Erection Program Forthe 443-3P1preheater towerName of the document：The Erection program of the443-3P1 preheater towerNo. of the document：GU3-方案-M-010Editing department：The Engineering department of CBMIEdited by：Liu Li Da Date：2013-11-20 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主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升机、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, providingproduction 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 basis1.HOLCIM(ECUADOR)GU3水泥厂烧成窑尾工艺布置图。

HOLCIM(ECUADOR)GU3 PROJECT PREHEATER TOWER GENERAL ARRANGEMENT DRAWING文件编号：GU3-方案-M-010工艺布置图General arrangement drawing52.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 drawings3.HOLCIM(ECUADOR)GU3水泥厂预热器制作、安装图。

HOLCIM(ECUADOR)GU3 preheater fabrication, installation drawings4.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主要包括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 andthe 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 tableSTT403-24T塔吊载荷信息表STT403-24T Tower crane load chart文件编号：GU3-方案-M-010塔吊布置图Preheater tower crane layout文件编号：GU3-方案-M-010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要求，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文件编号：GU3-方案-M-01011四．Flow Sheet for Guarantee System of Quality and Safety质量安全保证体系流程图五.施工工艺过程 The construction process主管经理Mananger ：ZhouyougenTech director ：Zhuziwu Supervisor ： Xue zhimin Xiang xianlun质量安全：Quantity and safety ：BowenshuaiDucumentation ：Zhangqingthe bridge work execute （50workers ）SAFETT SUPERVISOR ：YANGHAICHAODocumentation record and storageLifting Zhangjie Chenlabao文件编号：GU3-方案-M-010item time activity method tools NumberofworkersNumberofpeoplearoundFeed-end chamber erection Start:25/12/13End:10/01/14Size(m)Width:5.15mHeight:8.6mLength:2.55mWeight:16.9ton1. Assemble allthe parts on theground.2.liftingfeed-endchamber3.StairserectionTower craneArc welderChain blockLength ruler45 15item time activity method tools NumberofworkersNumberofpeoplearound+16.000-27.000m column and frame girder erection Start:10/01/14End:25/01/14Column max.size(m):Length:≤12.4mGirder max size(m):length: ≤11mSingle part weight:≤ 5.5ton1.Nine columnserection2.Frame girdererection.Tower crane，Arc welder，Chain block，Theodolite，Length ruler，Electricwrench45 1513+27.000msub-girder and platform erection Start:26/01/14End:31/01/14Sub-girder size(m):Length: ≤10mSingle part weight:≤ 5ton1.Pipe erection2. +27.000m plansub-girdererection3.+27.000mplatformerection4.StairserectionTower craneArc welderChain blockTheodoliteLength rulerElectricwrench45 1514bottom section Precalciner erection Start:01/02/14End:02/02/14Size(m)diameter:4.616-6.416mLength:16.174mWeight:20.05tonFirstliftweight:7.5 tSecondly liftweight:14.05 t1. Assemble twoparts according tosketch map on theground.2.lifting first lift3.lifting secondly liftTower craneArc welderChain blockLengthruler45 1015+27.000-41.6 00m column and frame girder erection Start:03/02/14End:13/02/14Column max.size(m):Length:≤14.6mGirder max size(m):length: ≤11mSingle part weight:≤ 8 ton1.Nine columns erection2. Frame girdererection.Tower craneArc welderChain blockTheodoliteLengthrulerElectricwrench40 1516+41.600m sub-girder and platform erection Start:14/02/14End:20/02/14Sub-girder size(m):Length: ≤11mSingle part weight:≤ 4 ton1.Pipe erection2. +41.600 plansub-girder erection3.+41.600m platformerection4. Stairs erectionTower craneArc welderChain blockTheodoliteLengthrulerElectricwrench45 1517middle section Precalciner erection Start:21/02/14End:28/02/14Size(m)diameter:5.646-6.416mLength:8.57mWeight:20.05 tonThirdly lift weight:8.5tonFourthly liftweight:11.55 ton1. Assembletwopartsaccordingto sketchmap on theground.2.liftingthirdlylift3.liftingfourthlyliftTowercraneArc welderChainblockLengthruler45 15180m column and frame girder erection 01/03/14End:10/03/14Column max.size(m):Length:≤8.6mGirder max size(m):length: ≤11mSingle part weight:≤ 7 ton2. Frame girdererection.Arc welderChain blockTheodoliteLengthrulerElectricwrench19sub-girder and platform erection 11/03/14End:20/03/14Sub-girder size(m):Length: ≤10.95mSingle part weight:≤ 4 ton2.+50.200 plansub-girder erection3.+50.200m platformerection4. Stairs erectionArc welderChain blockTheodoliteLengthrulerElectricwrench20C5 cyclone Start: 1.Upper: 1. Assemble the Tower crane21top section Precalciner erection Start:28/03/14End:31/03/14Size(m)diameter:5-6.4mLength:8.6mWeight:19.40 ton1.Assembleparts accordingto sketch mapon the ground.2.lifting toppartsTower craneArc welderChain blockLength ruler45 1022+50.2m ~+66.0m sub-girder and platform erection Start:01/04/14End:09/04/14Sub-girder size(m):Length: ≤17mSingle part weight:≤ 8 ton1.Pipe erection2. +50.2~+66mplan sub-girdererection3.+60.8mplatformerectionTower craneArc welderChain blockTheodoliteLength rulerElectricwrench45 1523+66.000msub-girder and platform erection Start:10/04/14End:18/04/14Sub-girder size(m):Length: ≤11mSingle part weight:≤ 4 ton1.Pipeerection2.