大板梁吊装方案中英文

1、印度安巴拉（2×600MW）燃煤电厂工程C厂#1锅炉大板梁吊装方案India, Anpara C 2×600MW Project Boiler Ceiling Girder Lifting Manual本期规模2×600MW印度Lanco Infratech Limted公司2×600MW ANPARA THERMAL POWER PROJECT 类 别锅炉安装机组编号#1机组编 号AC-1GL-17大板梁吊装方案批 准：审 核：编 制：年 月Scope2×600MWIndia, Lanco Infratech Limited Co.2

2、5;600MW ANPARA THERMAL POWER PROJECT Sort Boiler Unit No.#1, #2 No.AC-GL-17Boiler Ceiling Girder Lifting Manual01/2009目 录Content 1工程概况Project brief introduction 2编制依据Compilation gist 3施工准备及安装前应具备的条件Construction preparation and required conditions before erection 4施工方法及工序Construction method and worki

3、ng procedure 5有关计算Related calculation 6安全质量保证措施Safety quality guarantee measure 1.工程概况project brief introduction本方案仅适用于印度安巴拉（2×600MW）燃煤电厂工程C厂#1锅炉大板梁吊装。This scheme is only for the ceiling girder erection in Indian Anpara C 2×600MW thermal power plant project.炉顶主钢架前后方向共计50920mm，分别为K1、K2、K3、K

4、31、K4、K41、K42、K5排柱。The length of the top boiler steel structure in front-rear direction is 50920mm, and the columns are K1, K2, K3, K31, K4, K41, K42 and K5.钢架左右方向共计45200mm，主要分为7列，分别为B1、B2、B21、B3、B32、B4、B5。The length of the top boiler steel structure in left-right direction is 45200mm. There are 7 r

5、ows columns and they are B1, B2, B21, B3, B32, B4 and B5.其中锅炉纵向中心线至外柱中心线宽度为22600mm。The width from boiler longitudinal centerline to external column centerline is 22600mm. 炉顶大板梁共8件，其中顶板梁MB-1、MB-5分别为K1排柱顶板梁、K5排柱顶板梁, 均为单梁结构。There are 8 pieces of ceiling girders. MB-1 and MB-5 are the ceiling girders of

6、 K1 row and K5 row. They are single beam structure. 顶板梁MB-2、MB-3、MB-4分别为K2排柱顶板梁、K3排柱顶板梁、K4排柱顶板梁，均为叠梁结构，上、下梁之间用高强螺栓连接。安装标高最高点为85.4m。MB-2, MB-3 and MB-4 are the ceiling girders of K2 row, K3 row and K4 row. They are double-beam structure and be connected by high-tensile bolts. The highest erection ele

7、vation is 85.4m.具体大板梁的数据见下表：Detailed data of ceiling girder refer to the following sheet: 名称/图号规格拼梁重量（kg）总重（kg）长度（m）MB-1/74N541-1-0BH3000x800x25x363588128.8MB-2/74N541-2-0上梁BH3200x950/550x30x100/30562509963529.1下梁BH1800x600/950x30x30/10043385MB-3/74N541-3-0上梁BH3200X1200/550X36X100/306674012318529.1下

8、梁BH2100X600/1200X36X30/10056445MB-4/74N541-4-0上梁BH3300X1500/550X45X120/309096417145429.1下梁BH2400X600/1500X45X30/12080490MB-5/74N541-5-0BH3000x800x25x364173433.34名称/图号Drawing No.规格Specification拼梁重量Weight(kg)总重Gross weight（kg）长度Length（m）MB-1/74N541-1-0BH3000x800x25x363588128.8MB-2/74N541-2-0上梁Top beam

9、BH3200x950/550x30x100/30562509963529.1下梁Bottom beamBH1800x600/950x30x30/10043385MB-3/74N541-3-0上梁Top beamBH3200X1200/550X36X100/306674012318529.1下梁Bottom beamBH2100X600/1200X36X30/10056445MB-4/74N541-4-0上梁Top beamBH3300X1500/550X45X120/309096417145429.1下梁Bottom beamBH2400X600/1500X45X30/12080490MB-5

