大型设备吊装方案#上海

1、上海赛科石油化工有限责任公司50万吨/年乙苯/苯乙烯装置大型设备吊装施工方案页码： 21 组织管理体系：organization management system1.1 现场吊装组织机构suspending organization on site吊装总指挥技术供应质量安全吊装顾问组抬尾指挥主吊指挥起重班机械操作员测量人员其他工种设备铆工班现场吊装指挥 suspending advisor team chief commander of suspending technology supply facility quality safety suspending commander on s

2、ite main suspending commander lifting trail commander lifting team machine operator other types workerrivet worker team measure worker1.2 主要人员职责 duties for important personnel吊装总指挥对大件设备吊装工作的总体运行进行协调控制，提供资源保证，签发吊装令。 the suspending chief commander correspond and control the whole suspending work of th

3、e heavy facilities, also supply the guarantee of materials and sign the command o suspending. 吊装现场指挥负责组织吊装方案的实施。 suspending commander on site take charge of organizing to practice the suspending scheme.技术负责人负责编制吊装方案，参加技术交底，参加技术攻关工作，参与风险评估和吊装前的检查确认。 technology principal take charge of writing the sus

4、pending scheme, telling the technology intentions, attending in tackling key technology problem and risk evaluating and affirming checking before suspending.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，组织设备基础验收、检查确认施工质量。 quality pricipal charge in examination and affirm the special worker mooount guard with

5、certification, he also attend in checking and accept the received facilities, organize to check and accept the facilities basic, check and affirm the construction quality.设备负责人负责对进场施工设备的状况进行核实确认。负责设备的日常维护管理，参与风险评估工作。 facility pricipal take charge of vertify and affirm the conditions of construction

6、facilities on site, daily maintaining and management of facilities and attending risk evaluating. 安全负责人负责提出hse实施计划，监督hse管理的实施。 safety pricipal take charge of supplying hse practice scheme and supervising hse management implementation.供应负责人根据工程需要及时保质保量供应器材，组织到货设备验收。 supply pricipal purvey equipments

7、with quality and quantity in time according to the project requirement, and organize to check and accept the received facilities. 2运输路线： （运输公司编制）transportation route: (workout by transport company)3运输车辆的性能特点（运输公司编制） functions and features of vehicles (workout by transport company)4卸车位置及方位 unloading

8、places and orientation 4.1大型设备卸车、吊装顺序（详见大型设备吊装运行计划） unloading and suspending orders of heavy facilities (see running plan of suspending heavy facilities)4.2 设备摆放所占的道路及时间： road and time occupied by putting the facilities:1）10#路：摆放t-4001、t-4003安装平台、保温、管线 03年10月15日-11月6日；2月1日-2月9日 no 10 road: put t-400

9、1 during october 15 to november 6, 2003; february 1st to 9,20042）8#路：1250t吊车组车 04年2月1日-2月9日。 no 8 road: install 1250t crane from february 1st to 9, 2004. 4.3 设备卸车配合及支撑 cooperating and supporting of unloading facilities 4.3.1 卸车 unloading 预搭设支撑垛; build the supporting buttress in advance; 油压板车进入指定位置；

10、enter the oil pressure plank machine to the appointed place; 在卸车支撑处摆好卸车用的钢梁及鞍座； putting the unloading girder and bicycle saddle in the unload supporting place; 启动油压板车升降千斤顶，将设备顶起； startup the lifting and droping jack of oil pressure to peak up the facilities; 将卸车用钢梁及鞍座放置到支撑垛上； put unload on the suppo

11、rting buttress by the girder and bicycle saddle; 降下油压板车，将设备落到卸车鞍座上； down the oil pressure plank and let the facilities on the unloads bicycle saddle; 退出油压板车。 exit from the oil pressure plank.4.3.2 支撑处理 supporting disposal设备下由2个支撑点4个支撑垛受力，每个支撑垛应满足受力要求，支撑垛与地接触面积为9平方米（每个支撑垛下面铺设3040mm钢板，支撑垛由钢结构支架或道木垛组成）

