槽钢基础吊装及安装方案.doc

拜耳异氰酸酯和聚醚项目 TDI联合装置基础设施BAYER ISOCYANATE & PET PROJECT TDI TRAIN-INFASTRUCTUREPCS楼C581、B551，C403R118盘柜槽钢基础吊装及安装施工方案PCS Building C581, B551, C403R118 Cabinet Channel Base Hoisting Construction Plan编 制： 陈 健Compiled by: Chen Jian审 核：Reviewed by:审 批：Approved by 中国核工业第五建设公司拜耳项目部China Nuclear Industry Fifth Construction Corporation Bayer Project Department 二九年十月十八日October 18, 200921Construction Plan Approval Form施工方案审批表Project Name工程名称Bayer isocyanates and polyether project TDI combination unit Infrastructure拜耳异氰酸酯和聚醚项目TDI联合装置-基础设施Structure Type结构类型Frame-wall, local steel框剪，局部钢结构Construction Unit建设单位Bayer Polyurethanes(shanghai)Co.,Ltd拜耳（上海）聚氨脂有限公司ManagementCompany管理公司M+D ZANDER美斯威尔Supervision Unit监理单位Construction Unit施工单位China Nuclear Industry fifth Construction Corporation中国核工业第五建设公司Compilation Section编制部门China Nuclear Industry fifth Construction CorporationBayer Project Department中国核工业第五建设公司拜耳项目部Compiled by编 制 人Jian Chen陈 健Compilation Date编制时间October 18, 20092009年10月18日Submission Date报审时间October 18, 2009 2009年10月18日ApprovalSection审批部门Approval Date审批时间Year Month Day 年 月 日 Approved by 审 批 人Program Name方案名称Bayer Isocyanate & PET Project TDI Train InfrastructureHoisting Construction Plan 拜耳异氰酸酯和聚醚项目 TDI联合装置基础设施吊装及安装方案审批意见：（填写讨论的主要结论 包括应修改的部分）Views of Approval:(Fill the main conclusions of the discussion, including the amended part)目 录 Contents1. 工程概况General statement 2. 项目组织机构Project organization3. 编制依据 Compilation basis 4. 槽钢基础运输路线及吊机站位平面图（见附图）Drawing of channel base transportation routes and stations of cranes (see attached drawing)5. 吊装步骤 Hoisting steps6. 索具选择Rigging options 7. 施工机具配备 Construction equipment and tools 8. 吊装操作流程 Hoisting operating process9. 吊装工作应注意的安全事项 Safety matters of hoisting work10. 质量标准 Quality standards 11. 起重吊装的指挥和吊装工艺岗位的分工 Command & division of labor of hoisting process12. 吊装作业风险评价报告 Risk assessment of hoisting work 13. 作业应急预案Emergency planPCS楼C581、B551，C403R118盘柜槽钢基础吊装施工方案PCS Building C581, B551, C403R118 Cabinet Channel Base Hoisting Construction Plan1 工程概况General statement1.1本方案属于拜耳异氰酸酯和聚醚项目TDI联合装置-基础设施-PCS楼C581、B551，C403R118盘柜槽钢基础吊装及安装施工方案。配电柜基础总共有大小120多个。所有配电柜基础均为10#槽钢制作，材质为碳钢，外表采用聚氨脂涂料。采取场外预制，现场安装。预制完成的槽钢基础大小不等，最大规格为8000*1000*800mm。重量为：540公斤。This program is based on Bayer Isocyanate & PET Project TDI Train Infrastructure PCS House building C581, B551, C403, and R118Cabinet Channel Base Hoisting Construction Plan. There is a total of more than 120 power distribution cabinet base. All those are made of 10 # channel steel. The material is carbon steel with polyurethane coating. Take the method of off-site prefabricated, on-site installation. There are different sizes of prefabricated channel base and the maximum size is 8000 * 1000 * 800mm. with the weight: 540 kilograms.1.2 C581为三层框架结构，槽钢基础分别安装在二层、三层。二层地面标高为7m，三层地面标高为11.8m。C581 is a three-storey frame structure and the channel base will be installed in the second and third floor. The second floors ground elevation is 7m and the third is11.8m.1.3 B551为四层框架结构，槽钢基础分别安装在二层、三层、四层。二层地面标高为5.4m，三层地面标高为9.9m，四层地面标高为14.4m。B551 is a four-storey frame structure and the channel base will be installed in second, third and fourth floor. Their ground elevation is 5.4m, 9.9m and 14.4m respectively.2 吊装组织机构Hoisting OrganizationCommander: Chen Jian现场总指挥:陈健Material:WuXuefei 材料: 徐兵Equioment:YinHaihua设备: 印海华Tecnology:WuHaidong技术: 吴海东Safety:安全:程宗强Quality: Xu Bin质量:吴雪飞Hoisting commander:吊装指挥: 徐永德:2.1.1 吊装总指挥对吊装工作的总体运行进行协调控制,提供资源保证。