装置吊装施工施工方案#上海.doc

档案号 file no：上海赛科石油化工有限公司90万 吨 / 年乙烯装置900 kt/a ethylene plant of shanghai secco petrochemical co. ltdt-1402t-1403t-1601e-1602a/bd-1601吊装施工技术方案methods statement for t-1402t-1403t-1601e-1602a/bd-1601 lifting编 制： 林土金 tujin lin originated by:施工技术审核： 李春法 chunfa li tech. reviewed by: 质量保证审核： 戴东明 dongming dai qa reviewed by : 安全技术审核： 边长刚 changang bianhse reviewed by: 审 定： 徐庆海 qinghai xu checked by:批 准： 褚振辉 zhenhui chu approved by:编制时间： 2003年11月17日 date: 2003-11-17 中国石化集团第十建设公司上海化学工业区工程项目部shanghai chemical industry park project department of tccs1 工程概况 project introduction在上海secco乙烯裂解装置急冷区中，由十公司负责安装的使用120t和280t吊装的立式设备（大件和过滤器除外）共计6台。详细情况见表-1。in quench area of shanghai secco ethylene unit , there are 6 sets of vertical equipment except heavy equipment and filter which will be erected with 120t and 280t crane by the tenth construction company. 立式设备明细表 vertical equipment list 表-1 sheet 1序号s/n设备名称 description设备位号item no.数量(set)设备外形尺寸dimension（）重量weight（t）1裂解燃料油汽提塔pyrolysis fuel oil strippert-140212200/110019346122裂解柴油汽提塔pyrolysis gas oil strippert-140311200148805.93工艺水汽提塔 process water strippert-1601128002032019.14中压蒸汽稀释蒸汽热交换器mp steam/dilution steam exchangere-1602a/b21900951942.55稀释蒸汽罐 dilution steam drumd-1601140001664138.5 合计11台 total 11 sets在确保吊装工程安全可靠、工艺合理的前提下，经过认真分析、研究，确定采用“单机提升、辅助吊车抬尾递送”的吊装方法来完成，各台设备均采用整体吊装。based on security and reasonable lifting process, after a serious analysis and study, will adopt “single crane lifting with assistant crane trailing”, and the equipment will be lifted as an integer.2编制依据references2.1化工塔类设备安装施工及验收规范construction and acceptance specifications for chemical towers hgj211-832.2 化工工程建设起重施工规范construction specifications for lifting in chemical engineering construction hgj201-832.3.大型设备吊装工程施工工艺标准construction process standards for heavy equipment lifting shj515-902.4 石油化工施工安全技术规程security technology regulations for petrochemical construction sh3505-19992.5 乙烯装置设备总平面布置图equipment plot plan of ethylene complex档案号file no.：e-10856-00010b2.6 乙烯装置地下管道布置图underground piping layout of ethylene complex档案号file no.：e-10856-00428a2.7 lr1280型吊车性能表load table of crane lr12802.8 nk1200型吊车性能表load table of crane nk12002.9 tg-500e-型吊车性能表load table of crane tg-500e-3.主要吊装技术参数 main technical parameters3.1 t-1402（裂解燃料油汽提塔pyrolysis fuel oil stripper）吊装lifting为减少高空作业，将t-1402（裂解燃料油汽提塔）附塔结构在地面预制、安装后，采用120t吊车主吊、50t抬尾的方案进行吊装，吊装平面布置见图-1，吊装立面图见图-2，有关技术参数如下：to reduce work at height, the accessories for pyrolysis fuel oil stripper t-1402 will be prefabricated and assembled on the ground, and lifted, together with main tower, with 120t main crane and 50t trailing crane. lifting plan and elevation view refer to figure-1. elevation view refer to figure-2.related technical parameters are as follows:1、吊装重量weight of lifting g=设备重量weight of equipment g1+吊钩重量weight