12、。 two supporting points and four supporting buttress under the facilities to bear the weight, each buttress should meet the requirements of bearing. the contact area between supporting buttress and ground is 5 square meters (lay 3040 mm armor plate under each buttress containing of steel structure p

13、lank or crosstie buttress.)支撑示意图supporting sketch map4.3.3 卸车原则上采用以下方法： unloading adopt the following measures in principle:1） 充分考虑设备进入现场与其吊装时间的逻辑关系，尽量使用cc8800直接从拖车上卸货及吊装。 consider the logical relationship of entering onsite and suspending time for facilities sufficiently, try best to use cc8800 to

14、unload and suspend directly from the trailer.2） 大型设备根据合同由运输方直接运输至现场指定位置。 according to the contract, heavy facilities should be deliveried by transport side directly to the appointed places3） 较小型设备直接运输至现场后，采用m250型250吨履带吊直接卸车或吊装。 use 250ton pedrail crane model 250 to delivery or suspend directly after

15、 the smaller facilities being deliveried on site.4） 如果设备卸于临时库房，则根据设备重量、规格尺寸等条件采用kmk5160型160吨汽车吊单车或160吨汽车吊与tg-1300型130吨汽车吊双车抬吊的方法将设备装车，封车后运输至现场，采用160吨汽车吊单车或160吨汽车吊与130吨汽车吊双车抬吊的方法卸车。 if delivery the facilities in a temporary storeroom, use 160ton auto suspending single vehicle model kmk5160 or 160 ton

16、 auto suspending and 130ton auto suspending twin vehicles lifting to install the vehicle, close the vehicle then delivery on site in accordance with conditions of fcilities weight and specification then adopt the measures of unloading facilities by 160ton auto suspending single vehicle or 160ton aut

17、o suspending and 130 ton auto suspending tiwn vehicles lifting.5） 说明: narration设备支点用4个支撑垛支撑。每个支撑面积9平方米（每个支撑垛下面铺设3040mm钢板）。the facilities pivot support by the four supporting buttress. each can support the area of 5 square meters (lay 3040mm stell plank under each buttress). 支撑鞍座利用设备运输的鞍座。use the del

18、iverying bicycle saddle of the facilities to support the saddle.4.4 设备摆放要求 requirements for putting the facilities4.4.1 t-4001 抬尾吊耳在正上面 suspending trail hole in the median above place主吊耳在水平位置the main suspending hole in the horizontal place主吊耳位置运到基础中心位置，方向按现场平面图位置摆放。 the main suspending hole carried

19、to basic center place and put direction as the ichnography place on site. 主吊及抬尾吊耳位置、方位按提供给上海医药工业设计院的条件执行。 according to the conditions supplied to shanghai medicament industry academy of design, perform the places and directions of main suspending and trail hole.4.4.2 其它设备other facilities抬尾吊耳在正上方susp

20、ending trail hole in the median above place按现场平面图位置摆放put as the ichnography place on site方向按现场平面图位置摆放。put as the direction as the ichnography place on site中国石化集团第四建设公司 上海赛科石油化工有限责任公司50万吨/年乙苯/苯乙烯装置 大型设备吊装施工方案页码：8 页码：94.4.3 大型设备摆放位置详见附图大型设备吊装平面图 see the closed form about the putting places of the heav

21、y faciilities 序号ref no设备位号no of facilities摆 放 要 求备注remarks塔头朝向direction of tower head塔头坐标cooperate of tower head两主吊耳方位orientations of the two main suspending holes塔尾部吊耳方位orientation of suspending hole in tower trail1e-2001a塔头朝东easte 3624 n 3442水平放置horizent抬尾吊耳向上up2e-2001b塔头朝东easte 3624 n 3423水平放置hor

22、izent抬尾吊耳向上up3e-3004/3006/3007塔头朝北northe 3650 n 3350水平放置horizent4r-3001塔头朝西weste 3716 n 3314水平放置horizent抬尾吊耳向上up5r-3002塔头朝西weste 3710 n 3332水平放置horizent抬尾吊耳向上up6t-2001塔头朝东easte 3614 n 3423水平放置horizent抬尾吊耳向上up塔体垫高1.4米1.4m higher for tower7t-2003塔头朝东easte 3631 n 3448水平放置horizent抬尾吊耳向上up塔体垫高1.4米1.4m hi