10、/74N541-5-0BH3000x800x25x364173433.342.编制依据compilation gist东方锅炉厂钢架安装图纸Erection drawings from Dongfang Boiler Group Company Ltd.锅炉大板梁安装图 Boiler ceiling girder erection drawingLR1400/2型液压履带吊说明书Specification of LR1400/2 hydraulic crawler crane3.施工准备及安装前应具备的条件Construction preparation and required condit

11、ions before erection3.1 措施性材料Self-contained material槽钢12Channel steel (12)50m管皮20对钢丝绳21Steel wire (21)30m道木Sleeper20根架杆3m20根架板100件铁丝#8Iron wire (#8)20kg3.2 施工机械construction mechanismLr1400/2型履带吊Crawler crane (Lr1400/2)1台set角向磨光机electric angle grinder1台set3T倒链Chain block (3 ton)15台sets初拧板手Preparatory

12、-tightening wrench2台sets千斤顶(16t)Jack (16 ton)4件pieces铰刀（手动可调式16-26）Reamer (manual adjustable 16-26)2台sets终拧板手Final-tightening wrench2台sets50t履带吊Crawler crane (50 ton)1台set3.3 计量器具及特殊工具measuring tools and special tools钢盘尺(50m)1件铁水平(500mm)1件经纬仪2件水准仪2件直角尺125×2002件线坠（1kg）1件钢板尺(1m)1件大锤（6磅）1件花兰螺丝（M12

13、）8件游标卡尺(200mm)1件力矩板手（1000N.M）1件钢卷尺(3m)5件弹簧称250N2件钢盘尺(50m)Steel tape (50m)1件piece铁水平(500mm)level bar1件piece经纬仪Theodolite2件pieces水准仪Water level2件pieces直角尺125×200L square (125×200)2件pieces线坠（1kg）Plumb (1 kg)1件piece钢板尺(1m)Steel tape (1m)1件piece大锤（6磅）Hammer (6 pound)1件piece花兰螺丝（M12）Turnbuckle (

14、M12)8件pieces游标卡尺(200mm)Vernier caliper (200mm)1件piece力矩板手（1000N.M）Torque wrench (1000N.M)1件piece钢卷尺(3m)Steel tape (3m)5件pieces弹簧称250NSpring balance (250N)2件pieces3.4安装前应具备的条件Required conditions before erection3.4.1钢架安装并找正结束。The erection and alignment of the steel structure is completed.3.4.2平台扶梯联通至炉

15、顶。The platform and ladder have been connected to the top boiler.3.4.3大板梁划线完毕。The lineation on the ceiling girder has been completed.3.4.4柱顶划线完毕。The lineation on the top column has been completed.3.4.5吊装机械负荷试验完毕能满足吊装。The lifting mechanism has been pass the load test and satisfy the lifting requiremen

16、ts.3.4.6设备到货正常。The equipments have been delivered on site normally.3.4.7顶板梁到货卸车后，按要求进行设备检查、划线测量，并做好记录。After unloading the ceiling girder, the equipments should be checked, lineation and measured according to the requirements. The records should be taken.3.4.8在叠梁下梁腹板两侧适当高度搭好上梁、下梁叠接的临时操作平台。The tempora

17、ry operation platform should be set on the two sides of the bottom girder web plate.3.4.9为满足吊装需要, LR1400/2型液压履带吊履带走道下方需铺设钢制走道，达到平移和吊装顶板梁的要求。In order to satisfy the crane requirements, the steely walkway should be arranged for the LR1400/2 crawler crane, so that it can satisfy the requirements for pa

18、rallel moving and ceiling girder lifting.3.4.10起重机械负荷试验完毕并布置在指定位置，起重工器具经检查合格。The crane should pass the load test and arranged on the pointed location. The lifting tools should be checked and eligible.4施工方法及工序Construction method and working procedure4.1 顶板梁上梁平放、翻立和吊装简介Brief introduction of horizontal

