起重机载荷试验

CSPCNANHAIPETROCHEMICALSPROJECT中海壳牌南海石化项目CRANELOADTEST起重机载荷试验PROJECTPROCEDURE:PR-8710-0000-0010项目程序：PR-8710-0000-0010ProjectManagementContractor(PMC)项目管理承包商(PMC)REV版本DATE日期REASONFORISSUE发布原因BY发布人CHK’D审核人QA质保APPR.批准人0023Jan02IssuedforITB招标用PFAVCFCB0124May02IncorporatedChineseTranslation加入中文翻译XYMJRDD0221Mar03IncorporatedEPCandCcontractorsresponsibility加入总承包商和施工承包商的职责DKTKOBCLKMCDOCUMENTISSUE/REVISIONINFORMATIONDocument#:PR-8710-0000-0010CraneuseandoperationCurrentRevision#:Rev02ReasonforIssue/Revision:Thisdocumentisrevisedbecause:CurrentProcedurerefersBSFasbeingresponsibleforthedirectroleinperformingtheload-testofcranemobilizedtothesite.ResponsibilityofEPCandCcontractorsareincorporatedinthisrevision.DescriptionofChange:RemoveBSFSeniorConstructionManagerresponsibilityinadministeringtheloadtestofliftequipment.IncludeEPCandCcontractorsasresponsibleintheadministeringandperformanceoftheloadtestofliftequipment.Applicability:Thisdocumentappliesto:EPCandCcontractorsandotherthirdpartycranerental.Nameofcontactperson:DennisKiuContactNumber:+867525565944CRANELOADTEST起重机载荷试验TABLEOFCONTENTS目录No.编号Page页码1.0PURPOSE目的42.0SCOPE范围43.0DEFINITIONS定义64.0RESPONSIBILITIES责任75.0REQUIREMENTS要求86.0REFERENCES参考167.0ATTACHMENTS附件161.0PURPOSE目的ThepurposeofthisprocedureistoestablishaconsistentapproachfortheloadtestingofhydraulicandconventionalliftcrawlerandwheelmountedcranesonallBSFprojects.本程序的目的是对BSF所有活动应用的各类吊装设备提供统一的载荷试验方法。2.0SCOPE范围ThisProcedureisapplicabletoallBSFConstructionprojectsthatusecranestoperformliftingactivities.本程序适用于BSF所有使用起重机进行吊装作业的施工。TheScopeofthisprocedurecoverscranesusedforconstructionpurposesthathavepreviouslybeen"qualified"foruse.Itisnotintendedtogivedirectiontoqualifynewequipment.Forthetestingandqualificationofnewequipment,refertothemanufacturersoperationsandmaintenancemanualsaswellasallapplicabletestplans,turnoverpackages,andowner/clientuseagreements.本程序的范围涵盖用于施工目的的合格起重机，不对检验新设备给予指导。对于新设备的试验和取得合格证，参考制造商操作与维修手册，以及所有适用的试验计划、移交文件和所有者/顾客使用协议。ThisprocedureappliestoallBSFconstructionprojectsincludingsubcontractorsand/orthirdpartycranes&liftequipmentrentals.Specifically,itappliestotheloadtestingofthefollowingformsofliftingequipment:本程序适用于BSF所有施工活动，包括分承包商和/或第三方吊装设备租赁。特别地，本程序适用于下列形式吊装设备的载荷试验：ConventionalLatticeBoomCrawlerCranes.传统的桁架起重臂履带式起重机HydraulicDrivenlatticeBoomCrawlerCranes液压驱动桁架起重臂履带式起重机ConventionalLatticeBoomTruckCranes,(friction/hydraulicdriven).传统的桁架起重臂式汽车吊(摩擦/液压驱动)RoughTerrain,CarryDecks,AllTerrain,andHydraulicTruckCranes.适于平坦地形、带支腿或适于所有地形的汽车起重机BridgeCranesandOverheadCranes.桥架和高架吊车JackingLiftsystemstoincludeGantryType,StrandType,andGinPole.牵引式起升系统，包括门架式、绞线式、把杆TelescopicBoom&BoomTrucks.