E3102吊装方案.docx
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E3102吊装方案.docx
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E3102吊装方案
目录
1。
设备的主要参数Mainparameterofequipment
2.吊装方案的选择Selectionofliftingscheme
3.吊装的平面布置Liftinglayout
4.吊车吊装工况的选用SelectionofOperatingConditionoftheCranes
5.吊索具的选用SelectionofSlingsandRigging
6.吊车对地面的压力核算CalculationofPressureofCranetotheGround
7.PRIMARYPRODUCTEXCHANGER的安装步骤TheErectionSequenceofPRIMARYPRODUCTEXCHANGER
8.安全措施Safetymeasures
9.LiftingEquipmentsandToolsNeeded
10.吊车的性能表CranePerformanceChart
PRIMARYPRODUCTEXCHANGER(E3102)的吊装
1.设备的主要参数Mainparameterofequipment
PRIMARYPRODUCTEXCHANGER(E3102)设备自重75t,吊装的设备总重量均为77t(包括梯子平台的重量),设备外形尺寸为φ3500mm×9600mm,设备基础为框架基础,吊装除框架外无构成影响的障碍物。
ThedeadweightofPRIMARYPRODUCTEXCHANGER(E3102)is75tandthetotalweightofequipmenttobeliftedis77t(includingtheweightofladderplatform)withaoutlinesizeof3500mm×9600mm.Theequipmentfoundationisaframeworkfoundation,andtherearenootherobstaclestoliftingexceptframework.
2.吊装方案的选择Selectionofliftingscheme
根据现场的条件及现有的吊装机具,吊装采用单台吊车提升、整体吊装的方法来安装,主吊车选用一台400t履带吊(德国的LiebherrLR1400型),另外还需用一台250t履带吊(日本的神户制钢CKE2500型)辅助溜尾。
Accordingtothesiteconditionsandtheriggingsavailable,PRIMARYPRODUCTEXCHANGER(E3102)willbeliftedwhollybyasinglecrane.A400tcrawlercrane(GermanLiebherrLR1400type)willbechosenasmaincrane,anda250tcrawlercrane(JapanCKE2500type)astailing.
3.吊装的平面布置Liftinglayout
3.1吊装时主吊车、溜尾吊车的站车位置,详见下面的吊装平面布置图(图1)Thepositionsofmaincraneandtailingcranewhenliftingareshowninthefollowingliftinglayout.(Sketch1)
图1
4.吊车吊装工况的选用SelectionofOperatingConditionoftheCranes
4.1主吊车吊装工况的选用SelectionofOperatingConditionoftheMainCrane
PRIMARYPRODUCTEXCHANGER(E3102)金属重量均为75t,设备保温2t,吊索具(包括吊钩、平衡梁、卸扣、钢丝绳等)的重量为5t,因此吊装计算重量应为:
ThemetalweightofPRIMARYPRODUCTEXCHANGER(E3102)is75t,equipmentinsulation2tandslingsandrigging(includinghook,spreader,shacklesandwireropesetc.)5t.Thetotalweighttobeliftediscalculatedasfollows:
G=75+2+5=82t
选LR1400型履带吊的工况为:
起重臂长70m,作业半径16m。
在此工况下,吊车的额定起重量为104t,吊车的起重负荷率为η=79%,其起重能力完全能满足吊装要求。
TheselectedoperatingconditionofLR1400typecrawlercraneisasfollows:
Boomlengthis70m,operatingradius16m.Theratedliftingcapacityofthecraneunderthisconditionis104t,thepercentageofliftingloadofthecraneisη=79%,whichfullysatisfiestheliftingrequirement.
吊车吊装时的净高度计算参见下图(图2),Thenetheightoftheliftingisindicatedinsketch2.
吊车在上述的工况下,起重臂顶部滑车组中心距地面的高度为71.3m,吊装时的净高度h应为:
Underthesaidoperatingcondition,theheightfromthecenterofthepulleyblockatthetopoftheboomtothegroundlevelis71.3m,andthenetheightoftheliftingis
其中3m为平衡梁下端绳长,6m为平衡梁上端绳长,6.5m为就位基础框架高度。
Where3misthelengthoflowerendropeofspreader,6misthatofupperendropeand6.5misheightofframeworkofpositioningfoundation.
可见吊装的净高完全能满足吊装要求。
Accordingtotheabovecalculation,thenetheightoftheliftingcompletelysatisfiestheliftingrequirement.
4.2溜尾吊车吊装工况的选用SelectionoftheOperatingConditionoftheTailingCrane
参见图2,溜尾吊车的提升力F为:
Refertosketch2,theliftingforceoftailingcraneFiscalculatedasfollows:
经计算设备重心在5.2m处,Thecenterofgravityofequipmentiscalculatedat5.2m.
