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1、HDPE Reactor R6300 Lifting Scheme1. General DescriptionSketch1The outline size of the HDPE reactor R6300 is 7600/500032765mm with a weight of 278.5t, which is to be installed vertically on the steel structural frame at an elevation on the ground of +23.25m (the reference elevation on the ground is +
2、0.00m). The elevation at the top of the equipment after installed in place is +42.75m. The maximum elevation at the top of the equipment during lifting operation is +57m. The main lifting lug is located at the flange face on the top of the equipment, which is a special lifting device connected to th
3、e flange face on the top by bolts. The tailing lug is set at a position 2.37m from the bottom of the equipment. Both the main lifting lug and the tailing lug are plate-typed lifting lug of single lifting point. The center of gravity of the HDPE reactor is at the axis 15.4m from the bottom of the equ
4、ipment. The outline and dimension of the reactor R6300 is shown in sketch 1.2. References2.1 Equipment drawing of HDPE reactor R63002.2 Plan layout of HDPE/PP plant2.3SH/T 35362002 Lifting Construction Specification for Petrochemical Engineering2.4 SHJ 51590 Technical Standard for Heavy Equipment Li
5、fting Construction2.5 Design Documents of Climbing Jack System provided by Bidlift Co. Ltd., U.K3. Lifting SchemeThe lifting of the reactor R6300 will be performed with the Kramo climbing jack system introduced from Bidlift Limited, U.K by our company. This system has a maximum lifting capacity of 2
6、,400t and a maximum lifting height of 140m according to the present configuration of the system we ordered. For this project, only part of the system is needed to perform the lift of the reactor R6300. Therefore, the system is to be used as main lifting gear for the lift of the reactor R6300 and a 4
7、00t crawler crane for tailing.The lifting process of the reactor is shown in the following sketches.1. Start Lifting2Jacks are climbing up while tailing-in crane carries the reactor forward3. With the help of the tailing-in crane, the reactor is lifted from horizontal position to vertical position.
8、4Jacks continue climbing until the bottom of the reactor is lifted over the top surface of the foundation. 5. The reactor is moved over the foundation by horizontally-moving jacks6. The reactor is lowered in place4. Route for the Equipment Access and Lifting Plan LayoutThe reactor R6300 will be tran
9、sported to the north side of the foundation along the road on the west side of HDPE/PP plant. After being offloaded, it will be laid as shown in sketch 2 with its top facing west and its end facing east. The plan layout for the lift and the locations of deadman are shown in sketch 3 below.图2Sketch 2
10、Sketch 35. Reactor Offloading The offloading of the reactor can be carried out by taking advantage of the hydraulic up-and-down performance of the bogie. The location for laying the reactor shall be leveled and compacted and paved with a 200mm thick layer of gravel. 8 reinforced concrete bearing blo
11、cks will be placed before hand for supporting the reactor. The concrete block will be 1.6m1m1.2m (LWH). These 8 concrete blocks will be arranged in position as shown in sketch 4 prior to the arrival of the reactor to allow access for the bogie to get the midst of the concrete blocks. When the 4 sadd
12、les of the reactor are aligned with the concrete blocks, the reactor can be offloaded.Sketch 46the Lifting System ConfigurationLifting elevation of HDPE reactor R6300 is shown in sketch 5 and sketch 6 below.Sketch 5Sketch 61Mast Tower2Lifting Beam3Climbing Jacks4Base5Base Sliding Rail6 Swivel7Guy Wi
13、re System the system components required for the lift of the reactor R6300 are described as follows.6.1Mast SectionsThe center dimension of the cross section of the mast sections is 2.2m3m. Altogether 14 sections of 12m long each are needed to build two 84m mast towers.6.2 Lifting BeamThe lifting be
14、am is 18m long with a capacity of 800t.6.3 JacksTwo 400t jacks, each with a power pack.6.4 BaseTwo mast tower bases have a bearing capacity of 1,200t each.6.5 Base Sliding BeamTwo base sliding beams is 15m long each.6.6 SwivelOne set of swivel with a lifting capacity of 800t.6.7 Guy Wire System Uppe
15、r and lower guy wires will be set up. There are 12 guy wires altogether, 6 for upper guy wires and 6 for lower guy wires.6.8 Square Bar28 square bars of 200mm200mm6000m each，8 square bars of 100mm100mm3000mm each.6.9 Jacks for horizontal movementThree 100t jacks for horizontal movement, each with a
16、power pack.6.10地锚 DeadmanTwo 60t deadman and four 40t deanman are required.6.11 Control System One set of computer controlled system is to be used.7.有关受力计算 Relevant Force Calculation7.1 Maximum Load Force of the Tailing CraneThe tailing crane has the maximum load force when the lifting starts. See s