23、gher for tower8t-4001塔头朝西weste 3651 n 3448水平放置horizent抬尾吊耳向上up塔体垫高1.4米1.4m higher for tower9t-4003塔头朝东easte 3642 n 3451水平放置horizent抬尾吊耳向上up塔体垫高1.4米1.4m higher for tower10e-4003a设备头朝西northe 3725 n3342水平放置horizent抬尾吊耳向上up11e-4003b设备头朝西northe 3725 n3348水平放置horizent抬尾吊耳向上up12e-4003c设备头朝西northa 3725 b335

24、4水平放置horizent抬尾吊耳向上up13e-3009aa 3725 b 3360水平放置horizent14e-3009ba 3725 b 3366水平放置horizent中国石化集团第四建设公司上海赛科石油化工有限责任公司50万吨/年乙苯/苯乙烯装置大型设备卸车及运输道路处理施工方案页码：435. 吊车性能特点： functions and features of crane5.1 吊车分ssl、svfl等6种工况，最大起重能力为1250t； six conditions for crane of ssl, svfl and so on, the most lifting capaci

25、lity is 1250t5.2 吊车长15米，宽12.5米，车高7.1米； crane is 15m(l), 12.5m(w) and 7.1m(h); 5.3 吊车的机动性能好，可载重行走； good flexibility of crane, which can walk with loading as well;5.4 吊装能力优越，超起配重600t，超起半径最大25米。 excellent lifting of super lifting 600t and the most semidiameter is 25meter.6 吊车组装位置和移动位置以及各吊装作业位置： coordin

26、ate of the cc8800 pedrail suspending station车位序号crane station no.e坐标cooperate en坐标cooperate n所吊设备位号lifted equipment no.1#3694.53433t-4003 t-4001 2#36443432t-2001 t-2003 e-2001a/b3#36703351r-3001 r-3002 e-3004/3006/3007e-4003a/b/c e-3009a/b7. 吊车站位及移动对场地的要求： requirements for lifting site by crane stan

27、ding position and moving:7.1 影响吊车占车及行走的设备基础及施工时间要求: requirements for facilities basic and construction time of influencing crane by being occupied and moved: 1） 吊车站位1: 装置北界区外管廊、p-4013a/b/c、p-4016；基础03年11月24日后施工。 crane station 1: outer pipe porch of installation north boundary p-4013a/b/c. p-4016;con

28、struct the basic from november 24, 2003. 2） 吊车行走： d-6005、p-6011、p-6004 and p-6006；基础03年11月24日后施工。 crane moving: d-6005, p-6011, p-6004 and p-6006; construct the basic from november 24, 2003. 3） 吊车站位3： z-6008、x-6010、p-6015、p-6016a/b；基础04年2月20日后施工。 crane station 3: z-6008, x-6010, p-6015 and p-6-16a/b

29、; construct the basic from february 20, 2004.4） 吊车站位影响的地下管道在吊车退场后开始施工。 北区：03年11月24日开始，南区：04年2月20日开始。 the underground pipeline influenced by the crane station will construct after exit of crane, the north: november 24, 2003; the south: february 20,2004.7.2 吊车承载地基处理设计计算：（3公司负责） design calculation of l

30、oading basic treatment: (no. 3 company in duty) 7.2.1 地基处理（由3公司提出）groudwork disposal8 吊装计算及依据： calculation basic for lifting8.1 编制说明 explanation for compiling8.1.1 适用范围 applicable scope 本方案适用于上海赛科石油化工有限责任公司50万吨/年乙苯/苯乙烯装置大型设备的吊装，涉及到重量在100t以上的设备共计17台。this scheme is applicable to suspending heavy facil

31、ities, which involved 17sets over 100 ton each, with installation of 500,000t/y for ethylbeneze & styrene of shanghai secco-petro company limited. 8.1.2 编制依据 compiling references1） 国家（行业）有关标准、规范； the relative standards and regulations of nation (trade);大型设备吊装工程施工工艺标准shj 515-90；- technics standar

