塔架施工方案.doc

Erection Program For
the 443-3P1preheater tower

Name of the document：The Erection program of the
443-3P1 preheater tower
No. of the document：GU3-方案-M-010
Editing department：The Engineering department of CBMI

Edited by：Liu Li Da Date：2023-11-20
Verified 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重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高机、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 basis
1. HOLCIM(ECUADOR)GU3水泥厂烧成窑尾工艺布置图。
HOLCIM(ECUADOR)GU3 PROJECT PREHEATER TOWER GENERAL ARRANGEMENT DRAWING

工 艺 布 置 图
General arrangement drawing

2. 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 drawings
3. HOLCIM(ECUADOR)GU3水泥厂预热器制作、安装图。HOLCIM(ECUADOR)GU3 preheater fabrication, installation drawings
4. 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重要涉及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 table

STT403-24T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规定，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：Bowenshuai
Ducumentation：Zhangqing
Tech director：Zhu ziwu

Supervisor：
Xue zhimin
Xiang xianlun

Lifting
Zhangjie
Chenlabao
Documentation record and storage
SAFETT SUPERVISOR：YANGHAICHAO

the bridge work execute（50 workers）

五.施工工艺过程 The construction process

item
time
activity
method
tools
Number of workers
Number of people around
Feed-end chamber erection
Start:
25/12/13
End:
10/01/14

Size(m)
Width:5.15m
Height:8.6m
Length:2.55m
Weight:16.9ton
1. Assemble all the parts on the ground.
2.lifting feed-end chamber
3.Stairs erection

Tower crane
Arc welder
Chain block
Length ruler
45
15

item
time
activity
method
tools
Number of workers
Number of people around
+16.000-27.000m column and frame girder erection
Start:
10/01/14
End:
25/01/14

Column max.size(m):
Length:≤12.4m
Girder max size(m):
length: ≤11m
Single part weight:
≤ 5.5ton

1.Nine columns erection
2.Frame girder erection.
Tower crane，
Arc welder，
Chain block，
Theodolite，
Length ruler，

Electric wrench

45
15
+27.000m sub-girder and platform erection
Start:
26/01/14
End:
31/01/14

Sub-girder size(m):
Length: ≤10m
Single part weight:
≤ 5ton

1.Pipe erection
2. +27.000m plan sub-girder erection
3.+27.000m platform erection
4.Stairs erection
Tower crane
Arc welder
Chain block
Theodolite
Length ruler
Electric wrench

45
15

bottom section Precalciner erection
Start:
01/02/14
End:
02/02/14

Size(m)
diameter:4.616-6.416m
Length:16.174m
Weight:20.05ton
First lift weight:
7.5 t
Secondly lift weight:14.05 t
1. Assemble two parts according to sketch map on the ground.
2.lifting first lift
3.lifting secondly lift

Tower crane
Arc welder
Chain block
Length ruler
45
10
+27.000-41.600m column and frame girder erection
Start:
03/02/14
End:
13/02/14

Column max.size(m):
Length:≤14.6m
Girder max size(m):
length: ≤11m
Single part weight:
≤ 8 ton

1.Nine columns erection
2. Frame girder erection.
Tower crane
Arc welder
Chain block
Theodolite
Length ruler
Electric wrench

40
15
+41.600m sub-girder and platform erection
Start:
14/02/14
End:
20/02/14

Sub-girder size(m):
Length: ≤11m
Single part weight:
≤ 4 ton

1.Pipe erection
2. +41.600 plan sub-girder erection
3.+41.600m platform erection
4. Stairs erection
Tower crane
Arc welder
Chain block
Theodolite
Length ruler
Electric wrench

45
15
middle section Precalciner erection
Start:
21/02/14
End:
28/02/14

Size(m)
diameter:5.646-6.416m
Length:8.57m
Weight:20.05 ton
Thirdly lift weight:8.5 ton
Fourthly lift weight:11.55 ton
1. Assemble two parts according to sketch map on the ground.
2.lifting thirdly lift
3.lifting fourthly lift

