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MEASURES FOR STEEL structural FABRICATION
category: COKING PLANT SECTION
Subcategory: J1, j2, j3, j4, J5 Belt conveyer gallery
PART I: INTRODUCTION
I. OVERVIEW ABOUT BELT CONVEYER GALLERY STRUCTURAL SYSTEM:
J1, J2, J3, J4, J5 belt conveyer gallery structural system is the item of Thai Nguyen Steel and Iron Corporation 2nd stage expansion project. Belt conveyer gallery steel structure is designed by the Principal Contractor China Metallurgical Group Corporation (MCC) and assign to this subcategory for Subcontractor is Thang Long Ferrous Metallurgy Joint Stock Company. This subcategory includes the following sections:
1. J1 belt conveyer gallery steel structure linking the J2 transport station with J3 transport station.
2. J2 belt conveyer gallery steel structure linking the J3 transport station with coke cutting room.
3. J3 belt conveyer gallery steel structure linking the coke cutting room with J4 transport station.
4. J4 belt conveyer gallery steel structure linking the J4 transport station with the coke screening house.
5. J5 belt conveyer gallery steel structure linking the coke screening house with G2 transport station.
Subcategory of belt conveyer gallery steel structure system is designed with steel column system which are manufactured from hot rolled steel geometric font size H . Structure of racking platform is used types of hot rolled angle steel, steel beam system supporting roof is using combined steel geometric font size I. Sub-beams system supporting the floor using hot rolled steel shape I, U .... Purlin roof system using steel shape C ... Flooring sheet and stairs on the conveyor using 6mm anti-slip religious.
This sub-category is designed to use plan of structural of hot rolled steel column linking stability bracing and racking platform system running along the conveyor gallery so the column structures and truss are applied similar production processes. So in this construction method,we just discuss the measures to produce steel truss’s frame structures.
II. SIZE AND STRUCTURE OF THE ITEM.
1. Describe the size of the belt conveyer gallery structural system (J1-J5):
J1 belt conveyer gallery steel structure has length of 10.56m. Truss system is arranged starting from cos-0.181m. And along the design slope to +2,894 m. The width of the steel truss system is 3.4m. The height of the truss system is 2.5m.
J2 belt conveyer gallery steel structure has length of 54.50m. Truss system is arranged starting from cos +0600m and along the design slope to +9,676 m. The width of the steel truss system is 3.4m. The height of the truss system is 2.5m.
J3 belt conveyer gallery steel structure has length of 124.00m. Truss system is arranged starting from cos +1219m and along the design slope to +23,779m. The width of the steel truss system is 3.4m. The height of the truss system is 2.5m.
J4 belt conveyer gallery steel structure has length of 20.35m. Truss system is arranged starting from cos +21,156m and along the design slope to +26,715 m. The width of the steel truss system is 3.4m. The height of the truss system is 2.5m.
J5 belt conveyer gallery steel structure has length of 12.666m. Truss system is arranged starting from cos +5007 m and along the design slope to +6,710 m. The width of the steel truss system is 3.4m. The height of the truss system is 2.5m.
Based on the design drawing, which were handed by the Principal Contractor to Subcontractor, we divided into the following types of components:
A. Steel columns Structure supporting the main truss structure:
- Column type 1 (JZ4) has cross section of empty column with width of 3.4m and height of 14.52m. Main bar by steel H300 * 305, bracing bar by steel U16, and L75 - L100.
- Column type 2 (JZ2 / 3) has cross section of empty column with width of 3.4m and height of 10.35m. Main bar by steel H488 * 300, bracing bar by steel U18, and L56 - L125.
- Column type 3 (JZ2 / 3) has cross section of empty column with width of 3.4m and height of 19.55m. Main bar by steel H700 * 300, bracing bar by steel U18, and L56 - L125.
- All the columns have length > 12m will be divided into smaller components with length <= 12m and all are produced in the plant, then combined and connected in the construction site.
B . J1-J5 belt conveyer gallery steel structure: Width 3.4m; Height 2.5m a total length is calculated as the design slope is: 222.076m.
- Racking platform (HJ1-HJ8) has structure of angle steel truss format: Height 2.5m, Length 31.2m (max). The bar in upper truss and the bar in bellow truss is used hot rolled steel 2L100- 2L130. The web bars use hot rolled steel 2L63- 2L90.