F=G'+3=41+3=44t
式中G'为起吊时溜尾吊车承受PRIMARYPRODUCTEXCHANGER(E3102)的金属重量与保温材料的重量之和,吊钩及索具的重量为3t,因此选250t履带吊的工况为:
起重臂长51.8m,作业半径12m。
在此工况下,吊车的额定起重量为72.5t,吊车的起重负荷率为η=61%,其起重能力完全能满足溜尾吊装的要求。
WhereG’isthesumofweightofmetalandinsulationmaterialsborneontailingcrane.Theweightofhookandriggingsis3t.Giventheabove,theoperatingconditionofthe250tcrawlercraneisdeterminedas:
boomlength51.8m,operatingradiuslessthan12m.Underthesaidoperatingcondition,theratedliftingcapacityofthecraneis72.5t,theliftingloadrateofcraneη=61%,whichfullymeetsthetailingrequirement.
5.吊索具的选用Selectionofslingsandrigging
5.1平衡梁Spreader
为了使PRIMARYPRODUCTEXCHANGER(E3102)在吊装过程中从水平状态能够顺利地转到垂直状态,需要使用平衡梁,平衡梁为我方自行制造,详见图3.InordertomakePRIMARYPRODUCTEXCHANGER(E3102)beliftedsmoothlytoaverticalpositionfromahorizontalpositionduringtheliftingoperation,aspreadermanufacturedbyusistobeused.Fordetails,seesketch3.
图3
5.2主吊耳及主吊索具MainliftinglugandMainSlingsandRigging
溜尾板式吊耳及设备主吊耳为设备的生产厂家制造,随设备供货。
参见设备制造图。
索具的受力计算如下:
Tailingplateliftinglugandmainliftinglug,suppliedtogetherwithequipment,aremanufacturedbyequipmentvender.Seetheequipmentmanufacturedrawings.Theslingbearingforceiscalculatedasfollows:
因此选用6个55t的卸扣,配合2对φ60.5mm钢丝绳扣(规格6×37+1(麻芯),σ=170kg/mm2,破断拉力为Pb=190t)作主吊索具,钢丝绳扣的长度为12m,对折后打两双使用,折减系数按0.75计,该钢丝绳扣的安全系数n为:
Accordingtotheabovecalculation,six55tshacklesaretobeusedmatchedbytwopairsofφ60.5mmwireropes(size6×37+1(hempcore),σ=170kg/mm2,breaktensileforcePb=190t)asmainslingsandrigging.Thelengthofwireropeis12m,whichwillbeusedafterbentdouble.Discountingcoefficientis0.75.Thenthesafetyparameterofthiswireropeiscalculatedasfollows:
5.3溜尾吊耳及溜尾索具LiftinglugsandslingsforTailing
溜尾的吊点选择在设备溜尾吊耳上,溜尾吊耳的结构及有关计算见设备制造图。
Theliftingpointfortailingissetatthetailingliftinglugsofequipment,thestructureofitandrelevantcalculationsseeequipmentmanufacturingdrawings.
选用2个25t的卸扣,配合1对φ43mm钢丝绳扣(规格6×37+1(麻芯),σ=170kg/mm2,破断拉力为Pb=97t)作溜尾吊索具,钢丝绳扣的长度为16m,对折后打两双使用,折减系数按0.75计,溜尾索具计算详见下列计算公式。
Two25tshacklesaretobeusedmatchedbyonepairofφ43mmwireropes(size6×37+1(hempcore),σ=170kg/mm2,breaktensileforcePb=97t)asslingsandriggingusedfortailing.Thelengthofwireropeis16m,whichwillbeusedafterbentdouble.Discountingparameteriscalculatedasper0.75.Detailsofcalculationfortailingslings,Seethefollowingformula:
该钢丝绳扣的安全系为:
Thenthesafetyparameterofthiswireropeiscalculatedasfollows:
>6
6.吊车对地面的压力核算CalculationofPressureofCranetotheGround
6.1主吊车的履带对地面的压力Pressureofcrawlerofmaincranetoground
LR1400型履带吊在上述工况时的车身总重量为328t,吊装的负荷为82t,因此主吊车LR1400型履带吊对地面的压力G=328+82=410t;吊车履带的接地面积F=22.4m2,因此主吊车对地面的压强P为:
Undertheaboveworkingoperation,thetotalweightofLR1400crawlercraneis328tandliftingloadis82t.SothepressureofmaincranetogroundG=328+82=410tandbottomareaofcrawlertothegroundF=22.4m2.ThenstrengthPofmaincranetogroundiscalculatedasfollows:
6.2溜尾吊车的履带对地面的压力Pressureofcrawleroftailingcranetoground
250t履带吊的车身总重量为180t,吊装的负荷为44t,因此溜尾吊车对地面的压力G=180+44=224t;吊车履带的接地面积F=17.2m2,因此溜尾吊车对地面的压强P为:
Undertheaboveworkingoperation,thetotalweightof250tcrawlercraneis180tandliftingloadis44t.SothepressureoftailingcranetogroundG=180+44=224t,andbottomareaofcrawlertothegroundF=17.2m2.ThenstrengthPoftailingcranetogroundiscalculatedasfollows:
为了保证吊装的安全,要求地面的地耐力大于20t/m2。
Forthesakeofsafety,thegroundbearingcapacityshouldbemorethan20t/m2
7.PRIMARYPRODUCTEXCHANGER(E3102)的吊装步骤:
TheErectionSequenceofPRIMARYPRODUCTEXCHANGER(E3102)
PRIMARYPRODUCTEXCHANGER(E3102)吊装的主要步骤为:
ThemainerectionsequenceofPRIMARYPRODUCTEXCHANGER(E3102)isasfollows:
7.1溜尾吊车和主吊车共同将设备抬起,离开地面200mm左右后试吊,停止进行检查,没有问题后再继续吊装。
LiftingPRIMARYPRODUCTEXCHANGER(E3102)byusingtailingcraneandmaincranetogether,trialliftingwillbestoppedandinspectionbeperformedafteritis200mmawayfromground.Continueliftingoperationwheneverythingischeckedsafeforalift.