17、ketch 7.图7One 400t crawler crane will be used for tailing. The operating condition of the crane is: boom length 49m, operating radius 9m. The rated lifting capacity of the crane under this operating condition is 204tons, the load percentage is 74.4%, which satisfy the lifting requirement.7.2 Maximum
18、 Load of JacksSee sketch 8. During the full process of the lifting operation, the maximum load of the jacks acts on the jacks on the north mast tower, that is the load after the reactor is lifted from the position starting lifting to vertical position. The maximum load P of the jacks is:NSketch 8 wh
19、ere：Greactor weight，G=278.5t gweight of swivel and rigging，g=20tQweight of the beam，Q=30t7.3 Load Force on the GroundSee sketch 9. During the whole process of the lifting operation, the maximum compressive stress the ground under the mast section base bears is: (1) maximum compressive stress 360t on
20、 the ground under the inner side of the mast tower; (2) maximum compressive stress 64t on the ground under the outer side of the mast tower.图97.4 Tension Force of Guy Wires and DeadmanSee sketch 10 and Sketch 11. By calculation, the maximum tension force of the guy wires in the direction of north-to
21、-south is 28.2t, their deadman horizontal component of forces is 44t while the vertical component of forces is 33.6. The maximum tension force of the guy wires in the direction of west-to-east is 19.8t, their deadman horizontal component of forces is 31t while the vertical component of forces is 23.
22、7t.The calculation of the tension forces of the guy wires and deadman is attached.Sketch 10Sketch 117.5 the Load Force of the Other ComponentsThe calculation of load forces of the other components will not be described in this scheme since the weight of the reactor R6300 is within the design capacit
23、y of the lifting system.8. Selection of Rigging8.1 Main RiggingThe maximum tension force of the main rigging is the same as the weight of the HDPE reactor R6300 278.5t. The rigging is made up by connecting in series 2 pieces of 20m in circumference, 184mm dia. non-joint wire rope loop to three 400t
24、shackles as shown in sketch 12. The break tensile force of a single 184mm non-joint wire rope loop is 1,800t and its allowable working load is 300t.8.2 Tail RiggingThe maximum tension force of the tail rigging is 160t. The rigging is made up by connecting in series one 16m long, 104mm dia. pressed w
25、ire sling to a 200t shackle. The sling is used bent double as shown in sketch 13. The break tensile force of a single 104mm sling is 853t and its allowable working load is 142t. The allowable working load increases to 213t when it is used bent double. Sketch 12 Sketch 139Procedure for the Erection o
26、f the Lifting System & the Lifting of the Reactor9.1 VesselCheck lifting attachments attached securely per specificationCheck lifting shackles fit lifting attachmentsCheck weight of vessel and location of C of G as expectedCheck for unexpected protruberances, ensure vessel may be delivered in the sp
27、ace allocatedPrepare delivery route, level and compact9.2 BasesPrepare mast base foundationsSurvey, level and shim, mark set out lines Assemble 2 No. mast basesPlace mast bases on foundations, check level, shim as required Check position and alignmentBolt into position9.3 Masts to 36mPre-assemble 12
28、m mast sections (14 total)Fit ladders and platformsClean and lightly lubricate mast point pins and joint holesClean climbing bar location fixing pointsClean bar mounting feet and bar/bar location dowel/holesEnsure bar clamps clean, free from blemishesFit 2 No. 6m 200 sq climbing bars to central fixi
29、ng points and clamp lightly in positionSecure bar for upending mastDeliver mast section c/w bar to Western mast baseLift mast section clear and upend using 2 cranesLift into position and fit mast joint pins, once secure - release craneRepeat process, lifting 2nd mast section onto 1st and securingRep
30、eat process, lifting 3rd mast section onto 2nd and securingRepeat process for Eastern mast base to 3 sections highTemporarily guy masts using Tirfors to concrete blocksCheck alignment of masts and bar / bar spacing and adjust if required9.4 Climbing jacksFit 400T climbing jack c/w articulating ring
31、to each climbing bar at approx foundation ELLevel the two jacks to the same elevationDeliver 18m lifting beam and lower into position supported on jacksDeliver and fit 100mm sq pushing bar to lifting beamDeliver and fit 2 No. pump platformsDeliver and locate 2 No. pump unitsHose up to jacks9.5 Suspe
32、nsionLightly grease assembly location on lift beam for slide bogieDeliver and fit sliding bogie c/w Teflon slide pads & drop link suspension pinDeliver and fit swivel and adapter plate, fit to each other and secureDeliver and fit drop links to swivelLift assembly to height and fit link heads over su
33、spension pin. Secure.Fit pump support platform to sliding bogiePlace 100T climbing jack on pushing bar and engageHose up pushing jackFit shackleFit suspension sling9.6 Controls and commissioningLocate control container Run power, control and signal cables to pump units and secureCommission control s
34、ystem, run beam up and down, check slide jack works Level lifting beam9.7 Masts to 48m & guyingContinue assembly of masts to 48m heightConstruct deadmen anchor pointsFit temporary x-wires between masts and lightly tensionAssembly 6 no lower level guy lines at ground level and lift up in turn to mast
35、, attachPull up 28mm wire with winch or similar to take out initial slack (opposing wires at same time)Secure 28mm wire back to itself using Crosby clipsRepeat for all 6 wiresUsing strand jacks progressively pull up guy wires to defined preload, opposite wires at same timeCheck mast alignment and co
36、rrect as required using guysRemove temporary Tirfors at 36m levelContinue assembly of masts to 60m heightFit permanent x-wires at 60m level, tension and remove 48m temporaries9.8 Masts to 84m & guyingContinue assembly of masts to 84m heightRepeat guying process9.9 ChecksCheck alignment of masts and
37、correct as requiredCheck bars all correctly engaged, no gaps at joints, slacken and pull down if requiredGrease beam lightlyCheck cables are secure, not snagged and have the freedom required to lift Set up theodolites in two directionsCheck weatherDefine exclusion zone for worksEnsure permits in pla
38、ce9.10 Receipt of vesselDeliver vessel to under the beam as defined in the lift studyFit shackle and attach to slingRaise beam to take weightConfigure tail crane as required for tailingLay mats if required for imposed pressureBring into radius and attach sling and shackle to tail lugTake weight, rem
39、ove lashing / securing to trailerLower trailer, lay down saddlesRemove trailer to NorthLay mats ahead of tail crane if required for imposed pressure9.11 LiftingClear zone, check weather window againProgressively raise beam, tailing to maintain vertical suspensionMonitor mast alignment throughout and
40、 correct with guys if requiredEnsure beam will clear intermediate cross wiresMake sure control cables dont snagWhen completely vertical, release and remove tail crane (manbasket required)Continue lifting to approx 1m above foundation heightCheck nothing to snag for x-slidingEngage jack and operate t
41、o smoothly slide suspended load along lifting beamCorrect orientation of suspended load using swivel, ensure safety rails around foundation firstSlowly lower vessel into foundation, correcting as required until bolts engage base ringPartially release load to prepared shims, check aligment and levelA
42、djust as requiredWhen satisfied, secure and release head rigging (manbasket required)9.12 Stripping lifting rigRelease jaws on 100T jack & slide suspension back to the North using TirforsLower lifting beam to just below 48m levelFit temporary x-wires at just below 48m levelSlacken guys wires at 84m
43、level (same on opposite wires)Release guys and remove masts down to 48m levelStrip out suspensionRemove lifting beamRemove climbing jacksSlacken wires at 48m level and strip rig out to groundDisassemble mast section and bases10 Safety Measures10.1 The lifting operation will be directed and managed b
44、y the U.K vendor of this Kramo climbing jack system.10.2 The lifting operation must be under unified control and the personnel engaged in the lifting operation shall be given clear responsibility and are required to concentrate on the work, to follow orders and to stick to his post. A general inspec
45、tion shall be conducted before lifting operation. Lifting operation shall not be started until the problems found during the inspection are properly solved.10.3 The banksman shall be standing at a location where he can see clearly the whole process of the lifting. Signals given to the operator must
46、correct and clear. The bankaman shall have free communication with the operator.10.4 There must be “Four Access and One Level” available at the site, that is “ access to water, access to electricity, access to communication, access to road and level site”10.5 No lifting or work at height is allowed
47、in a rainy or a foggy day or in a day with wind over 4 scale.10.6 All personnel who will work at height must have physical check up. Only those who pass the physical check up will be allowed to work at height. Personnel working at height over 2 m (including 2m) must wear approved safety harness. 10.7 Personnel working at height are pr