- Bottom floor of conveyors are horizontal beams support conveyer using steel I18, vertical beams support conveyer using steel I16, auxiliary beams using steel U8. Flooring sheet on the belt conveyor galleries and stairs use 6mm anti-skid steel plate.
- Steel structure covers belt conveyor galleries system: The framework is used to cover using combined steel. Bracing of the frame using angle steel L56 * 5, the structure supporting the religious roof using C200 cold- rolled shape steel, the structure supporting the religious wall using C120 cold- rolled steel.
- All the frames have length> 12m will be divided into smaller components with length <= 12m and are produced at the plant, then combined and connected in the construction site.
PART II:
PREPARATION OF FACILITIES, ENGINEERING SUPPLIES AND MATERIALS
FOR STEEL STRUCTURAL FABRICATION OF BELT CONVEYOR GALLERY
I. FACILITIES ENGINEERING STEEL PRODUCTION.
The entire steel structure of the item steel structure supporting belt conveyor gallery system J1 to J5 are manufactured at factory of Thang Long Ferrous Metallurgy JSC in My Hao District - Hung Yen Province.
The structural with weight ≤ 5.000kg and length ≤ 20m are produced in factories. The structural with weight > 5000kg and length > 30m are produced outside the processing of steel structures.
Our plant includes factory system, technical staff and skilled workers equipped with the modern equipment and machinery to produce products meeting the technical requirements of designs and current standards. Equipments for production in plants is as follows:
A Processing equipment embryos
1. Hydraulic cutter but flat production (Imported) : 01
2. CNC embryos cutter (Imported) : 02
3. Punching-and-shearing machine : 01
4. Hydraulic press machine 300T-PPN31200 : 01
5. Steel cutters : 01
B. Mechanical equipment
1. 3-axis wind machines : 01
2. U- mill machine : 01
3. Lathe T750, T823 : 01
4. Automatic drifting machine : 01
5. Large-diameter drill Z3050x16 : 01
6. Two stone grinder : 02
7. Hand forever : 05
8. Drilling machine : 01
C. Welding equipment – bending
1. Automatic Welding Machine 2 burners : 01
2. Semi-automatic welding machine : 03
3. Machine fitting combinations H-beams automatically : 01
4. Wing bending machine : 01
5. Ta350 CO2 welding machine – Win : 05
D. Cleaning and painting
1. Bogo compressors : 01
2. Sand blasting machine : 01
E. Transport equipment lifting
1. Q = 10 ton crane : 04
2. Fork-lift truck : 01
F. Test equipment
1. Equipment and test kits KCS : 01
2. Coating thickness measurement : 01
3. Pan me, grip size
G. Equipment and construction machinery at construction site
1. Welder : 02
2. Generators : 01
3. Iron cutting machines : 01
4. Machines for construction other
II. HUMAN resources for STEEL structure PRODUCTION.
Total number of technical workers of the factory went into production of steel structures for Coke belt conveyor galleries to 94 people at its peak. Of which:
1. Welder: 25 workers
2. Themed details fixtures: 15 workers
3. Mechanist skilled manufacturing grade 4 / 7 or more: 05 workers
4. Turner: 02 workers
5. Electrician: 02 workers
5. Cold assembly workers: 15 workers
6. The other workers for production: 20 workers
7. Technical engineering staff for production: 10 people
III. PREPARATION MATERIALS, MATERIAL STEEL PRODUCTION.
1. Steel: All types of steel in production of steel structures to ensure the new steel, stainless pitting, no warping. Steel must have a clear origin, must have a quality control check of each type of batch production. After the investment, supervision consultants to agree to test for sampling quality control to ensure the new steel was put into production. The entire production of steel for belt conveyer gallery steel structure is Q235B steel which made from China or other steel with equivalent specifications.
2. Welding materials: welding materials of choice for electric welding method according to automatic welding and manual welding.
a) Manual welding: At the request of designing in welding of Q235B steel structure, using E43 welding rods of China . Types of welding rods has the same technical features of J421welding rod of Vietnamese German Welding Company, FS-E421 and FS- E422 of the company ‘s Huu Nghi welding and construction of Vietnam's mechanical production.
b) Automatic welding: When welding steel structures with steel Q235A and Q235B using welding wire and welding compound H08E H08A or equivalent welding wire and welding compound FS-HW08A, HF-402.
