴穿过壳体，安装好密封装置的其他部件、液轮装置、行走车、轴承座、液压缸、行程开关装置等。ii安装时应确保轴水平，两侧的中心线严格对称。iii行程开关装置安装在距离液压站近的一侧。iv安装液压缸前，先将传动主轴精确调整到正中间位置并固定住，

27、然后用液压缸安装工具将轴承座固定好、拧紧螺栓，按要求焊接牢固后方可装入液压缸。v止动垫片待将螺栓拧紧后折弯。e, installation of transmission: design by drawing the location of the shaft axis to install in place. the horizontal axis, tolerance 0.2/1000. hydraulic system installed: i remove the seal before installation will interconnect and seal within th

28、e shell of other devices and other components separately fixed inside the shell, then through the shell axis, installed in other parts of sealing devices, hydraulic wheel device , running car, bearing, hydraulic cylinders, limit switch devices. ii should be installed to ensure that the axis level, o

29、n both sides of the center line of strict symmetry. iii travel switch device installed in the distance near the side of the hydraulic station. iv installation of hydraulic cylinder first before fine-tuning of the transmission shaft to the middle position and securely, and then install the tool cylin

30、der bearing fixed, tighten the bolts, as required welding firm before they can mount the hydraulic cylinder. v stopper gasket when tightening bolts after the bend. f、活动框架安装：在地面上预组装活动框架装置，检查每段框架的对角线，其偏差L1-L23mm将活动框架吊装到托轮装置上。活动框架中心线必须与篦冷机中心线相重合。然后将活动框架用螺栓固定到传动轴座架上,并用调整楔铁及顶丝将传动座架夹紧在活动框架的传动轴托架上。检查活动框架顶面

31、标高尺寸,并做必要调整。f, activity framework installation: In the framework of the activities on the ground pre-assembly unit, check each piece of the framework of the diagonal, the deviation of L1-L2 3mm the framework of activities to the wheel lifting device. centerline framework of the activities must coinc

32、ide with the center line of grate cooler. Framework of the activities and then bolted to the rack shaft seat, and by adjusting the wedge and the top wire will be clamped in the activities drive the mounting bracket on the frame of the drive shaft. Check the top level dimensions framework of the acti

33、vities and make necessary adjustments.g、篦板安装：篦板梁根据所分布区域温度不同采取的材质也不同，安装时必须按设计要求进行布置。篦板安装：从卸料端开始,将第一和第二固定篦板梁紧固到侧框架角钢支座上,然后,在它们之间安装活动篦板梁,调好梁间的间距,在篦板梁上安装篦板,并保持篦板和螺栓在安装图中给定的第一、二排固定篦板顶面的尺寸(利用卸料端第一排固定篦板作为基准作业点)。通过调篦板梁两端的垫片来调整活动篦板,与固定篦板之间交叠垂直间隙,且尽量使间隙均匀并保证在要求的范围之内,垂直间隙值见篦床的安装图。 如上所述,从卸料端按三排(固定、活动、固定)为一组依次地朝

34、进料端重复上述工序。为了保证组间的垂直间隙相同,前后两组应交迭进行。使篦板梁和篦板推料面与篦冷机的中心线垂直,在确认各部尺寸与图纸要求相符后,用螺栓将篦板紧固到篦板梁上。篦板安装按所需的篦板和篦板梁布置按图进行。注意按要求调整好篦板横向及垂直间隙。所有的篦板梁和篦板调整找正并固定好以后，按安装图安装盲板。g, grid plate installation: grate plate beam according to the temperature distribution is different in different materials to the installation must

35、 be arranged according to design requirements. grate plate installation: Starting from the discharge end, the first and second fixed comb plate fastened to the side of the frame beam bearing angle, and then, in their activities between the grate plate girder installation, tuning the spacing between