The commander in chief coordinates and controls the overall hoisting operation and provides resources.2.1.2 吊装现场指挥负责组织吊装方案的实施应由有实践经验、技术水平较高、组织能力较强的人担任，应充分了解并严格执行起重施工技术文件的规定。The on-site commander of hoisting is responsible for organizing implementation of the plan. He should have practical experience, high level of skills and high organization ability and should be fully aware of and strictly implement the provisions of hoisting technical documents.2.1.3 材料负责人根据吊装工作所需要的器具和材料及时供应,并做到质量保证. The one who is responsible for materials should timely supply the required hoisting equipment and materials and ensure the quality.2.1.4设备负责人负责对进场施工设备的状况进行核实确，负责设备的日常维护管理,参与风险评估工作. The one who is in charge of equipment should confirm the status of the on site construction equipment. He is also responsible for routine equipment maintenance and engages in risk assessment.2.1.5技术人员负责吊装技术指导,参加技术交底,参加技术攻关工作,参与风险评估和吊装的检查确认. Technical staff is responsible for hoisting technical guidance, participates in technical disclosure and research work and engages in risk assessment.2.1.6质量负责人负责审查、确认特殊作业人员上岗资格，参加到货设备的检查和验收，组织设备基础的验收、检查确认施工质量。The one who is in charge of quality should verify and confirm the qualification of special operations personnel. He also should participate in arrival-equipments inspection and acceptance, organize the acceptance of equipment foundation and inspect and confirm construction quality.3. 编制依据Compilation Basis3.1 浙江美阳国际石化医药工程设计有限公司绘制的施工图 Drawings of Zhejiang Meiyang International Petrochemical Pharmaceutical Engineering Co., Ltd. 3.2 电气装置安装施工及验收规范Specifications of electrical installation construction and acceptance.3.3 钢结构工程施工及验收规范 GB 50205-2001 Steel Structure Construction and Acceptance Norms GB 50205-20013.4 建筑施工高处作业安全技术规范JGJ80-91 Building Construction Height Works Safety Technical Code JGJ80-913.5 实用起重吊装手册Practical Hoisting Manual4.0 设备进场路线 Equipment Delivery Route5.0 吊装步骤 Hoisting steps施工方案编制（批准）施工准备（场地、路线、机索具）机索具的检查吊装前交底设备方位确认吊车的就位设备进入吊装位置卸车吊装设备就位吊车脱钩吊车退场清理场地 compilation of the construction plan (approved) construction preparation (site, routine, rigging) check the riggingdisclosure before hoisting confirm equipment position place the crane place the equipment into hoisting position unloading place the hoisting equipmentcrane decoupling crane exit clear the site 5.1 C581、B551施工方案construction plan of C581, B5515.1.1 根据本项目的槽钢基础参数、结构特点和施工现场条件，用机械吊装能满足设备吊装要求。经过反复计算和论证后，采用16吨汽车吊。As per the channel bases parameters, structural features and construction site conditions of the project, using mechanical hoisting equipment can meet the hoisting requirements. We decide to use 16 -ton truck crane after repeated calculation and verification.5.1.2 16吨汽车吊站位在C581、B551东侧，设备运输车开到指定位置。The 16-ton truck crane locates in east of C581 and B551 and equipment vehicles drive to the specified location.5.1.3 16吨汽车吊，吊车伸20米臂杆到槽钢基础中心位置，吊钩缓缓放下。使用两根12mm麻绳做设备溜绳起吊时控制设备的稳定性。吊装区域拉上警示带挂上警示牌有专职安全员负责管理，无关人员不准入内。The 16-ton truck crane stretches its 20-meter derrick boom to the center of channel base and lets the drop hanger slowly fall down. Use two 12mm hemp ropes as slip ropes to control device stability. Pull warning tapes, hang warning signs and let full-time security staff watch to ensure no admittance for irrelevant personnel.5.1.4 吊装准备工作结束检查无误后准备起吊，先车同时拉紧吊带慢慢起钩让设备离车20cm停下观察每一根吊带的受力情况、卸扣是否完全站立、吊车的稳定性如何。