of hook g2+索具及吊耳、平衡梁weight of rigging, lifting lug and compensating beam g3+附塔结构weight of tower accessories g4=12+0.6+2.0+4.8=19.4t2、主吊车参数main crane parameters型号type：nk1200作业半径operation radius：r=10m杆长length of boom：l=34m额定载荷rated load：27.35t吊装载荷lifting load：19.4 t负荷率load rate：71%3、辅助吊车参数assistant crane parameters型号type：tg-500e-作业半径operation radius：r=9m主杆长length of main boom：l=18.15m额定载荷rated load：13.1t吊装最大载荷max lifting load：9t最大负荷率max load rate：68.7%3.2 t-1403（裂解柴油汽提塔pyrolysis gas oil stripper）吊装lifting为减少高空作业，将附塔结构在地面预制、安装后，采用120t主吊、50t抬尾的方案进行吊装，吊装平面布置见图-1，吊装立面图见图-3，有关技术参数如下：to reduce work at height, the tower accessories will be prefabricated and assembled on the ground, and lifted, together with pyrolysis gas oil stripper, with 120t main crane and 50t trailing crane. lifting plan refer to figure-1 and elevation view and refer to figure-3. related technical parameters are as follows:1、吊装重量weight of lifting g=设备重量weight of equipment g1+吊钩重量weight of hook g2+索具及吊耳、平衡梁weight of rigging, lifting lug and compensating beam g3+附塔结构weight of tower accessories g4=5.9+0.6+2+4.5=13t2、主吊车参数main crane parameters型号type：nk1200作业半径operation radius：r=7m杆长length of boom：l=34m额定载荷rated load：32t吊装载荷lifting load：13t负荷率load rate：41%3、辅助吊车参数assistant crane parameters型号type：tg-500e-作业半径operation radius：r=9m主杆长length of main boom：l=18.15m额定载荷rated load：13.1t吊装最大载荷max lifting load：6t最大负荷率max load rate：49%3.3 t-1601（工艺水汽提塔 process water stripper）吊装lifting为减少高空作业，将附塔结构在地面预制、安装后，采用120t主吊、50t抬尾的方案进行吊装，吊装平面布置见图-1，吊装立面图见图-4，有关技术参数如下：to reduce work at height, the tower accessories will be prefabricated and assembled on the ground, and lifted, together with process water stripper, with 120t main crane and 50t trailing crane. lifting plan refer to figure-1 and elevation view and refer to figure-4. related technical parameters are as follows:1、吊装重量weight of lifting g=设备重量weight of equipment g1+吊钩重量weight of hook g2+索具及吊耳、平衡梁weight of rigging, lifting lug and compensating beam g3+附塔结构weight of tower accessories g4=19.1+0.6+2+5.9=27.6t2、主吊车参数main crane parameters型号type：nk1200作业半径operation radius：r=8.5m杆长length of boom：l=34m额定载荷rated load：32t吊装载荷lifting load：27.6t负荷率load rate：86.3%3、辅助吊车参数assistant crane parameters型号type：tg-500e-作业半径operation radius：r=7.5m主杆长length of main boom：l=18.15m额定载荷rated load：18.5t吊装最大载荷max lifting load：13.2t最大负荷率max load rate：71%3.4 e-1602a/b（中压蒸汽稀释蒸汽热交换器mp steam/dilution steam exchanger）吊装liftinge-1602a/b（中压蒸汽稀释蒸汽热交换器mp steam/dilution steam exchanger）将采用280t（lr1280）吊车主吊、50t抬尾的方案进行吊装，吊装平面布置见图-5，吊装立面图见图-6，有关技术参数如下：e-1602a/b（mp steam/dilution steam exchanger） will been lifted with 280t main crane and 50t trailing crane. lifting plan and elevation view refer to figure-5 and figure-6. respectively and related technical parameters are as follows:1、吊装重量weight of lifting g=设备重量weight