Tower crane
Arc welder
Chain block
Length ruler
45
15
+41.600-50.200m column and frame girder erection
Start:
01/03/14
End:
10/03/14
Column max.size(m):
Length:≤8.6m
Girder max size(m):
length: ≤11m
Single part weight:
≤ 7 ton
1.Nine columns erection
2. Frame girder erection.
Tower crane
Arc welder
Chain block
Theodolite
Length ruler
Electric wrench

45
15
+50.200m sub-girder and platform erection
Start:
11/03/14
End:
20/03/14

Sub-girder size(m):
Length: ≤10.95m
Single part weight:
≤ 4 ton

1.Pipe erection
2.+50.200 plan sub-girder erection
3.+50.200m platform erection
4. Stairs erection
Tower crane

Arc welder
Chain block
Theodolite
Length ruler
Electric wrench

45
15
C5 cyclone erection
Start:
21/03/14
End:
27/03/14

1.Upper:
weight: 30 ton
2.middle:
weight: 20.2 ton
3.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 crane
Arc welder
Chain block
Water level
Length ruler
Electric wrench
45
10

top section Precalciner erection
Start:
28/03/14
End:
31/03/14

Size(m)
diameter:5-6.4m
Length:8.6m
Weight:19.40 ton
1.Assemble parts according to sketch map on the ground.
2.lifting top parts
Tower crane
Arc welder
Chain block
Length ruler
45
10
+50.2m ~+66.0m sub-girder and platform erection
Start:
01/04/14
End:
09/04/14

Sub-girder size(m):
Length: ≤17m
Single part weight:
≤ 8 ton

1.Pipe erection
2. +50.2~+66m plan sub-girder erection
3.+60.8m platform erection

Tower crane
Arc welder
Chain block
Theodolite
Length ruler
Electric wrench

45
15

+66.000m sub-girder and platform erection
Start:
10/04/14
End:
18/04/14

Sub-girder size(m):
Length: ≤11m
Single part weight:
≤ 4 ton

1.Pipe erection
2.66m plan sub-girder erection
3.+66m platform erection
4. Stairs erection
Tower crane
Arc welder
Chain block
Theodolite
Length ruler
Electric wrench

45
15

C4 cyclone erection
Start:
19/04/14
End:
25/04/14

1.top
weight: 26.7 ton
2.middle:
weight: 20 ton
3.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 crane
Arc welder
Chain block
Water level
Length ruler
Electric wrench
45
10

Gas duct from precalciner to C5 cyclone
Start:
26/04/14
End:
30/04/14

1. tube one
weight: 38.8 tons
2.bend
weight: 11.08 tons

1. Assemble the bend section and Dust one 2. Lift the tube one
3.lift the dust one
4.lift the bend
Tower crane
Arc welder
Chain block
Theodolite
Length ruler
Electric wrench

45
10
C5-C4 gas duct erection
Start:
01/05/14
End:
05/05/14

1. Tube
weight: 9.09 tons
2.Bend
Weight：10.5tons
1. Assemble the tube section and bend section on the ground.
2. Lift each section in turn.

Tower crane
Arc welder
Chain block
Theodolite
Length ruler
Electric wrench

45
10

+66-82.4m column and frame girder erection
Start:
06/05/14
End:
18/05/14

Column max.size(m):
Length:≤16.4m
Girder max size(m):
length: ≤11m
Single part weight:
≤ 6 ton

1.Nine columns erection
2. Frame girder erection.
3.+70.9m platform erection
Tower crane
Arc welder
Chain block
Theodolite
Length ruler
Electric wrench

45
15
+82.4m sub-girder and platform erection
Start:
19/05/14
End:
31/05/14

Sub-girder size(m):
Length: ≤11m
Single part weight:
≤ 5 ton

1.Pipe erection
2. +82.4 plan sub-girder erection
3.+82.4m platform erection
4.Stairs erection
Tower crane
Arc welder
Chain block
Theodolite
Length ruler
Electric wrench

45
15

C3 cyclone erection
Start:
01/06/14
End:
05/06/14

1.Upper
weight: 25.05 ton
2.middle
weight: 20.09 ton
3.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 crane
Arc welder
Chain block
Water level
Length ruler
Electric wrench
45
10
C4-C3 gas duct erection
Start:
06/06/14
End:
10/06/14