当一切检查正常后听从指挥吊车慢慢起钩，让设备平稳的吊起来。把设备吊运指定位置有安装工慢慢松钩、摘钩，吊装结束。注：在进行汽车吊室外设备吊装是一定要设置吊装区域保护拉上警戒线，非吊装人员严禁入内。有专职安全员负责安全警戒。保证工作安全顺利进行。?Start hoisting when preparatory work is finished and inspected , and correct lifting, the first car starting slowly at the same time taut sling hooks allow devices to 20cm away from the car stopped and observed the root of each tape of the stress conditions, shackles is completely standing crane stability how. When everything checks to normal obey the hook from the cable car slowly, so that equipment, smooth hung up. Specify the location of the equipment installed lifting slowly work loose hook, picking hook, lifting an end. Note: The outdoor equipment of vehicle crane hoisting hoisting area is definitely needed to protect one way or another security line, non-hoisting personnel is strictly prohibited to enter. There are full-time security staff in charge of security alert. To ensure safety at work carried out smoothly.6.0 施工现场吊装绳采用合成纤维吊装带，或者扁平型的吊装带，计算校核：a)槽钢基础参数 最大设备规格：8000*1000*800 设备重量: 0.54T 安装标高： C581 EL+7.0 00m，+11.800m；B551 +5.4m，+9.9m，+14.4m。 b). 1.合成纤维吊装带合成纤维绳的破断拉力为(仅为数据估算用,非规范公式) Sp=110d2 其许用拉力为 P=Sp/K 式中P许用拉力，N; Sp破断拉力，N; d合成纤维绳直径，mm; K安全系数，合成纤维绳的安全系数可根据工作时用状况的重要程度选取，但不得小于6。 现取K=7，P=mg=540kg*9.8N/kg=5292N，则Sp=PK=5292*7=37044N，计算： d=18.35mm故：合成纤维绳可取25mm。2.扁平型的吊装带扁平吊带（索）webbing sling ： 织带宽度： 25mm 拉力能力500kg，最小破断力1000kg 织带宽度： 35mm 拉力能力1000kg，最小破断力2000kg 织带宽度： 50mm 拉力能力2500kg， 最小破断力5000kg 织带宽度： 75mm 拉力能力3500kg，最小破断力7000kg 可取35mm宽度的吊装带。栓挂方式:1弯2股受力分析 S=G/n*1/sin式中:G-设备、吊索、吊钩及重量,取G=0.6T -吊索之间的夹角, =60 n- 绳索的股数,n=2 S-每根吊索的拉力S=(0.6/1)*(1/sin60)=0.346 T受力计算 T= Sp /K式中 T-吊装带的容许拉力 Sp -吊装带的破断拉力 K-安全系数,K=7合成纤维吊装带T=3.7/7=0.529T S符合扁平型的吊装带T=2/7=0.286T S 符合C).吊机吊装计算吊机性能选用16吨汽车吊回转半径9m 臂杆长度25m 起吊最大能力3.3T臂杆倾角计算 a=arc cos (S-F)/L =arc cos (9-1)/25 =71式中: S-吊车回转半径,选S=9m F-臂杆底铰盘至回转中心的距离,F=1m L-吊车臂杆长度,选L=25m7.0 吊装操作流程 Hoisting operating process7.1 由项目部有关部门会同吊装专业有关人员进行联合检查，全部确认后联合（包括项目经理）签发起吊后才可进行吊装。Carrying out hoisting after being inspected and confirmed by relevant departments and professional personnel of the project and signed together (include PM).7.2 所有各项准备工作完备后进行试吊，试吊要求吊耳点抬高200-500mm，检查内容为： Take a hoisting test after all the preparatory work and require lug-point to be elevated to 200-500mm. Contents of check as follows: 7.3 所有索具情况,吊车负荷情况,地基变化情况,吊耳及壳体情况. Include rigging, crane loads, ground changes, lug and shell conditions.7.4 试吊如出现问题则及时放回原位针对这些问题进行整改，直至正常。If problems of test appear, put back to in-situ for the rectification until it is up to the normal. 7.5 现场吊装指挥协调主吊吊车的变幅度速度，要求始终保持主吊车吊臂与设备在水平面上投影相垂直，吊钩始终保持与地面相垂直,然后再提升至安装位置。The on-site hoisting commander coordinates speed variable rate of the main crane. Maintain the boom derrick keeps vertical with the equipment projection in the horizontal plane and the drop hanger keeps vertical with the ground. Then rise to the installation location.7.6 槽钢基础吊至安装高度后，一端放在手动液压车上，另一端放在滑轮上，进行水平运输，运到安装位置后用龙门架就地放下。对于比较小的槽钢基础，用液压车水平运输到位后，人工抬下。7.7 槽钢基础安装前，先按施工图纸所标位置，进行施工放线，放线完成后，将预制好的基础型钢架放在正确位置上，用水准仪或水平尺找平、找正。用12膨胀螺栓固定。找平过程中，需要用垫铁的地方最多不能超过三片。然后，将垫铁用电焊焊牢。基础型钢安装允许偏差下表。基础型钢安装允许偏差 项目允许偏差mm/mmm/全长不直度13水平度13位置误差及不平行度58.0 吊装工作应注意的安全事项: Safety matters of hoisting work8.1吊装施工准备和实施过程中安全质量保证体系必须要保证正常运转,以确保吊装工程达到安全优质的要求.吊装前必须进行安全质量检查,并要符合化工工程建设起重施工规范(HGJ201-83)以及其他规程、规范的规定。