TK9530基础处理方案 R 3文档格式.docx
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5.Lift-uptankandrectifybasement.
6.Erection1~2EAmovablescaffolding（ThesafetyofmovablescaffoldingwasconfirmedbyTMDIHSEalready）.
7.Remaininsidenozzlework,weldingrepair,remainweldingbeadgrindingandfinalinspection.
8.Removemoveablescaffolding.
9.Hydro.test.
10.Erectionmoveable2~3scaffolding
11.ShotblastingwithSA2½
andrubberliningworkforinsideandweldingdripboarder,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.
Calculationforverticalloadforcolumnandtensionforceforhoist.
⏹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
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
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
tank,
clean
dirt
circular
within
1m
from
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
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
ring
control
by
discipline
surveyor.
The
height
fabricated
shall
strictly
according
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。
required
drawing
fill
depression
part
asphalt.
Concrete
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。
inspection
TMDI
and
Jianli,
enter
next
step
after
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:
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
2.04Ton*Cos30˚=1.80ton
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
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
750mm2*11.98kg/mm2=8.98＞2.08t，符合要求
750mm2*11.98kg/mm2=8.98＞2.08t,soitisOK.
3）地脚螺栓计算anchorboltcalculation
M16
M16
-有效截面积：
156.7mm2
-Effectivesectionarea:
156.7mm2
156.7mm2**11.98kg/mm2=1.88t*6个=11.28t＞3.11t，符合要求
156.7mm2*11.98kg/mm2=2.92t*6EA=11.28t＞3.11t,soitisOK.
4）吊耳计算lugcalculation
10mm*200mm*300mm
10mm*200mm*300mm
150mm*10=1500mm2
-Effectivesectionareaformainplate:
1500mm2
-Effectivesectionareafor2EAof5mmcheckplate:
100mm*5mm*2EA=1,000mm2
（1500mm2+1,000mm2）*11.98kg/mm2=29.95t＞5.46t，符合要求
-Capacityfortensileforce：
（1500mm2+1,000mm2）*
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