TK9530基础处理方案 R 3.docx
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TK9530基础处理方案 R 3.docx
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TK9530基础处理方案R3
目录
content
1、处理步骤Pre-Treatment2
2施工方法Constructionmethods……………………………………2
3、相关计算RelatedCalculation15
4、安全技术要求SafetyTechnicalRequirements17
5、施工计划WorkingPlan19
6、工作危险性分析及控制措施JobHazardAnalysisandControlmeasures21
7,Attachment………………………………………………………….…28
储罐基础处理措施
Treatmentmeasurefortankfoundation
针对现场施工的TK9530基础凹凸度超标的问题,我单位经过仔细研究讨论,特提出下述处理措施.
AsfortheflatnessofTK9530foundationisoutofrequirementforrelativeGBcodeandthemax.app.30mmgapsisaccruedbetweenbasementandbottomplate,sothefollowingtreatmentmeasuresisherebypreparedforthisissue.
1、处理步骤Pre-Treatment
1.1将目前剩余尾项工作正常施工完毕(包括顶板安装、附件安装、底部大角焊缝焊接、龟甲缝焊接等)将罐内脚手架拆除以减轻罐体重量,防止罐底板受脚手架压力而变形,调整外脚手架以便于设置提升装置。
Completethecurrentremainingitems(Includesweldingoftheroofplate,accessoryparts,andthefilletweldseambetweenshellandannularofthebottom,andsoon…..).
ØGeneralsequenceasbelow.
1.Removeinsidescaffolding.
2.Weldingbetweenbasementand1stshell.
3.Weldingcenterplateandannularplate,andanchorboxwelding.
4.Removeoutsidescaffolding.
5.Lift-uptankandrectifybasement.
6.Erection1~2EAmovablescaffolding(ThesafetyofmovablescaffoldingwasconfirmedbyTMDIHSEalready).
7.Remaininsidenozzlework,weldingrepair,remainweldingbeadgrindingandfinalinspection.
8.Removemoveablescaffolding.
9.Hydro.test.
10.Erectionmoveable2~3scaffolding
11.ShotblastingwithSA2½andrubberliningworkforinsideandweldingdripboarder,andtouch-uppaintingforsurfacedamagepartandfinishingcoatingforoutsideofroofandshell.
12.Removemoveablescaffoldingandrubberliningforremainingpartofbottom.
13.Finalinspection.
1.2利用提升系统将储罐提升1米,根据对底板的测量结果(见附件1)对四周靠近外沿1200mm左右区域填充沥青砂进行基础处理。
Usethehoistingsystemtojackupthetankfor1mwith24liftingasbelowsketch,fillupthebitumensandstorepairthefoundationaspersurveydataofbottom(aspersurveydataonlytheoutsideabout1.2metersurroundingareaofthefoundationedgeislower,pleaseseeattachedsurveydata).
2、施工方法Constructionmethods
2.1底部大角焊缝及龟甲缝焊接后,在底板上加设I20井字形支撑作为防止罐体在提升过程中底板下垂的反变形措施(如图)。
同时也增大了罐体的刚度。
Afterweldingthefilletweldbetweenshellandbottom,andweldofbottomandannularplate,takethemeasuresforpreventdeformationduringliftingbyaddingI20“#”typesupportonthebottomplate(asshowninsketchasbelow).Italsoincreasesthetankrigidityatthesametime.
2.2提升结构Liftingstructure
提升架采用φ219*8Q235钢管作为提升立柱,柱脚使用膨胀螺丝固定。
立柱间横梁采用φ89*5.5钢管,斜撑采用∠80*6角钢连接(如图)。
提升吊点利用储罐地脚螺栓座。
Steeltubeφ219*8Q235columnshallbeadoptedas24EA,and10toncapacityofelectrichoisting9(4MLong)foreachcolumn.
Thecolumnbefixedtobasementwithanchorbolt.
φ89*5.5steelpipeshallbeadoptedbetweenuprightcolumns,and∠80*6shallbeadoptedforconnectionamonguprightcolumn(seebelowsketchpage10of29).Theanchoredframeisutilizedastheliftingpoint.
2.3罐体提升施工Tankliftingwork
24组电动葫芦使用1个总配电箱4个分配电箱控制,每个分配电箱控制6组装置,提升时始终保持同步性。
为防止电动葫芦出现滑链,在提升到指定高度后在罐底板下部设置临时支撑(φ219*8L=1m8套均布,该支撑仅作为安全富余保证,正常工况下不参与受力。
当修复基础时随工作区域调整位置).