1.Duct
weight: 11ton
2.Bend
weight:10 ton

1. Assemble the gas duct section and bend section on the ground.
2. Lift each section in turn.

Tower crane
Arc welder
Chain block
Theodolite
Length ruler
Electric wrench

45
10
+82.4-98.4m column and frame girder erection
Start:
11/06/14
End:
19/06/14

Column max.size(m):
Length:≤16m
Girder max size(m):
length: ≤11m
Single part weight:
≤ 6 ton

1.Nine columns erection
2. Frame girder erection.
Tower crane
Arc welder
Chain block
Theodolite
Length ruler
Electric wrench

45
15
+98.4m sub-girder and platform erection
Start:
20/06/14
End:
27/06/14

Sub-girder size(m):
Length: ≤11m
Single part weight:
≤ 5 ton

1.Pipe erection
2. +98.4m plan sub-girder erection
3.+98.4m platform erection
4.Stairs erection
Tower crane
Arc welder
Chain block
Theodolite
Length ruler
Electric wrench

45
15

C2 cyclone erection
Start:
28/06/14
End:
29/06/14

1.upper
weight: 23.7 ton
2.middle
weight: 20.6 ton
3.bottom
weight: 4.24 ton

1. Assemble the bottom, the middle and the upper sections on the ground.
2. Lift each section in turn.

Tower crane
Arc welder
Chain block
Water level
Length ruler
Electric wrench
45
10
C3-C2 gas duct erection
Start:
30/06/14
End:
02/07/14

1.Duct
weight: 10.3ton
2.bend
weight: 9 ton

1. Assemble the bottom section and top section on the ground.
2. Lift each section in turn.

Tower crane
Arc welder
Chain block
Theodolite
Length ruler
Electric wrench

45
10

+98.4-111.4m column and frame girder erection
Start:
03/07/14
End:
10/07/14

Column max.size(m):
Length:≤13m
Girder max size(m):
length: ≤11m
Single part weight:
≤ 5ton

1.Nine columns erection
2. Frame girder erection.
Tower crane
Arc welder
Chain block
Theodolite
Length ruler
Electric wrench

45
15
+111.4m sub-girder and platform erection
Start:
11/07/14
End:
20/07/14

Sub-girder size(m):
Length: ≤11m
Single part weight:
≤ 5 ton

1.Pipe erection
2. +102.55 plan sub-girder erection
3.+102.55m platform erection
4.Stairs erection
Tower crane
Arc welder
Chain block
Theodolite
Length ruler
Electric wrench

45
15
C1 cyclone erection
Start:
08/03/06
End:
11/03/06

1.upper
weight: 39.5 ton
3.cone
weight: 18.7 ton

1. Assemble the cone and the upper sections on the ground.
2. Hoist each section in turn.

Tower crane
Arc welder
Chain block
Theodolite
Length ruler
Electric wrench

40
10
C2-C1 cyclone erection
Start:
10/03/06
End:
11/03/06

1. bend
weight: 12.4 ton
2.tube
weight: 6.8 tons
1. Assemble the tube section and bend section on the ground.
2. Lift each section in turn.

Tower crane
Arc welder
Chain block
Theodolite
Length ruler
Electric wrench

40
10

Bucket elevator erection

Start:
22/11/05
End:
24/03/06

Bucket elevator
total weight:53ton
level:0~120.2m
1. Lifting the shell from the bottom up.
2.Lifting the drive unit
3. Lifting the belt.
4.erection the bucket

Tower crane
Arc welder
Chain block
Theodolite
Length ruler
Electric wrench

40
10

Steel chimney erection
Start:
05/03/06
End:
14/03/06

Tower crane
Arc welder
Chain block
Theodolite
Length ruler
Electric wrench

40
13

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在高空作业，因此安全工作非常由为重要。
所有施工人员必须通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.施工小组设立专门的安全员，天天检查安全的防护。
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.吊装作业区内应设立警戒线。
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吊索具是否合适。
6.吊装时要有统一指挥信号，用对讲机指挥时应有备用的指挥旗。
7.配备消防器材，做好防火工作。
8.临时电源由电气负责人商定其电量配电箱位置和线路走向等，其别人未经允许不得拆接。
9.施工场地应整洁，设备堆放要合理有序。