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Clariant Specialty Chemicals (Zhenjiang) Co., Ltd. 25,000 tons/year chemical additives project main equipment hoisting plan 1, brief description: Clariant Specialty Chemicals (Zhenjiang) Co., Ltd. has built a new 25,000 tons/year chemical additives project in Dagang, Zhenjiang. In this project, there are about 15 pieces of heavy equipment in the MPP process unit and MPP tank farm unit, among which there are 8 reactors and tank equipment in the MPP process unit. There are 7 tank equipments in the MPP tank farm. Among the above-mentioned equipment, there are finished product tanks and raw material tanks weighing 8t, as well as reactor equipment weighing 20t. See Table (1) for details. MPP process, tank area main equipment cable list (1) Serial number Equipment name Overall dimensions (mm) Weight (t) Number of units Elevation (m) Material 1. Process 1 A10.1 Reactor φ2800×3850 7 1 5.2 316L 2 A30.1 Reactor φ2800×3850 20 1 5.2 Glass-lined 3 A40.1 Reactor φ2800×3850 20 1 5.2 Glass-lined 4 A50.1 Reactor φ1800×2900 3 1 5.2 316L 5 A60.1 Reactor φ2800×3850 8 1 5.2 316L 6 A70.1 Reactor φ2400×3350 6 1 5.2 316L 2. Tank area 1 T10.1 Raw material tank φ3000×8000 8 1 0.4 316L 2 T11.1 Raw material tank φ3000×8000 8 1 0.4 316L 3 T20.1 Raw material tank φ3000×8000 8 1 0.4 316L 4 T21.1 Raw material tank φ3000×8000 8 1 0.4 316L 5 T22.1 Finished product tank φ3000×8000 8 1 0.4 316L 6 T24.1 Finished product tank φ3000×8000 8 1 0.4 Fiberglass 7 T25.1 Finished product tank φ3000×8000 8 1 0.4 The E521 hot water tank and S101 safety tank in the fiberglass process equipment area are equipment on the first floor, and the remaining six reactor equipment are equipment on the second floor. Since the reactor equipment on the second floor cannot be hoisted by mechanization, a tic-shaped steel structure frame type and a hand-pulled chain are used for hoisting operations. Among the 7 tank equipment in the tank area, 4 use the QY50 50t fully hydraulic truck crane as the main crane and the QY16C 16t full hydraulic truck crane as the auxiliary crane. The other 3 tank equipment have long operating radius. , using the LTM1100N type 100t fully hydraulic truck crane as the main crane and the 16t crane as the auxiliary crane. After the tank equipment is hoisted in the air and upright, the main crane hoists it into place for the operation. 2. Basis for program preparation: 2.1, 25,000 tons/year chemical additives project drawings ； 2.2, Sinopec's "Construction Technology Standard for Large Equipment Hoisting Engineering" SH/T3515-2003 ； 2.3, Sinopec's "Technical Regulations for Safety in Petrochemical Construction" SH3505-1999 ； 2.4, "Chemical Engineering Hoisting Construction and Acceptance Specifications" HGJ201-83 ； 2.5, "Chemical Tower Equipment Construction and Acceptance Specifications" HGJ-85 ； 2.6, QY50 50t fully hydraulic truck crane performance table ； 2.7, QY16C 16t fully hydraulic truck crane performance table ； 2.8, LTM1100N 100t fully hydraulic truck crane performance table. 3. Preparation before construction: 3.1. Before the installation of tank equipment, the foundation must be formally handed over, accepted and measured, and the foundation strength test report and other technical information must be complete. On the basis, the elevation baseline and vertical and horizontal center lines must be clearly drawn. The appearance of the foundation is free of defects such as cracks, honeycombs, voids, and exposed ribs. The dimensions and position deviation of the foundation should comply with the requirements in Table (2) below. Table (2) Item deviation name Allowable deviation value (mm) 1 Foundation coordinate position (vertical and horizontal axis) ±20 2 Foundation levelness 5 Total length 10 3 Embedded bolt elevation (top) +20~0 Center distance (heel and top) ±2 4 Elevations of different planes of the foundation 0~-20 There should be no oil stains or loose layers on the surface of the foundation. The surface of the foundation should be shoveled out with 3 to 5 pockmarks per square decimeter and the depth should not be less than 10mm. The place where the pads are placed should be shoveled flat. The allowable horizontal deviation is:: 2mm/m。 3.2, Equipment acceptance and on-site unloading and hoisting: When the equipment is shipped to the site for acceptance, it must meet the design requirements. The overall dimensions, nozzle orientation, and pre-welded parts of the equipment body should meet the requirements of the drawings. After the equipment arrives on site, its unloading and placement location should meet the lifting requirements. 