3. Choose Paint :
- Epoxy Primer, Epoxy intermediate paint and coating of PU paint of manufacturers in Vietnam was accepted by the Investor and MCC (Hanoi General Paint Corporation / Jotun Viet Nam / Inter paint/ Chugoku ...) with appropriate quality meeting the requirements of the proposed design.
PART III:
STEEL FABRICATION
A- GENERAL PRINCIPLES
Fabrication of steel structures for belt conveyer gallery structural system complies with construction standards and acceptance of GB 50205-2001, steel structural welding standard JGJ 81-91, 205-83 China's manufacturing standards and structures 170-89 20TCN-steel of Vietnam as follows:
a, Steel structure and texture fontanel tiou non-standard part is manufactured according to design drawings, detailed drawings of components that are available for approval and promulgation.
b, When processing using advanced methods, in accordance with the requirements of technology and strict control of the stages.
c, Materials used for processing and manufacturing to quality and number of steel grades in accordance with design requirements.
d, For the particular steel components, in addition to general provisions also comply with specific regulations for steel materials of that structures.
e, Requirements for steel and welding materials: All the steel into the manufacturing to be tested muscle and physically by the legal unit's performance.
Welding rod, welding wire and welding compound’s quality certificates should call the manufacturer to provide, prior to use to check quality.
f, Other materials:
Bolts-link type must have the certificate, the quality.
Anti-rust paint and protected by paint are specified accurately as the design of paint a component or two components, the level of cleaning and coating thickness of each layer.
B- MANUFACTURING PROCESS OF STEEL COMPANY
Research design drawings, construction drawings made
Inspection and approva / Check, Approval
Up demand for materials
Purchase of supplies by project requirements
Check inputs
Return provider
No. Reach Ok reached
Impression, by cutting embryo drawings have been approved
Flat straightening, preparing joint combined details
Inspection and documentation
Detailed fitting combination
consortium welding after details have been combined
Straightening wing detail after welding
Perfect fitting assemblies
Inspection and documentation
Welding complete details
Straightening, flat, heated, ground fix
Inspection and documentation
Surface cleaning products
Inspection and documentation
Paint products
Inspection and documentation
Last inspection. Making records of completed tests
Public transport to construction site
C- Steel structure manufacturing
I. Billet process (billet forming, marking and cutting )
I.1. Forming and marking:Before forming and marking, steel surface must be cleaned so that there is no grease or dust. Steel must not be rusty and abscessed. Worker who is in charge of forming, marking must be skilled and well-trained experienced and able to understand, detail design drawing. Supervise engineer must popularize manufacturing oarts technology and instruet marking workder to make a redundancy in case of the shrinkage in cutting, welding and chamfering. The redundant index of billet is executed 4.1.2, 4.1.3, 4.1.5, 4.1.6 of the Chinese GB 50205-2001 standard or Vietnamese 20TCN170-89 standard (table 4 vµ table 7).
Tools for forming and marking are: steel pen, parane caliper square, iron-sheet measuring tape, set quare.
I.2. Billet cutting:
2.1. Cutting billet by heating method: During the cutting process , temper must be stable in order to reduce the billet warping. Temperature at the cutoff point should be controlled from 9000C to 10000C so that the cutting line is flat and not burned due and there is no steel slag at low temperature in order to reduce the labor cost for the billet cleaning process to chamfering.
Means and tools for billet cutting by heating method are including: Gas – oxy plane-shearing machine made in China, KEROI gas-oxy plate- shearing machine made in Japan..
2.2. Beveled: All the butt-welding for parts with the billet thickness ≥ 8mm should be chamfered by machine or autogenous cutting machine. Tolerance of chamfering is executed base on table 4.3.2 standard GB 50205-2001 Chinese standard or AWSD 1.1 standard on page 11. Table 5 applies to V manual welding joint.
2.3 Billet straightening before jigging welding:
- Method of straightening components made by straightening machine dedicated structures for hot-rolled structural steel and combined welding steel. Manual straightening method
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