36、beams in the grate plate beam Install grate plate and grate plates and bolts to keep the figure given in the installation of the first and second rows of the top comb plate size (using the discharge end of the first row of the fixed comb plate as the base operating point). Beam by adjusting the grat

37、e plate gasket to adjust activities across the grate plate, and the vertical overlap between the fixed comb plate gap, and even as far as possible gaps and to ensure the required range, the vertical gap values, see the installation diagram grate bed. As noted above, from the discharge side by three

38、rows (fixed, activities, fixed) for a group order to move the feed side to repeat the process. In order to ensure the vertical clearance between the same group, before and after the two groups should be overlap. Beams and comb to comb plate plate pusher grate cooler surface and the center line of ve

39、rtical, in identifying the size and drawings in line ministries, the grate plate will be fastened with bolts to the grate plate beam. Grate plate installed by the required plate girder grate plate and grate arrangement according to diagram. Note that the required adjust horizontal and vertical grid

40、plate gap. All of the grate plate and grate plate adjusting beam alignment and fixed, then, according to installation diagram to install blind plate. h、上机壳安装：安装上机壳钢构架。焊接侧壁板、顶板。首先检查检查口、进风口等的形位公差，是否符合图纸要求，要核对侧壁板、顶板的编号，对号就位。施焊时要求气密性好，不得有漏焊、气孔等疵病。h, upper casing installation: Install the chassis steel f

41、rame. welded wall panels, roof.First check the inspection port, the inlet shape and position tolerances, etc., whether the drawings, to check wall panels, roof number, sit in the right place. Shi welding required airtightness, not tainted welding, porosity, etc. Defects.i、 安装顶部壳体和冲击板。i, install the

42、top of the shell and the impact plate.j、安装机外固定及活动充气风管的主管道，注意适当调整风管与风机相连部分的角度及长度，使其与风机良好相配。j, install the machine and the activities of external fixation in charge of Road inflatable air duct, attention to appropriate adjustments to some of the wind pipe and fan connected to the angle and length to m

43、ake it a good match with the fans.6、破碎机安装F Crusher erection7、润滑系统安装a、按设计图纸布置进行安装。b、管道布置要牢固、整齐、美观，力求捷径，减少弯曲，弯曲半径不小于管径的3倍。c、管路安装前应进行酸洗，内部不允许有铁屑、氧化皮、杂物等。d、分配器应安装在易受到指示杆操作的地方，并使指示杆均指向一个方向。GInsulating system erectiona, according to design layout drawings for installation.b, piping layout should be firm,

44、clean, beautiful, sought a shortcut to reduce bending, bending radius of not less than 3 times the diameter.c, pipe pickling should be carried out before installation, within the allowed iron, oxide, and other debris.d, dispenser should be installed in vulnerable areas joystick directions, and to in

45、struct all point to a direction lever.8、无负荷试运转a、试车前准备工作首先应检查各联接螺栓是否拧紧，尤其是一些重要的部位，如地脚螺栓、活动框架与传动轴的联接螺栓、篦板与篦板梁的联接螺栓、篦板梁与活动框架及侧框架的联接螺栓等。各风机风管内畅通无异物，漏料斗中无异物，篦冷机各处不能有防碍其运行的工具及杂物存在。启动油泵，检查是否出油，分配阀的工作情况，管路是否有渗漏，起动调整润滑系统，确认供油系统工作正常。点动电动机检查运转方向是否正确。 检查各温度计及压力表指针是否灵活准确。HLoad free running testa, pre-trial prepa

46、ration should first check whether the connection bolts tightened, especially in some important parts, such as anchor bolts, a framework for activities connected with the drive shaft bolts, grate plate and grate plate beam connection bolts, grate plate girder frame and side with the activities framew

47、ork connection bolts. The fan duct no foreign body within the flow, no foreign body in the drain hopper, grate cooler running around can not have hampered the tools and debris in its existence. Start pump, check out the oil, the work of distribution valves, pipes have leaks, starting to adjust lubri

