Drum+lifting+construction+program锅筒吊装施工方案.docx
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Drum+lifting+construction+program锅筒吊装施工方案.docx
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Drum+lifting+construction+program锅筒吊装施工方案
锅筒吊装专项方案
SpecialProgramforDrumLifting
编制:
Preparedby:
审核:
Reviewedby:
审批:
Approvedby:
限公司
Co.,Ltd.
2015年1月
January2015
目录
Contents
一、概况I.Overview3
二、编制依据:
II.BasisforPreparation3
三、吊装前的准备工作III.PreparationforLifting4
四、施工程序及施工方案IV.ConstructionProcedureandConstructionProgram5
五、锅筒受力分析V.StressAnalysisofDrum11
六、质量和安全措施VI.QualityandSafetyMeasures17
七、人员的配备计划VII.StaffingPlan(Unit:
Person)19
八、机具计划VIII.Machinesandtools20
九、安全措施IX.Safetymeasures21
锅筒吊装专项方案
SpecialProgramforDrumLifting
一、概况I.Overview
热电厂建安工程225t/h循环流化床锅炉安装工程,该锅炉部件最大件为锅筒,重量约55000㎏,内部约6000㎏,总重为61000㎏。
锅筒外形尺寸:
10mx2.4mx2.4m。
安装于炉前(K1-K2)锅筒吊挂梁上(标高:
44900mm),锅筒安装中心标高40900mm。
Theobjecttobeinstalledinthepowerplantisthe225t/hcirculatingfluidizedbedboiler.Thelargestpartoftheboileristhedrumweighingabout55,000kg,theinternalpartsweighabout6,000kg,andtotalweightoftheboilerisabout6,100kg.Theexternaldimensionsofthedrumare10mx2.4mx2.4m.Thedrumishangedfromthedrumhangingbeam(withtheelevationof44,900mm)beforetheboiler(K1-K2),andtheelevationatthedruminstallationcenteris40,900mm.
因施工场地狭小,受锅炉钢架影响,不能直接采用吊车吊装。
通过对现场实际情况勘查并结合我公司多次安装锅炉锅筒的吊装经验,本次吊装拟采用在炉底布置两台10T卷扬机并辅以4个80T滑轮形成两个滑轮组配合进行并将锅筒倾斜450吊装的方案。
此吊装是整个锅炉安装的重点控制环节,安全工作尤其重要,为此特编制本吊装方案,用以指导锅筒的吊装作业。
Affectedbythenarrowconstructionsiteandtheboilersteelframe,thedrummaynotbedirectlyliftedwithacrane.Accordingtothesurveyonthephysicalcircumstancesatsiteandincombinationwithourliftingexperienceinboilerdruminstallationformanytimes,itisplannedtoarrangetwo10twinchesatthebottomoftheboilerandsupplementthewincheswithfour80Tpulleystoformtwopulleyblocksandthentiltthedrumto45°forlifting.Liftingisthekeycontrolprocessduringtheinstallationoftheboiler,sosafetyisespeciallyimportantandtheliftingprogramisespeciallypreparedtodirectthedrumliftingoperation.
二、编制依据:
II.BasisforPreparation
1.杭州锅炉集团提供的有关锅炉安装图纸
BoilerinstallationdrawingsprovidedbyHangzhouBoilerGroup
2.《蒸汽锅炉安全技术监察规程》
RulesforSafetyandTechnicalSupervisionofSteamBoilers
3.《电力建设施工及验收技术规范》(锅炉机组篇DL/T5190.2-2012)
CodeforErectionandAcceptanceofElectricPowerConstruction(SectionofSteamBoilerSetDL/T5190.2-2012)
4.《电力建设施工质量验收及评定规程》(锅炉机组篇DL/T5210-2009)
CodeforQualityAcceptanceandEvaluationofElectricPowerConstruction(SectionofSteamBoilerSetDL/T5210-2009)
5.《电力建设安全工作规程》DL5009.1-2002
RulesforSafetyofElectricPowerConstruction(DL5009.1-2002)
6.《一般用途钢丝绳》GB/T20118-2006
SteelWireRopesforGeneralPurpose(GB/T20118-2006)
7.《工程建设安全工程施工规范规程》HG20210-2000
SpecificationsforSafeEngineeringConstruction(HG20210-2000)
8.10吨卷扬机性能参数表
Performanceparametersofthe10twinches
三、吊装前的准备工作III.PreparationforLifting
1.锅炉钢架K1~K2主跨间炉左(②)高度约36000㎜暂不安装;炉右(④)高度约22000㎜、28000㎜临时安装,其它钢结构均应安装完毕。
FortheboilersteelframesinthemainspansK1~K2,about36,000mhighframe(②)attheleftoftheboilerisnotinstalledforthepresent,about22,000mmand28,000highframes(④)attherightoftheboileristemporarilyinstalled,andothersteelstructuresshouldbeinstalledcompletely.