3.3 Construction site requirements: In order to allow the crane to enter the construction site smoothly and the equipment to be transported to the site for unloading and placement, the following treatments must be performed on the site: (1) The surrounding area of the foundation should be backfilled, compacted and leveled without any obstacles. (2) If the on-site ground and road conditions are not good, they should be treated and steel plates should be laid. (3) When transporting and hoisting equipment, the road section should be closed to prevent stray people or vehicles from entering. 4. Hoisting plan for reactor equipment in process unit area: The process equipment area has 6 reactor equipment on the second floor with an elevation of 5.2m, as shown in Figure (1). Among them, the A301 and A401 reactor equipment are the heaviest, weighing 20t. The heaviest A301 reactor equipment is now made into a hoisting plan for reference. 4.1. Select the QY50 50t fully hydraulic truck crane to stand on the road outside the 1# axis of the process device on the factory road between the D and E axes, fully extend the four outriggers, and set them firmly. The 50t crane extends the main boom to 18.15m. When the operating radius is 6m, the rated hoisting load of the crane is 22.5t, see Table (3) and Figure (2). 4.2. Select a pair (2 pieces) of φ26mm, 6×37+1, tensile strength ≥155kg/mm2 steel wire slings, each with one bend and two strands to hang on the A301 reactor equipment. Command the 50t crane to lift slowly. Stop when the reactor equipment is lifted about 200mm from the ground. 4.3. Check whether the stress of the 50T lifting machine is intact. ； Check whether the legs of the 50t crane have sunk ； Check whether the sling of the 50t crane is well stressed ； Check whether the hooks and slings of the 50t crane are vertical, etc., if they are normal. 4.4. Command the 50t crane to slowly lift and rotate, as shown in Figure (3), until the A301 reactor equipment is hoisted on the steel trailer that has been placed. Use two 2t hand pull chains and slings to seal the reactor equipment on the steel trailer, as shown in Figure (4). 4.5. Use a 10t hand-pulled chain and a wire rope sling as traction, slowly roll the reactor equipment into the factory building until it is in place, and erect the completed tic-tac-toe steel structure frame within the BC and 4-5 axes, and hang four 20t and one 10-hand chain as required. The manufacturing method of the tic-tac-toe steel structure frame is shown in Figure (5). 4.6. The tic-shaped steel structure frame must be made according to the drawings. The lifting lugs of each part must also be welded firmly. The lifting lug plates must be broken. After the welding is completed, magnetic particle inspection is performed, as shown in Figure (6). 4.7. First use two 20t hand-pull chains and one 10t hand-pull chain on the side of the tic-shaped steel structure to lift the A301 reactor equipment from the horizontal state to the vertical state. See Figure (7) and Figure (8). 4.8. Then during the hoisting process of the reactor equipment, use two 20t hand-pulled inverted chains on the front of the Tic-Shaped steel structure to change the orientation of the reactor equipment in the air to the direction to be installed, see Figure (9), and hoist it directly above the foundation. 4.9. According to the installation requirements of the reactor equipment, after the steel ring on the foundation of the reactor equipment is welded and installed, use two 20t hand pull chains to slowly loosen the A301 reactor equipment onto the steel ring on the foundation. 4.10. Find the verticality of the equipment from the vertical and horizontal directions of the reactor equipment. * * Pull the 20t hand chain, remove the shackle, dismantle the tic-tac-toe steel structure frame, move the tic-tac-toe steel structure frame to the next reactor, and assemble the tic-tac-toe steel structure, and still use the above methods and steps to hoist the next reactor equipment. 4.11, Calculation of the force on the wire rope sling when the A301 reactor equipment is hoisted to the steel trailer: Look up table: φ26mm, 6×37+1, tensile strength ≥155kg/mm2, the breaking tension of the wire rope is: 38850kg 38850kg×0.82 (reduction factor) = 31857kg When the safety factor K=6 times 31857kg÷6=5310kg 5310kg×2 (root)×2 (one bend and two strands) = 21240kg≈21t 21t>20t Safety five, tank equipment hoisting plan in the tank area installation area: There are 7 tank equipments in the MPP tank farm installation area. Please see Table (1) for their overall dimensions, weight and installation elevation. The east side of the tank farm is a hard soil zone, but because it is covered with a steel canopy, hoisting cannot be carried out. The north and south sides of the tank farm are also unable to stand cranes because of the temporary housing and pipe gallery foundations. Currently, only the west side can be used, see Figure (10). To ensure that the equipment is transported to the site and hoisted in place. Since the seven tank equipments have the same weight, this plan is used as an unloading and hoisting plan for the T241 finished tank equipment for reference. 