32、ds for construction of suspending and installing heavy facilities, shj515-90 石油化工施工安全技术规程sh 3505-1999； -safety technology regulations for construction of petro-chemichal, sh3505-1999；建筑地基基础规范选编中国建筑工业出版社1993年版；- chapters from architecture groundwork basic regulations, china architecture industry publ

33、ishing company, 1993 edition起重工操作规程syb4112-80；-operation regulations for craneman, syb4112-80；2） secco ipmt提供的设备规格表（4月23日）及相关图纸，详见设备表； specification form and related drawings of facilities supplied by secco ipmt (april,23), see equipments table for details；3） 上海项目工程部提供的50万吨/年乙苯/苯乙烯装置安装工程施工投标文件； tend

34、er documents, construction of 500,000t/y installation for ethylbeneze & styrene plant, supply by shanghai project engineering department; 4） 上海项目工程部提供的图号为a1 10870-00010-j的装置平面布置图； ichnography a1 10870-00010-j of installation supplied by shanghai project engineering department; 5） demag cc8800型12

35、50吨履带式吊车性能表。 capability form of 1250ton pedrail crane model demag cc8800.8.2 总体吊装方案 wholel suspending scheme8.2.1 工程概况project general1） 场地条件site conditions上海赛科50万吨/年乙苯/苯乙烯装置属于新建项目，整个装置作业面开阔。装置界区达180米×120米，因此场地环境较好，有利于进行大型设备的吊装作业。另外装置内道路按照设备进厂、demag cc8800型1250吨履带式吊车行走及吊装对地面承载力的要求进行施工。shanghai s

36、ecco 500,000t/y ethylbeneze &styrene plant is a part of new projects, the whole installation site is wide and its boundary is 180 m*120 m, so the environment is better for suspending heavy facilities. otherwise, roads inside installation site construction is in accordance with facilities enterin

37、g factory, 1250ton pedrail model demag cc8800 moving route and requirements of ground bearing for suspending.2） 工程特点 project characteristics上海赛科50万吨/年乙苯/苯乙烯装置吊装工程大型设备较多，分布面广。其中100吨以上的设备17台：最大吊装重量的设备为乙苯蒸汽过热器/中间压力沸热换热器/低压沸热换热器（35e3004/3006/3007），重量达679吨吊装总负荷740吨；最高设备为eb/sm分离器（35- t-4001）高度为80.8米，为本次设备

38、吊装的重中之重。suspending project of shanghai secco 500,000t/y ethylbeneze& styrene plant has many heavy facilities distributed in a wild area. 17 sets of these are more than 100ton: the weighest suspending facility is ethylbeneze steam heat filter/ middle pressure boiling exchanger/ lower pressure boi

39、ling exchanger (35-e-3004/3006/3007), which is about 679ton and suspending bearing of 740ton; the highest facility, also the heaviest in all facilities, is eb/sm separator. (35-t-4001) about 80.8meter3） 大型设备一览表 form of heavy facilities 序号ref no设备位号facility number设备名称name 设备规格 (mm)standard 设备重量（kg）we

40、ight备注remark1d-3001乙苯/蒸汽分离罐steam separate tank for ethylbeneze f7000´1260010800024/4/2003 ssec设备表ssec faxility form of april,24, 20032e-2001a/b苯塔再沸器benzene tower reboiler8800024/4/2003 ssec设备表ssec facility form of april,24,2003 3e-3004/3006/3007乙苯蒸汽过热器/中间压力沸热换热器/低压沸热换热器ethylbeneze steam heat fi

41、lter for /middle pressure boiling exchanger/lower pressure boiling exchangerf5500´35000679000drawing no:20389734e-4009苯乙烯塔冷凝器styrene tower condensator10724024/4/2003 ssec设备表ssec facility form of april,24, 20035r-1001烃化反应器alkylation reactorf2600´256357590002329-00-907-11a6r-3001第一脱氢反应器the f

42、irst dehydrogen reatorf5200´29973268000drawing no:571a-22-017r-3002第二脱氢反应器the second dehydrongen reactorf5900´35315500000drawing no:571b-22-018t-2001苯塔benzene towerf4500´4146514000002329-00-907-01a9t-2003乙苯塔ethybeneze towerf3000´4480071530施工图eq30-0093m10t-4001eb/sm分离器eb/sm separa

