塔架施工方案

1、 文件编号：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、录contents一.工程概述 Summary3二方案编制依据Compilation basis 3三吊装机具的选择The choice of Lifting instrument6 四质量安全保证体系流程图The flow chart of quality safety guarantee system11五施工工艺过程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

3、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 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.编制依据Compilation basisHOLCIM(ECUADOR)GU3水泥厂烧成窑尾工艺布置图。 HOLCIM(ECUADOR)GU3 PROJECT PREHEATER TOWER G

8、ENERAL ARRANGEMENT DRAWING工艺布置图General arrangement drawingHOLCIM(ECUADOR)GU3水泥厂窑尾塔架钢结构制作、安装图。HOLCIM(ECUADOR)GU3 preheater tower steel structurefabrication, installation drawingsHOLCIM(ECUADOR)GU3水泥厂预热器制作、安装图。HOLCIM(ECUADOR)GU3 preheater fabrication, installation drawings钢结构施工验收规范Steel construction a

9、nd acceptance。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

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塔吊吊装性能表STT403-24T Tower crane performance tableSTT403-24T塔吊载荷信息表S

12、TT403-24T Tower crane load chart 文件编号：GU3-方案-M-010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 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质量安全保证体系流程图主管经理Mananger：Zhouyougen主管经理Mananger：Zhouy

14、ougen质量安全：Quantity and safety：BowenshuaiDucumentation：Zhangqing Tech director：Zhu ziwu质量安全：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 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