of equipment g1+吊钩重量weight of hook g2+索具及吊耳、平衡梁weight of rigging, lifting lug and compensating beam g3=43+4+4=51t2、主吊车参数main crane parameters型号type：lr1280作业半径operation radius：r=9m杆长length of boom：l=37.4m额定载荷rated load：122.6t吊装载荷lifting load：51t负荷率load rate：42%3、辅助吊车参数assistant crane parameters型号type：tg-500e-作业半径operation radius：r=4.5m杆长length of boom：l=10.8m额定载荷rated load：34t吊装最大载荷max lifting load：23t最大负荷率max load rate：67.7%3.5 d-1601（稀释蒸汽罐 dilution steam drum）吊装lifting为减少高空作业，吊装前将附塔结构在地面预制、安装后，采用280t吊车主吊、50t抬尾的方案进行，吊装平面布置见图-7，吊装立面图见图-8，有关技术参数如下：to reduce work at height, tower accessories will be prefabricated and erected on the ground and lifted, together with drum, with 280t main crane and 50t trailing crane. lifting plan and elevation view refer to figure-7 and figure-8 respectively and related technical parameters are as follows:1、吊装重量weight of lifting g=设备重量weight of equipment g1+吊钩重量weight of hook g2+索具及吊耳、平衡梁weight of rigging, lifting lugs and compensating beam g3+附塔结构weight of tower accessories g4=38.5+4+4+9.8=56.3 t2、主吊车参数main crane parameters型号type：lr1280作业半径operation radius：r=14m杆长length of boom：l=37.4m额定载荷rated load：75.9t吊装载荷lifting load：56.3t负荷率load rate：74.2%3、辅助吊车参数assistant crane parameters型号type：tg-500e-作业半径operation radius：r=4.5m杆长length of boom：l=10.8m额定载荷rated load：34t吊装最大载荷max lifting load：24.8t最大负荷率max load rate：73%3.6 设备吊装状况列表operation condition for equipment lifting设备吊装工况表 operation condition data for equipment lifting 表-2 sheet2序号s/n设备名称description设备位号item no.主吊车main crane辅助吊车assistant crane型号type半径radius(m)杆长boom length(m)吊装重量lifting weight（t）额定载荷rated load(t)负荷率load rate(%)型号type半径radius(m)杆长length(m)额定载荷rated load (t)吊装载荷liftingload (t)负荷率load rate(%)1裂解燃料油汽提塔pyrolysis fuel oil strippert-1402nk1200103419.427.3571tg-500e-918.1513.1968.72裂解柴油汽提塔pyrolysis gas oil strippert-1403nk1200734133241tg-500e-918.1513.16493工艺水汽提塔 process water strippert-1601nk12008.53427.63286.3tg-500e-7.518.1518.513.2714中压蒸汽稀释蒸汽热交换器mp steam/dilution steam exchangere-1602a/blr1280937.451122.642tg-500e-4510.8342367.75稀释蒸汽罐 dilution steam drumd-1601lr12801437.456.375.973tg-500e-4510.83424.873.4. 吊耳、平衡梁、索具的选择 selection of lifting lug and balance beam and riging4.1 吊耳 lifting lug根据sei提供的图纸，d-1601主吊耳由制造厂家设计并安装，主吊耳能力为75吨，可以满足吊装的需要，抬尾吊耳由十公司设计、制造厂家安装（见图-9）。t-1402、t-1403、t-1601吊装使用的主吊耳和抬尾吊耳依据中国石化集团施工规范大型设备吊装工程施工工艺标准shj515-90，由十公司设计、制造厂家安装（分别见图-1015）。according to the drawing supplied by sei, the lifting lug of d-1601 will been designed and erected by manufacturer, permit load is seventy and five tons, ok. trailing lug refer to figure-9 will been designed by tenth construction company, been erected by manufacturer. the lifting lug and trailing lug refer to figure 1015 of t-1402 and t-1403 and t-1601 will been designed by tenth construction company according to construction process standards for heavy equipment lifting of sinopec standard shj515-90, been erected by manufacturer.4.2平衡梁 balance beamt-1601和d-1601吊装使用的平衡梁见图-16，此平衡梁在t-2401吊装（吊装载荷186t）中已使用过，其强度可以满足吊装要求。