2×600MW Boiler Main Erection Plan

本期建设规模2×600MW燃煤发电机组。锅炉由ＳＥＣ提供。锅炉为亚临界参数、强制循环、一次中间再热、单炉膛平衡通风、固态排渣、露天布置、全钢构架的∏型汽包炉。
This project is 2×600MW coal fired thermal units, boiler shall be supplied by SEC. The boiler is all steel structural ∏ type drum boiler of a subcritical parameter, pump circulation, single reheat, single furnace balance draft, dry slagging and hypaethral placement.    

锅炉施工方案  Boiler Erection Plan

锅炉为上海电气集团生产的亚临界参数、强制循环、一次中间再热、单炉膛平衡通风、固态排渣、露天布置、全钢构架的∏型汽包炉。

The Boiler shall be supplied by SEC. The boiler is all steel structural ∏ type drum boiler of a subcritical parameter, pump circulation, single reheat, single furnace balance draft, dry slagging and hypaethral placement.

1 施工场地及主吊机械 Erection site and main hoisting equipments

1.1 施工场地布置  Erection site plot

锅炉组合场布置按总平面布置图，组合场内布置50t龙门吊各4台，锅炉受热面的大部分组合工作安排在此完成。

Boiler assembly yard will be arranged as per general layout drawing.  Four 50T gantry cranes will be provided respectively. Assembly of most heating surface structures will be done in this area.

1.2 施工机械选择 Selection of construction plants

根据本工程锅炉的结构特点，以及我公司的机械状况，选用以下机械作为锅炉主要施工机械。Given to the features of the boier and mechanical capacity of our company, we chose plants below as our main construction equipmemnts.

(1) FZQ2000/ 80T圆筒吊 FZQ2000/ 80T cylindrical crane

FZQ2000圆筒吊做为附吊机械，筒身高度102m，采用60m臂长工况，主要负责锅炉本体部件的吊装工作。FZQ2000 cylindrical crane is arranged as auxiliary hoisting plants, which is designed to hoist boiler & components (crane body height 102m , length of jib 60m).

(2)  250t履带吊 250t Crawler crane

CC1400/250t履带吊为锅炉主吊机械，采用SWSL塔式工况，后配重40t，主臂角度85度：主副臂：72m加36m；最大作业半径42m，负荷27t；最小作业半径24m时，负荷为39t。
CC1400/250 Crawler cranes are designed as main boiler hoisting euqipment, adopting SWSL tower working conditions, with a banlance weight of 40t and main jib angle of 85°; length of main & auxiliary jib,72+36m, max working radius 42m,load 27t;min working radius 24m,load 39t.

吊装主要内容为：Main hoisting scope:

a. 锅炉钢架吊装。Boiler steel structure lifting.

b. 锅炉受热面吊装、空气预热器吊装。Boiler heating surface ,airpreheater lifting.

c.烟、风、煤管道安装 Flue gas,air,coal piping erection.

d. 根据现场实际换工况用于大件设备的安装和卸车工作。
      Employed in erection of other heavy equipments and unloading works.

CC1400/250t履带吊性能表(SWSL塔式、后配重40t工况)主附臂(主臂角度85º)：72m+36m。CC1400/250t crawler crane performance list(SWSL TOWER type,banlance weight 40t), main & auxiliary jib,72+36m(main jib angle of 85°) .

(3)前期采用C7050/20t作为钢结构的主要吊装机械，后期作为电除尘的主吊机械。In prophase, C7050/20t shall be employed as main hoisting plants for structure;in anaphase shall be employed in hoisting ESP components.

(4) 其它吊装机械 Other lifting plants 

A四台50t龙门吊布置于锅炉组合场，负责设备装卸车、受热面膜式壁及蛇行管排的组合工作及烟风道的制作组合工作。
4 frame cranes of 50t shall be arranged in Boiler structure assembly yard, employed in equipments loading and unloading, heating surface and pipe coil assembly works and flue/air ducting fabricating asembly works.

b. 50t汽车吊负责现场设备卸车倒运等工作。 .

b. Truck crane of 50t shall be employed in equipments unloading in site.

c.卷扬机布置在锅炉0m，辅助进行炉膛内管排及小件的吊装。
c .  winch shall be arranged in 0m, assisting furnace internals lifting and the lifting of some samll units.

d. 劳辛格负责汽包吊装工作。Stand-jack system will be used in steam drum listing works.

(5) 施工电梯布置 service lift arrangment

为方便锅炉施工，在炉一侧布置一施工电梯。Sservice lifts shall be arranged in each side of the boiler.  

2锅炉本体钢架安装 Boiler steel structure erection

锅炉钢结构由顶板、柱和梁、垂直支撑、水平支撑等部件组成，顶板由主梁、次梁和小梁组成一个坚固的梁格，其四周有水平支撑，主梁端有垂直支撑。Boiler steel structure consists of roof, column, girder, vertical and lateral supporting, while roof comprising of girder, secondary beam, trabecula and forming a firm box.