Beforeliftingbecheckedforbelowthings:
⏹Theelectrichoistshouldhaveloadtestpriortoputintoservice.
⏹Theelectricalsystemforhoistisrequiredperformancetestbeforeusing.
Onegeneraldistributionboxandfoursecondarydistributionboxeswillbeadoptedforcontrollingthe24setsof10toncapacityelectricalhoist.Eachsecondarydistributionboxwillcontrol6setsofelectricalhoisting.
ØCalculationforverticalloadforcolumnandtensionforceforhoist.
⏹TanktotalWeight(105Ton)/24EA=4.38Ton
⏹20%unbalancefactor,so4.38*1.2=5.26Ton(VerticalforceforColumn)
⏹ActualtensionforceforHoist:
5.26/Cos15.29˚=5.45Ton
Thesynchronismshallbekeptduringtheliftingwork.Inordertoavoidthechain-slidingofelectricalhoisting,whenlifttothespecifiedheight,setupandweldingthetemporarysupportasbelowsketch(seebelowsketchpage12of29)asthesafetyguarantee.
Normallythissupportisusedassafetyguaranteeanddoesnotbearanyload,andattachedthissupportsarelocatedeveryotherliftingsupportwhendobeforefoundationrepairing.
ThetemporaryweldingseamforliftingdeviceisrequiredPTaftergrinding,andrepairalldefectforallpartifrequired.
TheelectrichoistwillbeusedforShanghaiHugongDHPtype4Mlongasattachment#3
2.4Finalinspection
落下储罐完成最终检查。
Liftdownslowlythetank,andgetfinalinspectionaccordingtorelativedrawingandspec.
2.5基础处理Foundationtreatment
进行基础处理工作的人员仅限于在基础外施工,填充沥青砂后使用机器压实,严禁人身进入储罐与基础的间隙中.
Duringfoundationtreatment,itisstrictlyforbiddentosteponthefoundationforcompactmachineorworkerman.
Thebitumensandfillingworkandcompactingshallbecarriedasbelow.
Thecompactmachinewillbeusedasattachment#1
Ø前期施工的罐基础沥青混凝土表面部分存在标高不足的问题,现针对这一问题做如下整改:
Regarding the insufficient elevation of asphalt concrete surface on tank foundation in early constructionperiod, hereby the following steps will be used for rectify this issue.
1).待圆罐吊起后,清理距罐基础边沿1m范围内圆环沥青混凝土表面的污垢。
After lifting the tank, clean the dirt on circular asphalt concrete surface within 1m from the tank edge.
2).人工在沥青混凝土表面涂刷冷底子油结合层。
Apply cold primer-oil combined layer on the asphalt concrete surface manually.
3).由专业测量使用水准仪沿圆环周圈每隔2m设置一个控制标高的砂浆灰饼,灰饼高度严格按照设计标高制作。
Use level meter to set up a motar ash cake every 2m along the circular ring to control the elevation by discipline surveyor. The height of fabricated ash cake shall be strictly according to the design elevation.
4).沥青砂用汽车运至现场,由挖掘机从车厢内挖放至摊铺位置后,人工随即用铁锹大大致扒平,然后用找平耙子拉线找平,控制松铺厚度为压实厚度的1.25~1.35倍。
Bitumensandshallbetransferredtothesitebyautomobile.Whenthesandismovedfrominsidecarriagetothelay-downareabythedigger,spadesshallbeusedtoflattenthesandandlevelingrakeshallbeusedforlinesettingandleveling.Thelay-downthicknessshallbecontrolledin1.25~1.35timesofthecompactedthickness.
5).使用设计图纸要求的沥青混凝土将沥青混凝土表面凹陷部位补平,用平板振压器压实,压实系数0.95。
Use the required asphalt concrete on design drawing to fill in the depression part on the asphalt.
Concrete surface to make it even. Andflat-platecompactingmachineshallbeusedforcompaction,withthecompactionfactoras0.95.
6).由于沥青砂压实时仅为基础边缘1m范围,所以人员不需要进入基础内侧,人员站在基础边缘处用平板振动器即可完成。
Theasphalticsandcompactioniswithin1mormorefromtheedgeofthefoundation,thereforetheoperatorcanfinishthecompactionwithflat-plateoutsideofthefoundationinsteadofgettinginside.
7).向TMDI及监理报验,报验合格后方可进行下一步施工。
Apply for inspection to TMDI and Jianli, and enter to next step after the inspection is acceptable.