Safety& quality assurance system must be ensured its normal operation during the hoisting preparation and implementation process to ensure that the hoisting works can achieve safety and high quality requirements. Carry out safety and quality checks before hoisting and be consistent with Chemical Engineering Construction Crane Construction Standards (HGJ201 - 83) as well as other procedures and norms. 8.2 起重作业人员应熟知施工方案、起重设备性能、 操作规程、指挥信号和安全要求。Hoisting operators should be familiar with the construction plan, lifting equipment performance, operational procedures, command signals and safety requirements. 8.3 起重机械和索具应具有出厂合格证. Lifting machines and riggings should have the factory certification. 8.4 起吊作业前,应在重物上系以牢固的溜绳,防止吊装过程中重物摆动、旋转或碰撞其他建、构筑物。Before hoisting, weights should be wrapped with solid slide ropes to prevent swinging, rotating or colliding other built structures.8.5 吊起的重物不得长时间空中停留,严禁重物下方有人停留或行走. Weights may not be stayed in the air for a long time and it is forbidden to stay or walk under heavy loads.8.6吊装用吊带应受力均匀,在使用过程中应经常检查吊带有无断丝、扭结、弯折、磨损、而引起的损坏等现象。The lifting force of the sling should be uniform. Check whether the slings are broken, kinked, bent, worn and damaged in other way. 8.7 吊装性能应满足吊装工艺要求,警报和液压系统必须可靠. Hoisting performance should meet the technical requirements. Alarm and hydraulic systems must be reliable.8.9 吊钩偏角不应大于30The deflection angle of the drop hanger should not be more than 30.8.10 禁止用吊车在地面上直接拖拉设备. Prohibit using cranes to haulage equipment directly on the ground.8.11 设备吊装前应进行试吊,试吊前,参加吊装的人员应按分工,严格检查吊耳,机械及索具的装设情况,达到要求后试吊,试吊时重物离地面200500mm,应观测吊装净距及吊车支腿处地基变化情况,发现问题应先把设备放回地面,故障排除后重新起吊,方可正式吊装. The personnel should strictly inspect installation of dugs, machinery and riggings in division. After meeting the requirement, carry out a test before hoisting equipment before hoisting. Weights should be off the ground up to 200 500mm. Observe the clear distance of the hoisting crane and foundation soil changes at the outrigger. If problems of test appear, put back to in-situ for the rectification until it is up to the normal.8.12 吊装过程中,应保持动作平稳,待设备就位后应及时找正找平,设备未固定前不得解开吊装索具. During hoisting, keep stable until the equipment is put in place, aligned and leveled. Do not unlock the hoisting riggings till the equipment is fixed. 8.13 吊装时,任何人不得随同设备或吊装索具上下. During hoisting, nobody can go up and down accompanying the equipment or hoisting rigging.9.0 质量目标与质量保证措施Quality objectives and assurance measures9.1 质量目标Quality objectives精心组织、精心施工、争创优良工程Careful organization and construction and striving for excellent project9.2 质量保证措施Quality assurance measures9.2.1建立以项目部总工程师领导的质保体系,认真搞好”五关”图纸会审关、方案编制关、设备验收关、施工工序质量检查关和资料收集关。使质量在各个环节上能得到有效的控制。Establish a quality assurance system leaded by general engineer of the project department and do a good job of five tests. They are drawing inspection, programming, equipment acceptance, construction process quality inspection and data collection. Thus the quality can be effectively controlled at the various links. 9.2.2施工前,技术人员应认真对施工班组进行技术交底,要有追踪性,在施工过程中要严格执行”三检查”原则. Before construction, technical personnel should do the clarification with traceability to the construction teams and groups. Strictly implement the three inspections principle in the construction process. 