5.1. When the load-bearing flat truck carrying the T241 finished tank arrives at the site, first command the QY50 50t fully hydraulic truck crane to stand on the north side of the tank area, that is, outside the 1# axis and outside the EG axis, fully extend the four outriggers, and securely pad all four outriggers. The 50t crane extends the main boom to 25.5m and the operating radius is 8m. The rated lifting load of the crane is: 14.9t, see table (3). 5.2. Choose 2 φ18mm, 6×37+1, tensile strength ≥155kg/mm2 steel wire rope slings, each with one bend and two strands to hang on the T241 finished tank equipment. Command the 50t crane to lift slowly. Stop when the finished tank equipment is lifted 200mm away from the carriage. 5.3. Check whether the force of the 50t crane is good. ； Check whether the outriggers of the 50 crane have sunk ； Check whether the stress of the crane's rigging is very good, etc. If it is normal, direct the load-bearing flatbed trailer to drive away. 5.4. Command the 50t crane to slowly lower the finished tank equipment to a height of about 200mm above the ground. Then start to rotate until the finished tank equipment is rotated to the place next to the cofferdam. Place sleepers in place. Command the 50t crane to place the finished tank equipment. The 50t crane * * Hook, remove the sling, see Figure (11). 5.5. Command the 50t crane to stand 10m away from the foundation of the T221 and T241 finished tank equipment. See Figure (11). Fully extend the four outriggers, securely pad the four outriggers, and extend the main boom to 25.5m. The rated lifting load of the crane is: 10.6t。 See table (3). 5.6. Select a pair (2 pieces) of φ18mm, 6×37+1, tensile strength ≥155kg/mm2 steel wire ropes and 2 shackles each capable of carrying 6t and lock them on the plate lifting lugs on the finished tank equipment. 5.7, command the 16t crane to stand at a radius of 6m on the rear side of the T241 finished tank equipment, as shown in Figure (10), fully extend the four outriggers, and set them firmly, and extend the main boom to 16.9m. The rated lifting load of the crane is 9.7t, see Table (4). 5.8, select a φ18mm, 6×37+1, tensile strength ≥155kg/mm2 steel wire rope sling, one bend, two strands and a shackle capable of carrying 6t to lock on the plate lifting lug at the bottom of the finished tank equipment. 5.9. Command the two cranes to lift slowly. When the finished tank equipment is lifted about 200mm from the ground, stop and check whether the respective forces of the two cranes are in good condition. ； Check whether the outriggers of the two cranes have sunk ； Check whether the lifting rigging is well stressed, etc., if it is normal. 5.10, command the 50t crane to slowly lift, luff, and rotate, and command the 16t crane to also slowly lift, luff, and rotate until the finished tank equipment is lifted into a vertical position. 5.11, command 16t crane * * Hook, remove the sling, and check whether the stress of the 50t crane is good. ； Check whether the legs of the 50t crane have sunk ； Check whether the finished product tank equipment is lifted vertically ； As normal. 5.12. Command the 50t crane to slowly rotate and luff until the finished tank equipment is rotated to the foundation. See Figure (12). Stabilize the equipment, align the direction, align the bolt holes, and instruct the 50t crane to smoothly release the finished tank equipment onto the pads of the foundation. 5.13. Put on the nuts, find the verticality of the equipment from the vertical and horizontal directions of the equipment, tighten the bolts, and command the 50t crane. * * Hook, remove the sling, and direct the 50t crane and 16t crane to hoist other T201, T101, and tank equipment according to the above steps and methods and requirements. Use LTM1100N 100t fully hydraulic truck crane and 16t crane to lift T211 and T111 tank equipment according to the above methods and steps and requirements, and attach Figure (13), Figure (14), and Table (5) for reference. 