Itisstrictlyforbiddenanybodytoenterintothegapbetweenbottomoftankandfoundation,inotherwordthefoundationworkbecarriedoutoutsideoffoundation.
2.6FinalAdjusting
Ifitisnotsatisfytherequirementduringfinalinspection,thetankliftagainandre-adjustfoundationafterthatliftdownthetankslowlyandgetinspectionagain.
3.相关计算Relatedcalculation
3.1CalculationBase
-使用材质:
Q235B
-Usingmaterial:
GBQ235B
-屈服强度:
235MPa=23.96kg/mm2
-Yieldingstrength:
235MPa=23.96kg/mm2
-按照安全系数0.5计算,则0.5*23.96kg/mm2=11.98kg/mm2(a)
-Accordingtothecalculationofsafetyfactorof0.5,so0.5*23.96kg/mm2=11.98kg/mm2(a)
3.2Calculationfortensionforceforhoist
-TanktotalWeight(105Ton)/24EA=4.38Ton
-20%unbalancefactor,so4.38*1.2=5.26Ton(VerticalforceforColumn)
-ActualtensionforceforHoist:
5.26/Cos15.29˚=5.45Ton
3.3Tensionforcefordiagonalangleforregularpart
-5.26Ton*Tan15.29˚/Cos45˚=2.08Ton
3.4Tensionforcefordiagonalanglefornarrowpart
-5.26Ton*Tan15.29˚/Cos60˚=3.11Ton
3.5TotalCompressionloadforcolumnforregularpart
-Basiccompressionload:
5.45Ton
-Additionalloadbytensionangleforregularpart:
2.08Ton*Cos45˚=1.47ton
-Totalcompressionload:
5.26+1.47=6.73Ton
3.6TotalCompressionloadforcolumnfornarrowpart
-Basiccompressionload:
5.45Ton
-Additionalloadbytensionangleforregularpart:
2.04Ton*Cos30˚=1.80ton
-Totalcompressionload:
5.26+1.80=7.06Ton
3.7DetailCalculationbaseonworstcase(Narrowpart)
1)a)立柱计算columncalculationforcompression
-使用规格:
φ219*8
-Usingsize:
φ219*8
-抗压强度:
5303mm2*11.98kg/mm2=63.5t>7.06t,符合要求
-Compressionstrength:
5303mm2*11.98=63.5t>7.06t,soitisOK.
b)立柱计算columncalculationforbucking
-KL/r=1x4,000/74.676=53.56<200,soitisOK.(Nonslendercolumn)
-D/tw=219/8=227.375<1.00xEs/Fy=88.61,soitisOK
Fy=kl/rπFy/E53.56/π235/200,000=0.584
0.3636
Fcr=(0.658)237Mpa=204.8Mpa
2.π
2.π
Ag=219x211=2,701.77mm2
Pn=Ecr.Ag=204.4Mpax2,701.77mm2=552,226N=552KN
ΦcxPn=0.9x280KN=522KN=53.2Ton>7.06t,soitisOK.
2)拉撑计算tensionbarcalculation
-Area:
160*6=960mm2
-抗拉强度:
960mm2*11.98kg/mm2=11.50>3.11t,符合要求
-Capacity:
960mm2*11.98kg/mm2=11.50>3.11t,soitisOK.
-IncaseL75x75x5forregularPartonlycanbeused
-Area:
150*5=750mm2
-抗拉强度:
750mm2*11.98kg/mm2=8.98>2.08t,符合要求
-Capacity:
750mm2*11.98kg/mm2=8.98>2.08t,soitisOK.
3)地脚螺栓计算anchorboltcalculation
-使用规格:
M16
-Usingsize:
M16
-有效截面积:
156.7mm2
-Effectivesectionarea:
156.7mm2
-抗拉强度:
156.7mm2**11.98kg/mm2=1.88t*6个=11.28t>3.11t,符合要求
-Capacity:
156.7mm2*11.98kg/mm2=2.92t*6EA=11.28t>3.11t,soitisOK.
4)吊耳计算lugcalculation
-使用规格:
10mm*200mm*300mm
-Usingsize:
10mm*200mm*300mm
-有效截面积:
150mm*10=1500mm2
-Effectivesectionareaformainplate:
1500mm2
-Effectivesectionareafor2EAof5mmcheckplate:
100mm*5mm*2EA=1,000mm2
-抗拉强度:
(1500mm2+1,000mm2)*11.98kg/mm2=29.95t>5.46t,符合要求
-Capacityfortensileforce:
(1500mm2+1,000mm2)*
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