9.2.3在施工过程中,要严格按照方案、规程规范进行每一道工序的施工During the construction process, strictly follow the program and procedures to conduct every construction process.10 起重吊装的指挥和吊装工艺岗位的分工Hoisting command and labor division10.1 起重吊装的指挥协调工作Command and coordination (1)凡参加吊装的施工人员,必须坚守岗位,并根据指挥者命令进行工作. Workers participating in hoisting construction must stick to their posts and work under the commanders order. (2)指挥者应把信号向全体工作人员交代清楚,明确各人的岗位职责.哨音必须正确、响亮、旗语应清楚. The commander should explain clearly to the entire staff and definitize responsibilities of each position. Whistle must be correct and loud. Semaphore should be clear.（3）在吊装作业中，为了保证正确，及时地下达信号，可在指挥者领导下，各吊装岗位的指挥工作，必须分工明确，紧密配合。, In order to issue signals correctly and timely in the lifting operation, workers at different positions should be under the leadership of commander, clear division of labor and cooperate with each other.（4）指挥者应站在能看到吊装全过程并被所有施工人员全能看到的位置上，以利直接指挥各个工作岗位，否则应通过助手及时传递信号。The commander should stand in a position where he can watch the whole process of loading and be seen by all the construction workers. So he can command various work directly. Otherwise, signals transmission need be done by his assistant.（5）指挥者及操作人员应使自己的视觉、听觉不受阻碍。The commander and operators should make their own vision and hearing not impeded.（6）吊装过程中，任何岗位出现故障，必须立即向指挥者报告，没有指挥者的命令，任何人不得擅自离开岗位。 During lifting process, find any failure must immediately report to the commander. No one can leave their posts without commanders permission.（7）吊装工艺岗位的分工 labor division of hoisting technology序号Serial No. 岗位号Post no. 岗位名称 Posts职责Responsibility11-0吊装指挥Hoisting commander具体指挥吊装全过程的工艺操作。Command the whole process1-1吊车司机Crane driver执行吊装指挥命令、准确、平稳操作、吊车动作。Carry out the commanders order and operate the crane correctly and stablely.1-2设备就位Equipment 负责设备的就位找平找正,做好安装记录aligning and leveling equipment and make installation record1-3预备队Reserve team执行吊装指挥命令,排除吊装故障. Carry out the commanders order and eliminate the hoisting failure。11.0 起重施工安全技术措施如下: Safety technical measures are as follows:1 凡参加施工的人员，必须熟悉起吊方法的工程内容，按方案要求进行施工，并严格执行规程规范。Workers involved in the construction must be familiar with the lifting contents, construct according to program requirements and strictly implement the specifications.2 在施工过程中，施工人员必须具体分工，明确职责，在整个吊装过程中，要切实遵守现场秩序，服从命令听指挥，不得擅自离开工作岗位。During the construction process, make specific division of labor and define responsibilities, comply with the on-site order and obey the command. No one can leave their posts without commanders permission.3 在吊装过程中，应使用国家统一规定的指挥信号，参加施工的全体人员必须熟悉此信号，以便各操作岗位协调动作。 During the hoisting process, use command signals that are united by the country. Workers must be familiar with this signal so that they can coordinate with other operational posts.4 吊装时，整个现场由总指挥调配，各岗位分指挥应正确执行总指挥的命令，做到传递信息迅速、准确，并对自己负责的范围内负有责任。The general commander deploys the entire site and the sub-commander carry out his orders correctly, so that information can be transmitted quickly and accurately. The sub-commanders are responsible for their own responsibility. 5 在整个施工过程中要做好现场清理，清除障碍物，以利操作。Do the on-site clean-up. Remove obstructions to facilitate the operation.6 施工中凡参加登高作业的人员，必须经过身体检查并合格，操作时要佩戴安全带，并系在安全可靠的地方，工具应有保险绳，不准随意往下扔物件和工具。 Workers who work in height should pass physical examination, wear belts and fasten in a safe and reliable place. Tools should have safety lines and do not allow to throw objects and tools down. 7 施工人员必须头戴安全帽。如冬季施工，应将护耳放下，以使听觉不受阻碍。Wear helmets. If it is winter construction, put down earmuffs so that hearing is not impeded. 8 带电的电焊线和电线要远离钢丝绳，带电线路距离