钢架内侧柱为主要承重钢柱，外侧副柱则通过梁、水平支撑与内侧柱相连，以增加钢架的整体稳定性。钢结构从前至后共有6排。锅炉钢架的连接，采用高强螺栓和焊接相结合的方式，顶板和主梁与次梁之间，柱和梁之间，垂直支撑、水平支撑之间采用扭剪型高强螺栓连接，其余构件间采用焊接连接。
Internal pillars of the structure are designed for bearing, while the external pillars are designed to reinforce the entire stability of structure by connecting with girders, lateral supporting and internal pillars. There are 6 rows. Bolt and welding are employed in the connection of structure. 

2.1 吊装方案   Hoisting plans

主吊机械选用一台FZQ2000圆桶吊，一台CC1400履带吊为附吊机械，圆筒吊布置于锅炉炉左K、L间距锅炉本体外侧柱中心线5米处，CC1400履带吊布置于炉的另一侧。钢架各段本着由炉前至炉后、先主柱后辅柱原则分段吊装，即安装一段找正一段，验收本段钢架后对高强螺栓进行终紧。钢架安装过程中相应段平台、楼梯、栏杆随之安装。
Main hoisting plants comprise of an FZQ2000 cylindrical crane and CC1400 crawler crane (as auxiliary  hoisting plants), the cylindrical crane shall be arranged at left side of boiller between boiler central line and it is 5 meters away from the boiler central line , CC14OO crawler shall be arranged on the other side of boiler. Each section of the structure follows the rule of from furnace front to back, from main pillars to complement pillars. Duiring the process of structure erection, platform,stairecase and handrails should be finishsed.

在钢架吊装过程中，视来货及制件完成情况，根据相应设备的安装位置和标高，把一次风热风道、二次风热风道、回转式空预器、预热器入口烟道、省煤器出口灰斗以及燃烧器连接风道等相关设备随之预存；各段吊装过程中，相应主降水管和刚性梁要临时吊挂在相应各层钢架梁上；视图纸具体情况缓装炉左侧及炉后7m标高下的部分拉条，做为炉内吊装设备的进入通道，炉膛内影响汽包(吊装中的初偏斜和炉顶调水平处)、板梁(炉膛内抬吊时)吊装的杆件缓装。
During the erection of structure, according to the progress of goods supply and parts fabrication, and erection position and height , we can save some equipments in their required position and ercet later such equipments including, primary hot air duct, secondary hot air duct, rotaty air preheator, preheator inlet flue gas ducting, economizer outlet ash bucket and burner connecting air duct. During each stage of erection, main downcomers and stiffening bars should be temporarily hanged in their girders of structure. As per the drawings , some braces on the left side of boiler or back of boiler below the height of 7m should be erected later, so that access for the hoisting works of boiler internals are made, in addition, any parts of boiler internal shafts that affect steam drum and plate girder lifting should be erected later.

2.2 施工顺序 Construction procedure

锅炉基础划线→标高复验和基础凿毛→柱底板安装→立柱1m标高线复检→结构第一段吊装→整体找正→柱脚二次浇灌→其它几层结构吊装→顶板梁吊装→钢结构完善。

Boiler Foudation Lining→ Level Call Back And Surface Preparation →Column Plate Erection →Column 1m Level Callback →Structure Erection Stage 1→   Structure Alignment → Column Foot Secondary Grouting →Other Floors Lifting →Roof Plate Girder Lifting →Stucture Maintenance
 

3顶板梁吊装方案 Roof girder hoisting plans

锅炉钢结构第八段立柱、横梁、拉条安装完毕后，根据大板梁吊装需要，部分杆件预留，经检验合格，才能进行板梁吊装。

After the erection of pillars of structure, beams , braces , to meet the requirement of girder hoisting, some shafts should be saved to their position and erected after passing test ,then plate beams hoisting could commence.

锅炉顶板梁的吊装机械为FZQ2000/80t圆筒吊和CC1400/CC2500履带吊。FZQ2000/80t圆筒吊布置在#1、#2炉的两侧,每台炉有一台磨机缓装，CC2500/CC1400履带吊在2台炉中间机动布置，看情况缓装一台磨煤机，使CC2500/CC1400满足顶板梁吊装工况。。
FZQ2000/80t cylindrical crane and CC1400/CC2500 crawler crane are employed to hoist boiler roof plate girder. FZQ2000/80t cylindrical crane should be arranged in both sides of boiler #1and#2, each boiler should be arranged with one mill after later. , while CC1400 or CC2500 crawler crane should be arranged between the tow boilers ,one mill should be erected later if necessary so that CC2500/CC1400 can meet the requirement of roof plate girder hoisting.

板梁由专用平板车运输至炉右侧0m处，利用CC1400履带吊卸车或者两主吊同卸，其中J、K、 L三根板梁利用FZQ2000塔吊和CC2500/CC1400共同抬吊到安装位置。顺序依次为L、K、J，其余板梁由FZQ2000塔吊或CC2500/CC1400履带吊单独吊装。

Plate girder should handled to 0 m in the right side of boiler by special platform lorry, CC1400crawler cranes or main cranes should be used to unload. FZQ2000 tower crane and CC2500/CC1400 are used to lift J,K,L plate girder. Consequence is L,K,J, other plate girders should respectively be hoisted by FZQ2000 tower crane or CC2500/CC1400 crawler crane.

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