2.吊装设施制作安装完毕并对参与吊装工作设备必须进行一次严格的清查,认真检查,设备的性能是否符合吊装要求,设备是否完好,灵敏性是否可靠。
Thefacilitiesusedforliftingshouldbefabricatedanderected,theliftingappliancesmustberigorouslychecked,anditshouldbecarefullycheckedwhethertheperformanceoftheequipmentmeetstherequirementsforlifting,theequipmentisingoodconditionanditssensitivityisreliable.
3.对起重吊具、卡具,所有钢丝绳等进行全面的检查,规格是否符合要求、完好,如发现问题的必须更换,未更换严禁使用。
Itshouldbecomprehensivelycheckedwhethertheliftingslings,fixturesandallwireropesetc.meetthespecificationsandareingoodcondition.Incaseofanyproblem,theymustbereplaced.Otherwise,theymaynotbeused.
4.对捆扎绳及捆绑绳在使用前要严格检查捆绑位置及是否在管口或其它的棱角上,如无法避免的应作好保护措施。
(如加木板或汽车轮胎作垫料或加钢管瓦等其它方法予以保护)
Foranyropeusedforbindingandtying-up,itshouldbecarefullycheckedwhetheritisatanynozzleoranyofitsedgesorcorners.Ifitisunavoidable,protectivemeasuresshouldbetaken.(Forexample,woodboardorcartireisusedforpackingorotherprotectivemethodsofsteeltubetileetc.aretaken.)
5.施工前技术人员必须认真仔细进行技术交底,施工人员需熟悉图纸、吊装方案和有关的标准,明确吊装的具体方法步骤、工艺、过程,明确指挥信号和传递方式,确定指挥位置。
Beforeconstruction,techniciansmustcarefullycarryouttechnicalclarification,andconstructionworkersneedtobefamiliarwiththedrawings,liftingprogramandapplicablestandards,pinpointthespecificliftingmethods,steps,techniquesandprocesses,pinpointcommandsignalsandtheirtransmissionmodes,anddeterminethecommandpositions.
6.锅筒到货后作好设备进场验收,并卸到指定位置以便于吊装。
锅筒在吊装前要根据图纸设计要求和施工规范对设备进行检查、划线。
安装好锅筒的吊架和链条装置。
Afterarrivingatthesite,thedrumshouldbeacceptedandunloadedataspecifiedlocationtofacilitatelifting.Beforebeinglifted,thedrumshouldbechangedandmarkedaccordingtothedrawingandconstructionspecifications.Thenthedrumhangerandchainshouldbefixed.
7.锅筒吊装前,应复核大板梁挠度,测量一次钢架1米标高线,做好锅炉沉降观测点的原始记录。
依据1米标高位置用油漆标记锅筒吊装时的标高位置。
Beforethedrumislifted,thedeflectionofthelargeplategirdershouldberechecked,the1melevationlineofthesteelframesshouldbemeasured,andtheoriginalelevationsoftheboilersettlementobservationpointsshouldberecorded.Theelevationwhenthedrumisliftedismarkedwithpaintaccordingtothepositionofthe1melevation.
8.炉顶临时平台、不影响吊装的锅筒平台搭设好,走道贯通。
Boththetemporaryplatformabovetheboilertopandthedrumplatformnotaffectingliftingshouldbeerectedandthewalkwaysshouldbelinkedup.
四、施工程序及施工方案IV.ConstructionProcedureandConstructionProgram
1.施工流程Constructionprocess
吊装设施安装→锅筒吊架检验→锅筒吊架组装→锅筒检查→锅筒划线→锅筒吊装安装→锅筒找正→锅筒内部装置安装检查→锅筒封闭
Erectthefacilitiesusedforlifting→inspectthedrumhanger→assemblethedrumhanger→inspectthedrum→markthedrum→liftthedrum→alignthedrum→installandinspectthedevicesinthedrum→closethedrum
2.施工方案Constructionprogram
该锅筒吊装采用两台卷扬机相配合进行吊装的作业方式,利用锅炉钢架吊挂锅筒的2根承重横梁和炉膛上部(左、右方向)中心的1根大板梁为基础,在上面安装双门型锅筒吊装梁。
具体做法:
在承重横梁下方用三根L=2000㎜Ø273×20㎜厚壁管分别焊接在锅炉钢架K1(②-④)、K2(②-④)间锅炉中间大板梁和两根汽包吊挂梁上方,并在吊挂横梁立柱两侧用[]10#或[16#槽钢作好斜撑并焊接牢固。
在承重横梁上拴挂吊装定滑轮。
用两台卷扬机进行牵引,卷扬机设置在标高为0m层(地面)钢架立柱上,工作绳采用φ28mm钢丝绳,通过双门形架两个80吨五轮滑轮两组,捆绑绳采用φ32.0mm钢丝绳,固定在承重梁及锅筒中间两侧适当位置。
Twowinchesareusedfordrumlifting,andthetwoloadbearingbeamsusedforsteelboilerframestohangthedrumandtheonelargeplategirder(left-rightdirection)atthecenteroftheupperpartofthefurnacearebasedtoerectthedoubledoortypedrumliftingbeam.Specificmethod:
belowtheloadbearingbeam,weldthreetubes(L=2,000mmandØ273×20mm)respectivelytothelargeplategirderinthemiddleoftheboilerandbetweenthesteelboilerframesK1(②-④)andK2(②-④)andtwodrumhangingbeams,anderectandfirmlyweld10#or16#channelsatbothsidesthecolumnsofthehangingbeamasbracing.Hangtheliftedfixedpulleyfromtheloadbearingbeam.Usetwowinchesfortowing,setthewinchesonthesteelcolumnswiththeelevationof0m(ontheground),useφ28mmwireropeforworking,andfixtwo80tfive-pulleyblockswithφ32.0mmwireropethroughthedoubledoortypeframetotheproperlocationsatbothsidesofthemiddlebetweentheloadbearinganddrum.