48、cation system, oil supply system is working correctly identified. Check operation to move the motor direction is correct. Check the thermometer and pressure gauge pointer is flexible and accurateb、试运转篦冷机主要空负荷试车时间不得小于8小时。 运转时仔细检查传动是否平稳，无异常声响。 篦床运行平稳，无卡碰、跑偏现象，篦缝均匀。 液压系统工作正常。 各部位轴承不允许有过热现象。 润滑系统工作良好，各润

49、滑点满足润滑和密封要求，管路无渗漏情况。 各测量设备、控制装置及报警装置工作正常。 各风机工作正常。以上检查项目必须认真做好记录。b, commissioning cooler time of the main air load testing not less than 8 hours. carefully check the drive is running smoothly, no abnormal sound. grate bed is stable, no card touch, deviation phenomenon, even sew grate. hydraulic syst

50、em working properly. various parts of bearings does not allow overheating. lubrication system working well to meet the lubrication points, lubrication and sealing requirements, pipeline without leakage. The measurement equipment, control devices and alarm device is working properly. The fan is worki

51、ng properly.Check the above items must be seriously good record.五、施工技术保证措施1各道工序的施工，必须严格执行施工规范及设备安装图纸；2现场出现的设计更改，修配改工作，必须办理现场签证手续，并报AVIC工程师审批，批准后执行。5， technique guarantee1. Each process of construction, must be strictly enforced construction specifications and installation drawings;2. Scene design ch

52、anges, repair work to change, to apply for the visa site and report to the AVIC Engineer for approval, approval and implementation.六、 安全与文明施工保证措施 1、 安全工作方针： 以防为主，防管结合，专管与群管相结合，做到文明施工，以人为本，安全第一。 2、 保证措施: 1） 现场设置专职安全管理机构。 2） 在计划、布置、检查、总结、评比生产任务的同时，计划、布置、检查、总结、评比、安全工作。 3） 根据工程进度情况和季节情况，组织进行施工阶段性安全大检查和季

53、节性安全大检查，对不安全情况，限期整改落实到施工班组和人员上。 4） 进入施工现场的一切工作人员，必须正确穿戴好防护用品。 5） 施工现场文明整洁、材料、设备、机具放置有序道路畅通。 6）集体操作的工作，要分工明确，操作时应有专人统一指挥，步调一致。 7） 工机具使用前必须检查，消除事故隐患。 8） 夜间施工时要有足够的照明设施。 9） 吊装作业的规定 a、吊装设备必须有专人负责指挥，吊装前，要进行安全交底。 b、起吊前，对起吊重物的重量一定要查清，严格计算，选择吊点，严禁吊装机具超负荷工作。 c、吊装前，对于大件一定要试吊，起吊后重物下面严禁站人，大型设备吊装时，要设警戒线。 d、设备就位时

54、，严禁把手、脚塞入起吊物和垫木、垫块之间，以免压伤。 e、所有钢丝卡扣要卡牢，钢丝绳和卡扣要符合规定要求。 10） 防火、防爆措施 a、氧气瓶、乙炔瓶等易燃易爆物品，严禁碰撞和在太阳下直晒。 b、在进行焊(割)工作时，应将周围易燃易爆品清除，或防护，防止火花溅落引起燃烧或爆炸。 c、清洗设备时，严禁吸烟，清洗油严禁乱倒。 d 、施工现场应设有消防器材。 15） 临时用电规定 a、现场临时用电施工现场临时用电安全技术规范的要求。b、施工现场使用的电气工具，必须装有漏电保护装置及其它安全防护措施，绝缘性工具要经常保持干燥，并经常进行外观检查与耐压试验。6. Safty guarantee1, se

55、curity policy: Case-based, anti-tube combination, specifically to deal with the combined control group, so that the construction of civilization, people-oriented, safety first. 2 assurance measures: 1) Setting the scene full-time security management institutions. 2) In the plan, layout, inspection, review and asses