balance beam of t-1601 and d-1601 refer to figure-16, this balance beam has been used during t-2401 lifting, (load 186 tons), its strength is enough.t-1402、t-1403、和e-1602a/b吊装使用的平衡梁见图-17，此平衡梁在t-5503吊装（吊装载荷81t）中已使用过，其强度可以满足吊装要求。balance beam of t-1402 and t-1403 and e-1602a/b refer to figure-17, this balance beam has been used during t-5503 lifting, (load 186 tons), its strength is enough.4.3索具rigging4.3.1 t-1402选用起重量为50t的合金钢弓形卸扣、4个作为平衡梁上方和下方的卸扣，选用起重量为10t的d形卸扣、1个作为尾吊卸扣；four alloy shackles of type and rated load is fifty tons will been used upper and under of balance beam, one shackle of type d and rated load is ten tons will been used for trailing.选用规格为56-637+1（1700 mpa等级）、长度为10米/根的钢丝绳、两根作为平衡梁上方索具，每根钢丝绳绕卸扣一圈，共四股受力，其安全系数为n=16400004/（1.095170103）=356two slings of diameter 56-637+1 (strength class 1700mpa), and 10 meters will been used up of balance beam. the safe modulus is below:n=16400004/（1.095170103）=356选用规格为56-637+1（1700 mpa等级）、长度为12米/根的钢丝绳、两根作为平衡梁下方索具，每根钢丝绳绕卸扣两圈，共八股受力，其安全系数为n=16400008/（170103）=776two slings of diameter 56-637+1 (strength class 1700mpa), and 12 meters will been used down of balance beam. the safe modulus is below:n=16400008/（170103）=776选用规格为34.5-637+1（1700 mpa等级）、长度为5米/根的钢丝绳、一根作为尾吊索具，共两股受力，其安全系数为n=6216002/（90103）=13.86one sling of diameter 34.5-637+1 (strength class 1700mpa), and 5 meters will been used for trailing. the safe modulus is below:n=6216002/（90103）=13.864.3.2 t-1403选用起重量为50t的合金钢弓形卸扣、4个作为平衡梁上方和下方的卸扣，选用起重量为10t的d形卸扣、1个作为尾吊卸扣；four alloy shackles of type and rated load is fifty tons will been used upper and under of balance beam, one shackle of type d and rated load is ten tons will been used for trailing.选用规格为56-637+1（1700 mpa等级）、长度为10米/根的钢丝绳、两根作为平衡梁上方索具，每根钢丝绳绕卸扣一圈，共四股受力，其安全系数为n=16400004/（1.095130103）=466two slings of diameter 56-637+1 (strength class 1700mpa), and 10 meters will been used up of balance beam. the safe modulus is below:n=16400004/（1.095130103）=466选用规格为56-637+1（1700 mpa等级）、长度为12米/根的钢丝绳、两根作为平衡梁下方索具，每根钢丝绳绕卸扣一圈，共四股受力，其安全系数为n=16400004/（130103）=506two slings of diameter 56-637+1 (strength class 1700mpa), and 12 meters will been used down of balance beam. the safe modulus is below:n=16400004/（130103）=506选用规格为34.5-637+1（1700 mpa等级）、长度为5米/根的钢丝绳、一根作为尾吊索具，共两股受力，其安全系数为n=6216002/（60103）=206one sling of diameter 34.5-637+1 (strength class 1700mpa), and 5 meters will been used for trailing. the safe modulus is below:n=6216002/（60103）=2064.3.3 t-1601选用起重量为50t的合金钢弓形卸扣、4个作为平衡梁上方和下方的卸扣，选用起重量为20t的d形卸扣、1个作为尾吊卸扣；four alloy shackles of type and rated load is fifty tons will been used upper and under of balance beam, one shackle of type d and rated load is twenty tons will been used for trailing.