43、torf7600´80780560100施工图eq30-009811t-4003苯乙烯塔styrene towerf4800´38480104410施工图eq30-0100m12e-4003a/b/ceb/sm冷凝器eb/sm splitter condenser f3600´11641146700drawing no:203896913e-3009a/b冷却器trim coolerf2700´rawing no:20389958.2.2 总体方案概述 general of whole scheme 1） 对于苯乙烯装置的设备吊装

44、特点来说，采用机动性好的吊装机具能适用于重型设备多而分布较广的特点。同时为使吊装工期尽量缩短，国内最大起重能力的1250吨履带式起重机的引进，给我们用于上海赛科苯乙烯装置大型设备吊装的机具注入了新的内容。 for chatacteristics of styrene facility suspending, using good flexibility suspending machinery can apply to facilities characteristics of quantity and distributeing wildly. meanwhile, to shorten t

45、he working time, 1250ton pedrail crane of the biggest lifting ability introduced in china inject new content to heavy facilities suspending machinery of shanghai secco styrene plant.2） 经现场勘察和反复论证，兼顾了技术上的先进性，安全上的可靠性和经济上的合理性，在赛科苯乙烯装置大型设备的吊装工程中，我们决定采用大型移动式起重机作为主吊机具的总体方案，即demag cc8800型1250吨履带式起重机主吊，m250

46、型250吨履带起重机抬尾配合。 according to the reconnaissance on site and demonstration repeatedly, we paid attention to advanced technology, dependable safety and rational economy, and decided to adopt the whole shceme of heavy jenny as the main suspending machinery, in which 1250ton pedrail crane demag cc8800 i

47、s the main suspending machinery and 250 ton pedrail crane model 250 cooperate with lifting the trail.3） 根据合同，所有大型设备应运抵fcc指定的吊装位置、方向、角度及高度卸车，并且直接利用设备出厂装车原支撑鞍座位置进行支垫。 according to the contract, all heavy facilities should be deliveried and unloaded to appointed suspending place, direction, angle and h

48、eight by fcc, and underlay directly facilities in the original supporting saddle points as the facility leaving factory.4） 所有塔类设备尽量在地面完成附件安装（包括附塔管道、梯子、平台、绝热防腐）然后吊装，吊耳以上部分妨碍吊装绳索及设备摆放支撑处的附件在塔吊装后施工。 all the tower facilities try the best to install accessories on the ground（including attached tower pipe

49、line,ladder,platform, adiabat and antisepsis）before suspending. the parts higher than suspending hole, where accessories obstruct suspending lines and places to put suppoting facilities, should construct after suspending tower. 5） t-4001塔顶部大口径管道因吊车的有效吊装高度所限，不能随塔吊装，在其吊装后，再用cc8800吊装此管线。 t-4001 big cal

50、iber pipeline is limited in height because of its available suspending height and could not suspend with the tower freely. after suspending it, use cc8800 to install this pipe cable.8.3 大型设备吊装施工工艺 construction techncis of suspending and installation of heavy facilities8.3.1 设备参数表 parameter form of f

51、acilities序号ref no.位号no.名称name规格（m m）stardard设备吊装重量明细（t）details of suspending weight本体noumenon平台platform绝热heat insulation配管attached pipe吊装重量weight1d-3001乙苯/蒸汽分离罐ethylbeneze/steam separate tankf7000´126001080005521202e-2001a/b苯塔再沸器reboiler of beneze tower880001410101223e-3004/3006/3007乙苯蒸汽过热器/中间压

52、力沸热换热器/低压沸热换热器ethylbenezesteam separater/middle pressure boilingchanger/lower boiling changerf5500´350006790006794e-4009苯乙烯塔冷凝器styrene tower condesator1072401075r-1001烃化反应器alkylation reactorf2600´256357590010971026r-3001第一脱氢反应器the first dehydrogen reatorf5200´299732680002687r-3002第二脱氢反应器the second dehydronge