7.2在起吊过程中溜尾吊车跟随设备以微速向前行走数米。
在溜尾吊车的配合下,将PRIMARYPRODUCTEXCHANGER(E3102)从水平状态起吊至垂直状态。
溜尾吊车松钩脱绳。
Thetailingcranetravelsafewmetersforwardbyfollowingequipmentatanextremelyslowspeedduringliftingoperation.Withthecooperationofthetailingcrane,themaincraneliftsPRIMARYPRODUCTEXCHANGER(E3102)toaverticalpositionfromahorizontalposition.Thenremovethehookandropeoftailingcrane.
7.3转动主吊车的起重臂,将PRIMARYPRODUCTEXCHANGER(E3102)对准设备基础的方向。
Turnthemaincraneboomtotheequipmentfoundation.
7.4到达就位的位置后,将PRIMARYPRODUCTEXCHANGER(E3102)对正基础,放下就位。
Whenreachedthepositionforlowering,PRIMARYPRODUCTEXCHANGER(E3102)isaimedatthefoundationandloweredinplace.
8.安全措施Safetymeasures
8.1必须严格执行吊车随机技术文件的规定,不能违章作业。
Allspecificationssuppliedwiththecranemustbestrictlyfollowed.Anyviolationofspecificationsisprohibited.
8.2设备吊装过程中,所用绳扣的长度必须符合本方案的要求,不能过长或过短。
Thelengthofallslingsusedfortheliftingoperationmustbeinlinewiththatrequiredinthisscheme.Thattheslingsareeithertoolongortooshortisnotallowed.
8.3起吊前,现场的杂物应清除干净,并平整场地,对吊装过程有影响的物体或已安装的构件要拆除,吊车吊装时的站车位置要平整坚实,防止出现下沉现象。
Beforelifting,thesiteshallbecleanedandleveled.Anyobjectsorstructuralmembersinstalledthathaveimpactontheliftingshallberemoved.Thelocationwherethecranestandsforliftingshallbelevelandsolidtopreventsinking.
8.4风力≥4级的天气不能进行吊装作业。
Noliftingoperationiscarriedoutwhenthewindforceis≥4scale.
8.5在吊装期间,现场必须拉上安全线,设置警戒区,严禁非作业人员进入。
Warningsignsandsafetybarricadesmustbeprovidedaroundtheareaduringliftingtopreventunauthorizedentry.
8.6吊装前要进行安全检查,确认无误后,再进行试吊,试吊高度为200~300m,经检查合格后再正式起吊。
Beforelifting,safetyinspectionmustbeconducted.Whensafetyisensured,performliftingbytrialanderrormethod.Theheightfortrialliftingis200~300m.Whenthetrialliftingproveseverythingissafeforalift,startliftingoperation.
8.7参加吊装的人员要明确分工,集中精力,服从指挥,坚守岗位。
吊装的作业人员共有8人:
2名吊车司机(朱玉华、陈星华),1名监工(陈敏),5名起重工(黄增革、吴水龙、邓运红、廖继、谭耀才),信号指挥是黄增革,采用哨音信号及旗指挥信号。
Thepersonnelengagedintheliftingoperationshallbegivenclearresponsibilityandarerequiredtoconcentrateonthework,tofollowordersandtosticktohispost.Acrewof18isassignedtoperformtheliftingactivity,thatincludes2craneoperators(ZhuYuhua,ChenXinghua),1supervisor(ChenMin),5riggers(HuangZengge,WuShuilong,DengYunhong,LiaoLi,TanYaocai).ThebankmanisHuangZengge.Whistlesignalandflagsignalareusedfordirectingtheliftingoperation.
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