选用规格为56-637+1（1700 mpa等级）、长度为10米/根的钢丝绳、两根作为平衡梁上方索具，每根钢丝绳绕卸扣一圈，共四股受力，其安全系数为n=16400004/（1.095260103）=236two slings of diameter 56-637+1 (strength class 1700mpa), and 10 meters will been used up of balance beam. the safe modulus is below:n=16400004/（1.095260103）=236选用规格为56-637+1（1700 mpa等级）、长度为12米/根的钢丝绳、两根作为平衡梁下方索具，每根钢丝绳绕卸扣两圈，共八股受力，其安全系数为n=16400008/（260103）=506two slings of diameter 56-637+1 (strength class 1700mpa), and 12 meters will been used down of balance beam. the safe modulus is below: n=16400008/（260103）=506选用规格为34.5-637+1（1700 mpa等级）、长度为5米/根的钢丝绳、一根作为尾吊索具，共两股受力，其安全系数为n=6216002/（132103）=9.46one sling of diameter 34.5-637+1 (strength class 1700mpa), and 5 meters will been used for trailing. the safe modulus is below:n=6216002/（132103）=9.464.3.4 e-1602a/b选用起重量为50t的合金钢弓形卸扣、4个作为平衡梁上方和下方的卸扣；four alloy shackles of type and rated load is fifty tons will been used upper and under of balance beam.选用规格为56-637+1（1700 mpa等级）、长度为12米/根的钢丝绳、两根作为平衡梁上方索具，每根钢丝绳绕卸扣一圈，共四股受力，其安全系数为n=16400004/（1.095510103）=11.76two slings of diameter 56-637+1 (strength class 1700mpa), and 12 meters will been used up of balance beam. the safe modulus is below:n=16400004/（1.095510103）=11.76选用规格为56-637+1（1700 mpa等级）、长度为10米/根的钢丝绳、两根作为平衡梁下方索具，每根钢丝绳绕卸扣一圈，共四股受力，其安全系数为n=16400004/（510103）=12.86two slings of diameter 56-637+1 (strength class 1700mpa), and 10 meters will been used down of balance beam. the safe modulus is below:n=16400004/（510103）=12.86选用规格为52-637+1（1700 mpa等级）、长度为30米/根的钢丝绳、一根作为尾吊索具，共两股受力，其安全系数为n=13981002/（230103）=126one sling of diameter 52-637+1 (strength class 1700mpa), and 30 meters will been used for trailing. the safe modulus is below:n=13981002/（230103）=1264.3.5 d-1601选用起重量为50t的合金钢弓形卸扣、4个作为平衡梁上方和下方的卸扣，选用起重量为50t的d形卸扣、1个作为尾吊卸扣；four alloy shackles of type and rated load is fifty tons will been used upper and under of balance beam, one shackle of type d and rated load is fifty tons will been used for trailing.选用规格为56-637+1（1700 mpa等级）、长度为10米/根的钢丝绳、两根作为平衡梁上方索具，每根钢丝绳绕卸扣一圈，共四股受力，其安全系数为n=16400004/（1.095510103）=11.76two slings of diameter 56-637+1 (strength class 1700mpa), and 10 meters will been used up of balance beam. the safe modulus is below:n=16400004/（1.095510103）=11.76选用规格为56-637+1（1700 mpa等级）、长度为12米/根的钢丝绳、两根作为平衡梁下方索具，每根钢丝绳绕卸扣两圈，共八股受力，其安全系数为n=16400008/（510103）=256two slings of diameter 56-637+1 (strength class 1700mpa), and 12 meters will been used down of balance beam. the safe modulus is below:n=16400008/（510103）=256选用规格为56-637+1（1700 mpa等级）、长度为5米/根的钢丝绳、一根作为尾吊索具，共两股受力，其安全系数为n=16400002/（248103）=13.26one sling of diameter 52-637+1 (strength class 1700mpa), and 5 meters will been used for trailing. the safe modulus is below:n=16400002/（248103）=13.265施工计划 construction plan设备的吊装计划将根据赛科提供的设备的到货计划确定，具体时间待定。