5.14, Calculation of sling force when unloading finished tank equipment: Look up table: φ18mm, 6×37+1, tensile strength ≥155kg/mm2, the breaking tension of the wire rope is: 17250 kg, 17250 kg: 6.1. Strengthen safety management at the construction site. Set up a warning area at the hoisting site and assign full-time safety personnel to supervise and guard. Non-operating personnel are strictly prohibited from entering. 6.2. Carefully and meticulously prepare for hoisting, prepare equipment and lifting rigging according to the plan requirements, strictly implement performance inspection of hoisting equipment, inspection, test lifting, testing and hoisting procedures of lifting rigging to ensure that the hoisting operation is carried out safely and reliably. 6.3. The hoisting operation area and the placement of reactor equipment and tank equipment must be handled according to the requirements of the plan. The crane's walking, standing, and outrigger pads must meet the requirements. 6.4. Provide detailed technical explanations to the personnel participating in the construction operations in advance to ensure that the workers understand the operation essentials, procedures and requirements. After the crane enters the site, the hoisting plan is introduced in detail to the crane driver and the unified command signal is clear. 6.5. When the crane is hoisting, the subgrade box plate or steel plate must be placed under the outriggers. The underlay must be firm and reliable. During the hoisting operation, pay close attention to the settlement of the outriggers. 6.6. The contact between the on-site commander and the crane driver must be timely and reliable, and the command signals, flags, and gestures must be clear and understandable. If any abnormal situation is discovered, it must be reported to the on-site commander in time so that effective measures can be taken as soon as possible. 6.7. When the double crane is lifting tank equipment, unloading and hoisting for aerial luffing, the cooperation of the two cranes must be coordinated, the movements must be smooth and slow, and the operation must be strictly in accordance with the lifting performance table and specification requirements. The load lifted by the double crane shall not exceed 80% of the rated load. 6.8. The two reactor equipments A301 and A401 in the MPP process unit area are glass-lined equipment. During the hoisting and hauling process, collisions must be strictly prohibited. The lifting rigging is in contact with the equipment (such as: When using crane rigging to seal the reactor equipment on the steel trailer, a wooden board, thick cloth, or thick cardboard should be laid. 6.9. When the reactor equipment is towed and rolled on the steel drag row, the pulling speed should be slow and steady. The steel pipe rollers should be careful not to collide with the reactor equipment when transporting. 6.10. When hoisting the reactor equipment using a tic-shaped steel structure frame, it must be stable and slow. It is strictly forbidden for the reactor equipment to shake in the air. 6.11. The inner lining of T241 and T251 finished tanks is fiberglass. When unloading and hoisting, collision is strictly prohibited. When the tank equipment is placed on site, the oblique plugs of the sleepers must be well drilled. 6.12. Wear a safety helmet when entering the construction site, and wear a safety belt when working at a height of more than two meters. 6.13. When the wind force is level 5 or above, hoisting operations are strictly prohibited in thunder, rain, fog, etc. 6.14. Hoisting operations must be under unified command, and workers must obey orders, perform their duties, and cooperate closely so that the hoisting operations can be completed safely and smoothly. 7. Organizational measures for equipment hoisting: 7.1. The reactor equipment in the MPP process unit is an important and key equipment in the unit area. The two heaviest reactor equipment are made of glass-lined materials and are difficult to hoist. The finished product tanks and raw material tanks in the MPP tank area unit are hoisted on the ground. Not good, and there are two units made of fiberglass. In order to ensure the smooth progress of the hoisting work, a hoisting leadership group was established to direct and coordinate the personnel organization of hoisting preparation, loading and unloading transportation, formal hoisting, material supply, material, machine tool management, etc. Hoisting leadership group: Team leader: member: 7.2. Hoisting site organization structure (also safety and quality assurance system) Construction manager (site safety person in charge) Hoisting site general commander: Hoisting technical person in charge (safety responsibility engineer): On-site dispatch: security officer: quality inspector: Lifting squad leader:: Fitter monitor: