Project slag processing workshop of CHAMZ

Contents

I Initial data

II Main production technology

III Architecturally building section

General plan

Space Planning Solution

Architecturally constructive solution

Heat Engineering Calculation

IV Constructive section

Cross Frame Layout

Static Column Calculation

Calculation of rafter truss

Calculation of crane beam

V Technology of construction production

VI Construction organization

Calculation of Work

Calculation of construction site

VII Safety of life

VIII Economics of construction

Feasibility comparison of options

Local estimate

IX Literature

Summary

Kharitonov A.V. The construction project "Slag processing workshop is located on the territory of CHAMZ in Chelyabinsk." Chelyabinsk: SUSU, ASG, TSP, 2005,.... Table 102c.

Bibliography of literature - 19 titles.

12 sheets of A1 format drawings.

This diploma project was developed for the construction of a building with a prefabricated metal spatial frame in the form of a transverse frame with horizontal ties as spacers.

In terms of technology and organization of construction, three process charts and a schedule for the period of construction of the building have been developed.

The project justified the feasibility of design options and erection technology and selected the most preferred and expedient.

The following sections of the explanatory note have been developed in the diploma project:

Architecturally building section

Calculation and Design Section

Construction production technology

Organization of construction

Safety precautions

Feasibility comparison of options

I Initial data

The raw material preparation department of the slag processing shop is located on the territory of CHAMZ in Chelyabinsk.

Design winter temperature of external air t = - 39 wasps. Wind area II, wind load - 30 kg/m2. Snow region - III, snow load - 180 kg/m2.

Soils of the base - layering of clay with a high-plate consistency, loam and fine sand of medium density. There are watered and buried soil groups. Groundwater level - 2.8 m.

Groundwater does not have aggressive properties. On the construction site there is no seismicity and frozen soils.

II Main production technology

General provisions

The construction of high-throughput oil and gas pipelines operated under low temperature conditions requires the use of large-diameter pipes, the welded joints of which have high impact toughness. For this, one of the conditions for the production of pipes is the use of high-quality welded materials. In the production of pipes, arc automatic flux welding is usually used.

The AI60 (pumice-shaped) flux has been used until recently. It has high welding and processing characteristics, but does not provide the required level of toughness of the weld material, and the high content of manganese oxide in the flux and the formation of gaseous fluorides during slag smelting and welding creates an unfavorable environmental situation during the operation, production of flux and pipe production workshop No. 6.

One of the main challenges that must be met as a result of flux production is the radical improvement of the environmental situation and the provision of normal sanitary and hygienic working conditions for workers.

The tasks that need to be addressed to solve environmental problems in the design process are as follows:

1 Welding flux with possible minimum manganese and fluorine content when added to toxic additives shall be used;

2 Provide for the use of non-waste welding flux manufacturing technology;

3 Use modern process equipment ensuring minimal dust and gas release;

4 Design the application of an effective dust and gas cleaning system;

5 Develop schemes for automation and mechanization of the flux manufacturing process, especially in areas of increased hazard;

6 Ensure the use of modern means to improve sanitary and hygienic working conditions in welding, flux production, including slag smelting.

III Architectural part

General plan

The complex of slag smelting section includes:

Slag processing shop consisting of raw material warehouse, charge preparation compartment and smelting compartment. On the south side there is an administrative building, in which there is a computing center and a laboratory. This ensures the shortest possible access to jobs and the safety of people's movements. To the south of the main building and ABK is gas treatment with pumps by recyclers, radial settling tanks, a waste water treatment unit, a slag pumping station, and a receiving chamber. On the northern side, the territory is limited by a factory fence.

The planning marks of the designed building are taken on the basis of the high level of groundwater, the decrease in the volume of construction work, the elevation of the rail head of existing railway tracks and roads. Elevation of the main building 232.00 (building elevation system CHAMZ).

Water removal from buildings, adjacent territory and roads is carried out through rainwater receivers and a closed rainwater sewage network.

The bulk of the supply networks (water, electricity, gas and heat supply) is concentrated on the overpass running along the main roads.

According to the sanitary design standards of industrial enterprises (CH2451), the slag processing site is classified as class III harmful, the sanitary protection zone has a radius of 300 m and does not go beyond the fence of the plant. Therefore, special measures are not required to create a protective zone.

Areas free from development are subject to landscaping. The total area of ​ ​ landscaping and landscaping is 27.2 thousand m2. Pavements with asphalt concrete pavement are provided for the safe passage of workers; sidewalk area 1000 m2. At the intersection with the railways, the crossings are equipped with traffic lights and sound alarms.

Space Planning Solution

The charge preparation department consists of a raw material warehouse and the charge preparation department itself.

The raw material warehouse is located in a span with a width of 30 m, a length of 84 m, floor closures with an elevation of 2.800 m are located in it, for the reception and storage of raw materials, a railway track is laid for supply for unloading railway gondola cars, and an installation for unloading wagons is located at the end of the span. Unloading hoppers are installed over closures to supply charge materials to the charge preparation compartment along row E.

In span E-G there are two bridge cranes (grab) installed with lifting capacity of 5.0 t with elevation of crane track 14.5 m for loading of service hoppers, maneuvering device, rotary crushers and pneumatic conveying for loading of bulk materials.

The charge compartment is located in axes D-E in a span 30 m wide, 84 m long. In the compartment there are lines for preparing charge materials for melting, equipped with dispensers, conveyors, drum dryers, a hopper and a accumulator.

Slag regeneration area is located in built-in room.

On the floor of the compartment there are paths of a transfer trolley with a lifting capacity of 10 tons.

Two bridge cranes with a lifting capacity of 10 tons and with a crane track elevation of 14.5 m are installed in the span.

At the end of the compartment there is a ventilation room, a rest room, a bathroom.

In row D, four storey ABK building adjoins the branch. In the same building with the charge preparation department, there is a smelting compartment in the span D-E in axes 1533, connected with the OPSh technologically.

Charge materials in the bulk are supplied to the raw materials warehouse in railway gondola cars in bulk, partially in containers, bags and covered cars.

In winter, manganese ore, bauxite, in a gondola car, are previously defrosted in the garage by defrosting bulk cargoes.

Slag crust comes from welding mills of pipe-electric welding shop No. 6 in containers by road.

Energy carriers are supplied to the site in the necessary quantities from the power networks and facilities of the plant.

In the shop the air heating combined with forced ventilation, providing the normalized tvn temperatures =10os is accepted. For built-in rooms, water heating with local heating devices - convectors is provided. The heat carrier - superheated water with the TON parameters =130os, TOBR =70os from a factory heating main.

The main hazards in the workshop are:

dust release generated in sheet storage during sheet unloading from cars and its storage and further sheet processing;

gas release;

heat generation from process equipment in the workshop and in the built-in rooms.

All control stations and workplaces are provided with the supply of outdoor air, previously cleaned in filters.

In all in-house rooms, general exchange ventilation is mechanical. For harmful substances, eluded by local suction, the workshop has general exchange plenum ventilation.

The workshop has a recycled water supply system. Pipes are laid openly along the columns and walls of the building.

Domestic fire-fighting water supply networks are designed from cast iron pipes 150200 mm. Fire hydrants at a distance of 100150 m are provided on the network.

Charge materials from the raw material preparation warehouse and the charge preparation compartment to the melting compartment are transferred in self-destructing containers using transfer trolleys. In the smelting compartment, the valves are transmitted directly to the electric furnace and the cyclone smelter.

The finished products of the slag smelting area are welding slag, in containers they are sent by road directly to the welding equipment.

Architectural and structural solution

The main production process from storage to delivery of finished products is located in a single production building. The constructive solution of the task is due to its purpose and specific conditions of the technology.

The main production building is adopted with a steel frame. In accordance with the soil situation, a pile foundation with a pile depth of 6.000 and - 7.000 meters was adopted at the construction site. Waterproofing is performed on top of the foundation from cement sand mortar composition 1:2 on portland cement M400.

Along the external walls of the building, make paving from concrete of class B1.5 150 mm wide and 100 mm thick, on a crushed stone-compacted base.

Since the technological processes are directed along the span and are serviced by cranes, a span-type building is accepted. According to the nature of the process and the dimensions of the equipment, the level of the rail head is 14.57 m, the building of two spans of 30 m each. The total dimensions of the workshop are 60 × 120 m, and together with the adjacent melting compartment, the total length is 192 m. The pitch of the main columns is 12 m, the fachverkov - 6 m. The section of the upper part of the columns is continuous I-beam, the lower part is through. The height of the columns from the floor level to the bottom of the girder is 18 m. Within the height of the truss, a column toil is installed. The height of the truss is 3.15 m. The truss is welded steel with I-belts and a grid of paired corners, the belts are parallel (i = 0.025).

External walls are mounted three-layer panels with plating of galvanized steel profiles with protective and decorative coating and insulation between them from semi-rigid mineral wool plates with = 150 kg/m3, = 100 mm on a synthetic binder.

The roof is warm with a steel duct. The bearing element laid along the ducts is a steel structural steel.

In accordance with the requirements of [], Table 42, a temperature seam passes along axis 21.

Vertical connections of portal type are installed in axes 11-13. Upper links are installed in columns along axes 1-3 and 13-15.

The coating link system consists of horizontal and vertical links. Horizontal links are located in the lower and upper belts of trusses. Horizontal links consist of transverse and longitudinal links. Vertical links are arranged between trusses in plane of vertical posts of rafters.

Basement parts of trusses from elevation 10,000 to elevation 1.185 m, as well as sections in axes 7-15 along axis "D" from elevation 0.000 to 7.200 are made of hinged three-layer panels = 240 mm. Outer layers = 45 mm and ribs of slag concrete panels = 1900 kg/m3. Insulation = 150 mm - semi-rigid mineral wool boards on bitumen binder = 300 kg/m3. Sections of the base at the gate and external doors from the top of the foundation to the mark 1.185 m made of brick on M50 cement sand mortar with stitching on the inner side and wasteland on the outer side.

Plastering the basement parts of brick walls with cement sand mortar composition 1/3 on M400 cement. Panels with steel coverings from the outer side have to be painted industrially in light-gray color organozolyyu by ODHV221.

All steel elements of the frame partitions shall be unloaded.

Unload and paint steel structures with enamel for two layers.

Slag regeneration section partitions in axes 6 - 11, D - D/2, along axis 15 in axes D-E from steel profiled sheets of grade C441000.8 (GOST 2404586) according to steel frame.

Internal walls in axes E/2 - E/4, 1 - 2 made of red brick with facing on the side of the workshop with silicate brick. Masonry with stitching on both sides.

In the rest room, wipe the walls, face the GVL, whiten with lime. Paint the bottom of the walls with enamel.

In the bathroom, plaster the walls, whiten with lime. The bottom of the walls is lined with glazed tiles.

Wipe the walls of the ventilation rooms and the storeroom of the inventory, whiten with lime.

The walls of the air intake shaft are subject to silicate painting, on the side of the workshop - facing 18L, = 10 mm.

Paint internal doors with GF230 enamel.

Open water supply pipelines along the columns and walls of the building and paint with enamel for two layers.