lifting schedule of equipment will been arranged according to the equipment arrival plan offered by secco, detail time is hold.6 hse安全技术管理措施hse management measures6.1施工过程中可能发生的安全事故风险分析jha during construction施工现场地质条件差，易发生吊车倾覆事故；bad ground condition on site will easily cause crane overturn;设备吊装施工属于高空作业，易发生高空坠落事故；equipment lifting needs work at heights, and falling accident is easily occurred;物体打击；stricken by objects;设备运输事故；transportation accident;钢丝绳、卡具不合格；unqualified wire rope and shackles;吊装作业过程中，发生吊装物件倾倒，损坏吊车等；equipment overturns and crane damage during lifting;在平台和坑、洞口旁作业或路过时发生坠落事故；falling accident from platform, pit, hole during working or passing by;吊耳和平衡梁制作、焊接不合格，发生坠落事故。unqualified lifting lug and compensating beam cause falling accident;6.2相应对策corresponding measures加强安全教育，严格执行班前安全讲话和周一安全活动制度，有针对性地交代近期工作中的安全注意事项；enhance safety training, strictly carry out the system of tool box meeting and routine monday safety meeting, make safety clarification according to recent work;凡参加大型设备吊装的工作人员，如安全监督、吊装指挥、配合吊装作业的起重工人、吊车操作员等，必须持有国家有关部门颁发的上岗证。all participated personnel such as safety supervisor, lifting commander, rigger and crane operator etc. shall have qualification certificate issued by related national authority;针对物体打击和高空坠落事故的原因，采取下列措施：following measures shall be taken to avoid object striking and falling from height:1）戴好安全帽，系好安全带，高空作业时做到安全带高挂低用，使用安全带前仔细检查安全带有无损坏。高处作业、交叉作业应张挂安全网，有高处作业处下方12米必须有安全网，否则不得施工。correctly use safety helmet and harness. harness shall be hung at height and used at lower level, and checked carefully prior to using. safety net shall be used during work at height and cross work, and shall be provided 12m under work position, otherwise, work is forbidden.2）高处作业应使用合格的脚手杆、吊架、梯子、脚手板，防护围栏，挡脚板和安全带，作业前应认真检查所用安全设施是否坚固、牢靠，脚手架应经安全员检查认可后，挂牌标识，并办理工序交接手续后，方可使用。qualified scaffold pole, hanger, ladder, gangplank, guardrail, toe board and harness shall be used during working at height. carefully check if all the safety facilities are fixed and reliable before working. scaffold shall be checked and labeled by safety inspector, and used only after procedure hand-over. 3）高处作业使用工具、材料等应放在安全、不易失落处，防止砸伤下方人。tools and other materials shall be put at safe place during work at height to avoid falling and striking accident.4）为防止设备运输事故的发生，必须认真封车，运前探路，小心谨慎，确保安全。to ensure safety and avoid transport accidents, equipment must be fixed carefully and transport route shall be ascertained 5）吊装作业区应设置明显的警告牌，并设专职安全员负责安全监护。作业前，将可能发生事故的区域隔离，无关人员不得入内；warning board shall be set up at eye-catching position in lifting area, and full-time safety inspector shall be arranged for supervision. prior to lifting, potential accident area must be isolated and closed to irrelevant person.6）为防止发生吊装事故，手拉葫芦使用前应检查是否完好，不得超载使用，严禁强拉硬拽；检查钢丝绳、卡具是否合格。吊装作业时，人员不得站在重物正下方，吊装指挥穿着由secco公司指定的指挥人员服装进行指挥，应统一、明确。安装的设备应及时固定，确保稳固性。to avoid lifting accident, cha