Equipment lifting
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The factory needs to replace two converters; each unit weighs over 60 tons, has a diameter of 3 meters and a length of 21 meters. The foundation for these devices is 200 mm high. The key issue is that they are located on the first floor of the factory building, whose ceiling height is 6 meters. We would like to seek advice from experts in lifting operations on how to install these converters in place. The devices are situated at one end of the factory floor, with walls on all three sides. It’s a problem; I hope everyone can help come up with a solution. This post was last edited by laiqi on 2009-3-30 at 21:09.]
The size of the equipment isn’t important; what matters is to determine the lifting location, ensure there are sufficient lifting points, and figure out the lifting radius. The calculation is done based on the crane’s capacity and its operational parameters. Two crane operators are needed to handle the lifting signals, and it’s no different from installing regular equipment!
The key point is that the equipment is inside the house; it’s not as simple as you say
If the workshop isn’t moved, is it possible to consider using manual labor to build 2–4 gantry cranes that are 4–5 meters tall, along with heavy-duty hoists, ensuring an optimal layout in relation to the equipment. Haha, it’s a bit crude of a method. It’s a bit slow, but it’s still workable after all
In the 1980s, I saw an original method at a construction site for reference. Due to the height limitations of the secondary equipment platform, cranes could not be used to position a large reactor; therefore, an experienced level-8 lifting technician came up with a makeshift solution using rollers and a winch, and eventually the equipment was positioned. On the first floor, round bars with a diameter of >200 MM can be used as rollers; two winches are placed at the front on each side to pull them. Upon reaching the equipment foundation, the rollers are placed on either side, and jacks are used to position them in place below the foundation.
It is recommended to construct track vehicles; after laying the tracks, use chain blocks to slowly move the equipment toward the foundation. Then build a lifting frame to lift the equipment, and use chain blocks to pull it into place before lowering it
Using a roller bar together with a chain block will work!
Check whether it is vertical or horizontal; if it is within a frame, find lifting points to attach rigging and use a winch for lifting.
Did you install the overhead crane without considering maintenance, disassembly, and such things? It’s not going to be that the factory building will be constructed only after installation is complete, right? Just as during installation, locate the lifting points on the furnace, use a crane to lift it onto a flatbed truck, and then transport it away!
When using a winch, be careful to check whether the factory floor can bear the weight
Sometimes old-fashioned methods still work
From the description, it can be seen that the device is long and horizontal, with limited installation space. During the lifting process, two main issues need to be addressed: 1. How to transport the equipment to the installation location ； 2. Equipment in place ； Solution: 1. If it’s not possible to remove the wall, nor to lift the item into place from above, and access can only be gained through a door, then the best approach is to use a winch + rollers + fixed and movable pulley systems. The winch provides the pulling force, while the rollers reduce friction with the factory floor. 2. To position the equipment, a winch is also required; it is advisable to have one main winch and one auxiliary winch to help adjust the direction.
It is highly recommended to hire a professional lifting company; avoid those so-called lifting companies that operate informally. Literally speaking, it is best to use a simple gantry for lifting operations. The equipment is large in size, making it prone to problems. There is a professional German lifting company in Shanghai. Go and look for it.
Use rollers and winches to pull the equipment into the factory building, bringing the upper part in first; once the top is in place, pull it in while dragging it forward. Two winches are required – one for pulling and one for lifting it vertically
Check how large the lifting opening on the first floor is and whether it can be enlarged. It can also be grouped and matched in segments.
It’s difficult to determine without being on site; the lifting operation must be carried out based on the actual circumstances, and care cannot be taken lightly
In my opinion, the use of slide rails and bilateral winches provides a higher safety factor; this allows the equipment to be adjusted into place
It would be better to be able to share a few current pictures for more in-depth discussion
This lifting plan should be considered in three steps: 1. Unloading the equipment: It is necessary to decide on the type of crane as well as the lifting rigging to be used. With the equipment weighing 60 tons, if a positioning arrangement in a \"T\" shape is possible at the entrance to the factory, a 200-ton truck crane should be sufficient. Remove the equipment from the vehicle, shorten the distance between the two lifting points (the two sling lifting points); this allows the equipment to be moved further into the factory building, thereby reducing the length of the planks that need to be laid, and then move it inside the factory building. Apply planks in advance to form the roller track (since the equipment foundation is 200 mm high, one layer of planks is sufficient). Since the equipment is relatively long, seamless steel pipes with dimensions of Φ108×8 can be used for the rollers; at least 35 such pipes are required. I-beams should be used to connect the two saddles, along with cross braces, to ensure a flat surface that facilitates rolling. The wire rope clips should be selected using a coefficient of 6. 2. Rolling the equipment: If the distance to be transported is not large, it is possible to use two 10-ton hand chain hoists for pulling; the pulling force generated by using rollers is not very high, with only greater friction at the time of starting. 3. Placement of the equipment: After transporting the equipment directly above the foundation, it is possible to use four jacks to lift it. Holes can be drilled at the four lifting points on the second-floor platform, and pipes can be used for lifting purposes (four 20-ton chain hoists can be installed; if not available, four 16-ton single-pulley hoists can be used. A steel wire rope is passed over the pulleys, with a 10-ton chain hoist connected to the other end. Since only a short distance needs to be lifted, rollers can be removed after that. ), it is also possible to consider using a gantry crane for lifting; the lifting rigging should be arranged in the same way (we have used a self-made gantry crane to lift and install 110-ton heat exchangers by removing the rollers). The difficulty in this lifting operation lies in the size of the factory floor on the first floor; moreover, it is crucial to determine whether the path taken by the equipment as it moves into the factory and to its final position is a straight one or one that requires turns Additionally: The removal of the old equipment will be carried out first. I’m not sure whether the specifications of the old equipment are the same as those of the new one? Demolition work and installation work are just reverse processes. Since there was no on-site inspection, it is difficult to specify the details of the lifting process; I’m sorry!
It’s very simple – just use a moving pad to handle it.