19、 laying, turning and lifting of the top ceiling girder大板梁均由LR1400/2型液压履带吊单车平放、翻立及吊装就位。All the ceiling girders should be horizontally laid, turned and lifted by LR1400/2 hydraulic crawler crane.LR1400/2型液压履带吊布置在B2和B4列柱之间，回转中心与锅炉纵向中心线重合，沿锅炉前后方向移动，顶板梁全部平放在K5排柱后进行翻立和吊装。The LR1400/2 crane should be arran

20、ged between B2 and B4. The rotary center should be coincide with the boiler longitudinal centerline. It should be moved along the boiler front-rear direction. All the ceiling girders are turned and lifted by horizontally laying behind the K5 row.MB1、MB2、MB3和MB5顶板梁从K5排柱后起吊后直接向炉前走车，走到就位位置后转杆180°,

21、然后就位固定。The ceiling girders (MB1, MB2, MB3, MB5) should be lifted behind K5 row and directly be moved to the front of boiler. After reaching the correct location, the boom should be turned 180°and be fixed.MB-4顶板梁吊装时直接将吊车走到就位位置，起吊后转杆直接就位固定，Directly arrange the crane on the correct location when

22、lifting the MB4 ceiling girder. The boom should be fixed after lifting,顶板梁放置位置可参考以下顺序the layout location of the ceiling girder can refer the following sequence:MB-1顶板梁放置在离K5排柱中心线2000mm处,MB-1 ceiling girder should be laid 2000mm far away from centerline of K5 row,MB-2下梁放置在离K5排柱中心线5000mm处,bottom ceili

23、ng girder of MB-2 should be laid 5000mm away from centerline of K5 row,MB2上梁放置在离K5排柱中心线8000mm处，top ceiling girder of MB-2 should be laid 8000mm far away from centerline of K5 row,MB-3顶板梁下梁放置在离K5柱中心线11000mm处，bottom ceiling girder of MB-3 should be laid 11000mm far away from centerline of K5 row,MB-3顶

24、板梁上梁放置在K5排柱中心线14000 mm处，top ceiling girder of MB-3 should be laid 14000mm far away from centerline of K5 row,MB-4下梁放置在离K5排柱中心线17000mm处,bottom ceiling girder of MB-4 should be laid 17000mm far away from centerline of K5 row,MB-4上梁放置在离K5排柱中心线21600mm处，top ceiling girder of MB-4 should be laid 21600mm f

25、ar away from centerline of K5 row,MB5顶板梁放置在离K5排柱中心线25000mm处，MB5 ceiling girder should be laid 25000mm far away from centerline of K5 row,放置时所有顶板梁的横向中心线应尽量与锅炉纵向中心线重合.During the laying, all the transverse centerlines of the ceiling girders should be coincide with the boiler longitudinal centerlines.因为

26、MB-2、MB-3、MB-4顶板梁上梁设备到货时均为上翼板向下，所以应先将上梁翻转180°，使上翼板向上才能满足就位要求。MB-2、MB-3和MB-4上梁均由LR1400/2型履带吊单车进行平放及翻立。When the MB-2, MB-3, MB-4 ceiling girders reach site, the top girders are upward, so the top girder should be overturned 180°until the top girder satisfy the erection requirement. The top g

27、irders of MB-2, MB-3 and MB-4 should be laid and overturned by LR1400/2 crawler crane.因吊车起吊高度有限，顶板梁长度又长，顶板梁起吊后不能随意转动，顶板梁纵向中心线应始终与吊车主臂保持垂直，所以平放和翻立后应保证顶板梁就位时方向正确Because the crane lifting height is limited, and the ceiling girders are big and heavy, the ceiling girders cannot be arbitrarily turned afte

28、r lifting, the longitudinal centerline of the ceiling girder should be vertical with the main jib of the crane during the lifting. The erection direction of the ceiling girders should be kept correct after laying and overturning.LR1400/2型履带吊布置图Layout figure of LR1400/2 crawler crane：4.2顶板梁上梁卸车平放及翻立U

29、nloading, horizontal laying and overturning of the top ceiling girders 以最重梁MB-4顶板梁上梁卸车平放及翻立为例，Take an example of unloading, horizontal laying and overturning on the heaviest MB-4 ceiling girder,梁卸车平放时和翻立时的吊车工况一样，the working condition of the crane is same when unloading, horizontal laying and overtur

30、ning the girders,LR1400/2履带吊大钩与钩绳共计约5 t重，the weight of the hook and rope of LR1400/2 crawler crane is 5t,绑扎用绳约1.7吨重，the weight of the binding rope is about 1.7t,平放及翻转工况如下the working condition about the horizontal laying and overturning is as following：带附加配重the crane should be with the additional wei

31、ght,主臂98米main rib is 98m long,幅度为R=17m the extent is R=17m,额定负荷115t,rated load is 115t,承载负荷97t bearing load is 97t,负荷率为84.5% load efficiency is 84.5%，平放及翻立过程中选用钢丝绳扣1470MPa、2（1/2）英寸、 L=30m（4件）、4只32tD型卸扣。During the horizontal laying and overturning, four steel wire hitch (1470MPa, 2（1/2）inch, L=30m) a

32、nd four shackle (32tD) should be used.MB-2、MB-3、MB-4顶板梁上梁平放和翻立时LR1400/2履带吊作业参数表：Working parameter of the LR1400/2 crawler crane when horizontal laying and overturning the MB-2, MB-3 and MB-4 ceiling girders refer to following sheet:梁 号净重(t)LR1400/2履带吊(吊具和绳重6.7t)额定负荷（t）承担负荷（t）幅度（m）负荷率MB-2上梁56.3115631

33、954.8%MB-3上梁66.811573.51964.0%MB-4上梁 91011597.71985.0% 梁 号Beam No.净重Weight(t)LR1400/2履带吊(吊具和绳重6.7t)LR1400/2 crawler crane (the weight of the lifting tool and rope is 6.7t)额定负荷Rated load（t）承担负荷Bearing load（t）幅度Extent（m）负荷率Load efficiencyMB-2上梁Top girder56.3115631954.8%MB-3上梁Bottom girder66.811573.519

34、64.0%MB-4上梁Top girder 91011597.71985.0%4.2.1顶板梁上梁平放Horizontal laying of the top ceiling girder 钢丝绳捆绑顶板梁2处, 以梁的对称中心线对称分布，暂定在每根梁两端各向里8000 mm处绑扎,吊点位置在梁侧面3/5处(见下图)，吊车缓慢起钩并缓慢涨杆，用一台5t卷扬机配合牵引（牵引位置在板梁中心结合面处），作业过程中保持钩绳与水平面垂直，平放顶板梁后用道木支垫平稳。平放过程见下图：Bind the ceiling girder on two locations with the steel wire.

35、The two locations should be symmetrical with the girder centerline and they can be temporary arranged on 8000mm from two ends to middle of the girder. The lifting points should be on the 3/5 of girder side (refer the following figure). The crane should slowly start and lift boom. One set of hoist (5

36、t) should cooperate for the drawing. The drawing position should be on the girder center connection surface. The hook should be kept vertical with the horizontal level during the work. After laying the ceiling girder, the sleeper should be used for the supporting. The horizontal laying procedure ref

37、ers the following figure.4.2.2 顶板梁上梁翻立Overturning of the top ceiling girder 钢丝绳捆绑顶板梁2处, 以梁的对称中心线对称分布，暂定在每根梁两端各向里8000 mm处绑扎,吊点在梁翼板顶面中心位置，缓慢起钩，并保持钩绳始终铅垂，将上梁翻立，在采取防倾翻加固措施后方可解钩。翻立过程见下图：Bind the ceiling girders on two locations with the steel wire. The two locations should be symmetrical with girder cent

38、erline and they can be temporary arranged on 8000mm from two ends to middle of the girder. The lifting points should be on the center of the top girder surface. Slowly lift the hook and keep the rope vertical with the horizontal level. Overturn the top girder and release the hook after take some ant

39、i-slip measures. The overturning procedure refers the following figure.4.3顶板梁吊装Ceiling girder erection4.3.1吊装顺序Erection sequence MB-1顶板梁吊装就位MB-2顶板梁下梁吊装就位MB-2顶板上梁吊装就位MB-3顶板梁下梁吊装就位MB-3顶板梁上梁吊装就位MB-4顶板梁下梁吊装就位MB-4顶板梁上梁吊装就位MB-5顶板梁吊装就位MB-1 ceiling girderMB-2 ceiling girderMB-2 ceiling girderMB-3 ceiling gi

40、rderMB-3 ceiling girderMB-4 ceiling girderMB-4 ceiling girderMB-5 ceiling girder4.3.2顶板梁吊装（以MB4梁为例）ceiling girder erection (take MB-4 ceiling girder as an example)顶板梁地面检查无缺陷，划线完毕，脚手架及爬梯搭设完毕后开始吊装。The ground check of the ceiling girder should be without defect and the lineation should be completed. Th

41、e erection should be taken after complete set the falsework and ladder.MB-4上梁为大板梁中最重件91t，履带吊吊钩重量约4吨、钩绳重量约1吨、脚手架和爬梯重量约1吨，吊装用绳和吊耳重量约1吨，吊装总重量按照98t考虑。LR1400/2型履带吊回转中心距MB-4板梁安装纵向中心线距离16至17米之间,起吊位置距吊车回转中心距离最大不超过17米。MB-4 top ceiling girder is the heaviest girder and the weight is 91t. The weight of the cra

42、wler crane hook is about 4t. The weight of the rope is about 1t. The weight of the binding steel wire and lug is about 1t. The total erection weight should be considered as 98t. The distance between LR1400/2 crawler crane rotating center to MB-4 ceiling girder erection longitudinal centerline is abo

43、ut 16m or 17m. The largest distance between lifting location to crane rotating center should not be bigger than 17m.MB-4上梁吊装时选用钢丝绳扣（1470MPa、2（1/2）英寸、 L=9m）4件、4只32吨D型卸扣。Four steel wire hitch (1470MPa, 2（1/2）inch, L=9m) and four shackle (32tD) should be used during the erection of MB-4 top ceiling gir

44、der.共4个吊点，吊点为焊接型吊耳，There are four lifting points and they are welding lugs,吊耳中心对称布置在MB4上梁横向中心线两侧2000mm处位置，the lug center is symmetrical located on 2000mm two sides of transverse centerline of MB-4 top ceiling girder,离纵向中心线400mm处，and it is 400mm away from longitudinal centerline,吊耳纵向中心线向板梁纵向中心线倾斜6

45、76;，the lug longitudinal centerline is 6° decline with girder longitudinal centerline,吊耳材料选用A3钢，the material of lug should be adopt as A3 steel, 许用应力为800kg/ cm², the allowable stress is 800kg/ cm², 吊耳尺寸300mm×300mm×330mm, the lug size is 300mm×300mm×330mm, 吊装孔径80mm。

46、The pore diameter is 80mm.孔中心与吊耳中心重合.吊耳与顶板梁焊接时两端用150mm×150mm×20mm钢板进行焊接加强。The center of pore and lug should be coincided. The steel plate (150mm×150mm×20mm) should be fixed on the two ends when welding the lug and ceiling girder.MB-4上梁起吊时工况和吊装过程中的工况应保持一致，工况如下：带附加配重、主臂98m、上梁结合面处提升

47、高度84米、工作半径16.5米至17米、额定负荷115t、承载负荷98吨、负荷率85.2%。The working condition of lifting and erecting of MB-4 top ceiling girder should be same. It should be as following: the crane should be with additional weight, the length of main rib is 98m, the top girder connection surface should be lifted to 84m, work

48、ing radius is 16.5m to 17m, rated load is 115t, bearing load is 98t and the load efficiency is 85.2%.起吊前做机械性能测试，将MB-4顶板梁上梁抬起离地面300mm后，吊车停止动作5分钟，检查是否有溜钩动作，检查一切无异常后进行吊装。当MB4上梁起升高度满足安装高度后转杆并调整杆位，在转杆过程中认真观察杆位并调整使梁纵向中心线始终与主臂保持垂直,且保证钢丝绳与水平面垂直。到达炉前方向后适当涨杆调整至安装位置，最后回钩就位。The mechanism test should be taken be

49、fore lifting. Lift the MB-4 top ceiling girder to 300m above the ground, then stop the crane for 5 minutes. Check whether there is any hook slipping. The erection can be started again after check is eligible. After the lifting height of MB-4 top ceiling girder satisfy the erection requirement, rotat

50、e and adjust the boom. Seriously observe the boom position during the rotating and adjust the boom to make the girder longitudinal centerline is vertical with the main rib and the steel wire is vertical with horizontal level. After the ceiling girder reach the boiler front, adjust the boom to the er

51、ection location and lower the hook.MB-4上梁吊装时选用钢丝绳扣（1470MPa、2（1/2）英寸、 L=17m）4件、4只32tD型卸扣。共四个吊点，吊点为焊接型吊耳，对称布置在MB-4上梁2000mm处位置，其余顶板梁吊装用绳扣，卸扣和吊点布置同MB-4上梁一致，吊装就位后，顶板梁两端分别用15钢丝绳四根和四台5吨倒链拉紧，然后解钩。Four steel wire hitch（1470MPa, 2(1/2)inch, L=17m）and four shackles should be used during the MB-4 top ceiling gi

52、rder lifting. There are four lifting points and they are welded lug. The lugs should be symmetrically arranged on the 2000mm of the MB-4 top ceiling girder. Other ceiling girders are lifted by hitch, the shackle and lifting points are same with MB-4 top ceiling girder. After lifting to the correct l

53、ocation, the two ends of the ceiling girder should be tightened with four steel wire (15) and four chain blocks, then release the hook.MB4下梁可直接绑扎进行吊装，吊装用绳扣、卸扣同地面翻立时规格一致，吊点布置可参照MB-4上梁。MB4下梁同MB4上梁吊装时履带吊吊装工况一致，起吊后转杆至炉前方向，到达炉前方向后适当涨杆调整至安装位置，最后回钩就位。The MB-4 bottom ceiling girder can be erected by directl

54、y binding. The specification of the lifting hitch and shackle should be same with the ones during the overturning. The arrangement of lifting points can refer the MB-4 top ceiling girder. The working condition of the crane should be same when erecting the MB-4 top and bottom ceiling girder. After li

55、fting, the boom should be rotated to the front-boiler direction, be adjusted to the erection location and lower the hook finally.MB2、MB3上梁吊装用绳扣、卸扣、吊耳形式，吊点布置同MB-4上梁一致。MB2、MB3上梁同MB4上梁吊装时履带吊吊装工况一致，起吊后适当走车并转杆至炉前方向，然后调整至安装位置，最后回钩就位。The hitch, shackle, lug and lifting location for lifting top ceiling gird

56、er of MB-2 and MB-3 should be same with MB-4 top ceiling girder. The crane working condition for lifting top ceiling girder of MB-2 and MB-3 should be same MB-4 top ceiling girder. After raising the hook, the crane should be moved and rotated to the front-boiler direction and be adjusted to the erection location and lower the hook finally.MB1单梁、MB5单梁、MB2下梁、MB3下梁可直接绑扎进行吊装，吊装用绳扣、卸扣同地面翻立时规格一致，吊点布置可参照MB-4上梁。MB1单梁、MB5单梁、MB2下梁、M