+66mplansub-girdererection3.+66mplatformerection4. StairserectionTower craneArc welderChain blockTheodoliteLength rulerElectricwrench45 1524C4 cyclone erection Start:19/04/14End:25/04/141.topweight: 26.7ton2.middle:weight: 20 ton3.bottomweight: 3.55ton1. Assemble thecone the bottom,the middle andthe uppersections on theground.2. Lift eachsection in turn.Tower craneArc welderChain blockWater levelLength rulerElectricwrench45 1025Gas duct from precalciner to C5 cyclone Start:26/04/14End:30/04/141. tube oneweight: 38.8 tons2.bendweight: 11.08 tons1. Assemble thebend section andDust one 2. Liftthe tube one3.lift the dustone4.lift the bendTower craneArc welderChain blockTheodoliteLength rulerElectricwrench45 1026C5-C4 gas duct erection Start:01/05/14End:05/05/141. Tubeweight: 9.09 tons2.BendWeight：10.5tons1. Assemble thetube section andbend section onthe ground.2. Lift eachsection in turn.Tower craneArc welderChain blockTheodoliteLength rulerElectricwrench45 1027+66-82.4m column and frame girder erection Start:06/05/14End:18/05/14Column max.size(m):Length:≤16.4mGirder max size(m):length: ≤11mSingle part weight:≤ 6 ton1.Ninecolumnserection2. Framegirdererection.3.+70.9mplatformerectionTower craneArc welderChain blockTheodoliteLength rulerElectricwrench45 1528+82.4msub-girder and platform erection Start:19/05/14End:31/05/14Sub-girder size(m):Length: ≤11mSingle part weight:≤ 5 ton1.Pipeerection2. +82.4 plansub-girdererection3.+82.4mplatformerection4.StairserectionTower craneArc welderChain blockTheodoliteLength rulerElectricwrench45 1529C3 cyclone erection Start:01/06/14End:05/06/141.Upperweight: 25.05 ton2.middleweight: 20.09 ton3.bottomweight: 4.35 ton1. Assemble thebottom, themiddle and theupper sectionson the ground.2. Lift eachsection in turn.Tower craneArc welderChain blockWater levelLengthrulerElectricwrench45 1030C4-C3 gas duct erection Start:06/06/14End:10/06/141.Ductweight: 11ton2.Bendweight:10 ton1. Assemble thegas duct sectionand bend sectionon the ground.2. Lift eachsection in turn.Tower craneArc welderChain blockTheodoliteLengthrulerElectricwrench45 1031+82.4-98.4m column and frame girder erection Start:11/06/14End:19/06/14Column max.size(m):Length:≤16mGirder max size(m):length: ≤11mSingle part weight:≤ 6 ton1.Nine columnserection2. Frame girdererection.Tower craneArc welderChain blockTheodoliteLengthrulerElectricwrench45 1532+98.4msub-girder and platform erection Start:20/06/14End:27/06/14Sub-girder size(m):Length: ≤11mSingle part weight:≤ 5 ton1.Pipe erection2. +98.4m plansub-girdererection3.+98.4mplatformerection4.StairserectionTower craneArc welderChain blockTheodoliteLengthrulerElectricwrench45 1533C2 cyclone erection Start:28/06/14End:29/06/141.upperweight: 23.7 ton2.middleweight: 20.6 ton3.bottomweight: 4.24 ton1. Assemble thebottom, themiddle and theupper sectionson the ground.2. Lift eachsection in turn.Tower craneArc welderChain blockWater levelLength rulerElectricwrench45 1034C3-C2 gas duct erection Start:30/06/14End:02/07/141.Ductweight: 10.3ton2.bendweight: 9 ton1. Assemble thebottom sectionand top sectionon the ground.2. Lift eachsection in turn.Tower craneArc welderChain blockTheodoliteLength rulerElectricwrench45 1035+98.4-111.4m column and frame girder erection Start:03/07/14End:10/07/14Column max.size(m):Length:≤13mGirder max size(m):length: ≤11mSingle part weight:≤5ton1.Nine columnserection2. Frame girdererection.Tower craneArc welderChain blockTheodoliteLength rulerElectricwrench45 1536+111.4msub-girder and platform erection Start:11/07/14End:20/07/14Sub-girder size(m):Length: ≤11mSingle part weight:≤ 5 ton1.Pipeerection2. +102.55 plansub-girdererection3.+102.55mplatformerection4.StairserectionTower craneArc welderChain blockTheodoliteLength rulerElectricwrench45 1537C1 cyclone erection Start:08/03/06End:11/03/061.upperweight: 39.5 ton3.coneweight: 18.7 ton1. Assemble thecone and theupper sectionson the ground.2. Hoist eachsection inturn.Tower craneArc welderChain blockTheodoliteLength rulerElectricwrench40 1038C2-C1 cyclone erection Start:10/03/06End:11/03/061. bendweight: 12.4 ton2.tubeweight: 6.8 tons1. Assemble thetube sectionand bendsection on theground.2. Lift eachsection inturn.Tower craneArc welderChain blockTheodoliteLength rulerElectricwrench40 1039Bucket elevator erection Start:22/11/05End:24/03/06Bucket elevatortotal weight:53tonlevel:0~120.2m1. Lifting theshell from thebottom up.2.Lifting thedrive unit3. Lifting thebelt.4.erection thebucketTower craneArc welderChain blockTheodoliteLength rulerElectricwrench40 1040文件编号：GU3-方案-M-01041Steel chimney erection Start:05/03/06End:14/03/06Tower crane Arc welder Chain block TheodoliteLength rulerElectricwrench40 13文件编号：GU3-方案-M-010六．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于高空作业，因此安全工作非常由为重要。