首先在锅筒进场前用150吨汽车吊和已准备好锅筒吊装装置将其卸于炉膛锅筒吊挂梁的正下方,卸车时注意锅筒的方向。
然后按照要求作好锅筒的吊装准备工作,准备工作就绪后,吊装人员服从统一指挥,对各点的捆绑绳及各滑轮组进行仔细的检查,确认无误后,进行起吊。
首先检查两台卷扬机是否同步及灵敏度情况,起吊至200mm高度时停止,检查无异常后,割去左、右支撑锅筒支座,进行吊装作业,将锅筒倾斜450吊装,两卷扬机需同步提升;提升至吊挂横梁下方至快到位时,停下主吊卷扬机,用辅吊卷扬机将锅筒吊平。
用准备好的葫芦吊挂锅筒链条,穿上吊杆及孔轴对锅筒进行找正。
找正时应紧张有序、应尽量缩短锅筒在空中悬吊的时间,以免出现意外。
Firstly,unloadthedrumunderitshangingbeamwitha150ttruckcraneandprepareddrumliftingappliances.Whenunladingthedrum,payattentiontoitsdirection.Then,liftingworkerspreparethedrumliftingasrequired,carefullychecktheropesusedfortying-upatallpointsandallpulleyblocksascentrallycommanded,andliftthedrumafteritisconfirmedthatthereisnoerror.Firstlycheckwhetherthetwowinchesaresynchronousandsensitive,thenstopliftingattheheightof200mmandcutofftheleftandrightandleftdrumsupportingabutmentsafteritischeckedthatthereisnoabnormality,continuallyliftthedrumatthetiltangleof45°,andkeeptwowinchesliftingsynchronously.Stopthemainwinchandliftthedrumtobelevelwiththeauxiliarywinchwhenthedrumisliftedbelowthehangingbeamandistobeinplacesoon.Liftthedrumchangewiththepreparedhoist,andputthehangerrodandhollowshaftthroughforalignment.Duringalignment,tighteningandtensioningshouldbeorderedandthesuspensiontimeofthedrumintheairshouldbeminimizedtoavoidaccidents.
3.具体吊装过程描述及示意图Specificliftingprocessesandsketchmap
1.捆绳子及作准备Tying-upandpreparation
绑扎好起吊用钢丝绳,绑扎用φ32.0×50米的钢丝绳,两吊点离中心分别为2000㎜和1500㎜,缠绕圈数不低于5圈,用80T卡环挂到滑轮组挂钩上,两端间距位置相等。
Tiethedrumupwithφ32.0×50mwireropeatleastfiveturnsforlifting,keeptwoliftingpoints2,000mmand1,500mmawayfromthecenter,andhangtheropetothepulleyblockhookwith80tsnapring,andkeepequalspacetobothends.
2.试吊Triallifting
指挥卷扬机缓缓起钩,待钢丝绳受力停止起钩。
分别检查卷扬机、转向滑轮、起重滑轮组、绑扎的钢丝绳等受力情况,如无异常,可以试吊。
具体操作步骤:
先将锅筒提升500㎜,再下降300㎜,再次检查钢索的张紧度、夹具的可靠性及卷扬机的制动性能。
Commandliftingworkerstostartthewinchesslowlyandstopthemwhenthewireropesareunderstress.Checkthestressofthewinches,anglepulleys,liftingpulleyblocksandtying-upwireropesetc.andstarttrialliftingprovidedthatthereisnoabnormity.Specificsteps:
firstlyliftthedrumupfor500mmandthenloweritfor300mmtocheckthetensionofthewireropes,thereliabilityoffixturesandthebrakeperformanceofthewinches.
3.起吊,检查各处受力无问题后起吊Liftthedru
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