伸缩臂式汽车吊DutyCycleCranes(Clamshell/Dragline)工作(负荷)循环提升设备(蛤壳式/铲斗式)Pilingequipment打桩设备Towercranes塔吊Note:Whilethisproceduredoesnotspecificallyaddressmanyliftingdevices,(Hoists,Tuggers,etc.).Thisprocedureshouldbeusedforguidanceforthoseitemsnotspecificallycovered.Alsorefertomanufactureroperationsandmaintenancemanuals,applicablejurisdictionalcodes,standards,andregulationsforanyrequirements.IntheabsenceoflocalorregionalstandardsutilizeapplicablePRCREQUIRED/regulationsandstandardsasguides.注：由于没有特别说明许多吊装设备(升降机、卷扬机等)，本程序应用于指导未提及的项目。对于任何要求，还要参考制造商操作与维修手册、适用的法律规范、标准和规程。没有当地或地区性标准时，使用国家规定和标准作为指导。AnydeviationfromthisprocedureshallbedocumentedandsubmittedinadvancetotheBSFProjectFieldEngineer(PFE)whowillobtainapprovalfromtheappropriateauthorities.任何与本程序的分歧均应书面记录并在事先提交BSF现场工程部经理，由现场工程部经理取得相关部门的批准。Changeinthisrevision.本版次修改.Paragraph2.5:Addsummariesoftheallchanges.2.5节:加入修改汇总Paragraph2.3:AddTowerCranes.2.3节:加入塔吊Paragraph4.1:Change“SeniorConstructionManager"to“EPCandCContractors".4.1节:修改“高级施工经理”为“承包商和施工承包商施工经理”.3.0DEFINITIONS定义TruckMountedCrane 汽车起重机Acraneconsistingofarotatingsuperstructure(Centerpostorturntable),boom,operatingmachinery,andoneormoreoperator'sstationsmountedonaframeattachedtoacommercialtruckchassis.Itsfunctionistolift,lowerandswingloadsatvariousradii.该起重机由安装在汽车底盘上的构造组成，包括上部回转结构(中心柱或转盘)、起重臂、运转机械、一个或几个驾驶室。其功能是起升、降低或以各种转弯半径旋转载荷物。CrawlerCrane 履带式起重机Acraneconsistingofarotatingsuperstructurewithapowerplant,operatingmachinery,andboom,mountedonabaseandequippedwithcrawlertreadsfortravel.Itsfunctionistolift,lowerandswingloadsatvariousradii.该起重机由安装在装备履带的基座上的构造组成，包括带发电装置的上部回转结构、运转机械、起重臂。其功能是起升、降低或以各种转弯半径旋转载荷物。DesignatedPerson(DP) 指定人员Anindividualselectedorassignedbytheemployeroremployer'srepresentativeasbeingcompetenttoperformspecificduties.由雇主或雇主代表选择或任命的人，胜任执行特殊的职责。4.0RESPONSIBILITIES责任EPCandCcontractorsConstructionManager(CM) 承包商和施工承包商施工经理(CM)Constructionmanagerisultimatelyresponsibleforthesafeuseandoperationofthecranesontheproject.Hemaydelegatehisresponsibilitythroughthefollowingpersonnel:Projectsuperintendent,Equipmentsuperintendent,MasterMechanicordesignatedperson(s).施工经理最终负责起重机在项目上的安全使用和运行。他可能通过下列人员代表其职责：项目总监、设备监理、技工工长或指定的人员。ProjectEquipmentMaintenanceandOperationTeam(PEMOT)项目设备维修与操作组(PEMOT)TheConstructionmanagershallassembleaprojectequipmentmaintenanceandoperationteamtomanageallcraneoperations(includingsubcontractors)attheproject.Thedesignatedperson(s)thatwillleadtheEquipmentmaintenanceteammustbefullyconversantwiththeimplementationofcraneoperationandmaintenanceprocedures,inspectionsthatarerequiredbythecranemanufacturersandbyPRCREQUIREDregulations,codesandstandards.施工经理将组建一个项目设备维修与操作组来管理项目(包括分包商)所有起重机的运行。领导设备维修与操作组的指定人员必须完全熟悉并执行起重机维修与操作程序，熟悉制造商和中国法律法规要求的检验。DuetothevaryingsizesandcomplexitiesofBSFprojects,onequalifiedindividualwithintheProjectEquipmentMaintenanceandOperationTeammayfillseveraldifferentpositions(i.e.RiggingSupervisor,MasterMechanic.&OperatingEngineer)由于BSF项目不断改变的规模和复杂性，在项目设备维修与操作组中的合格人员可能会安排不同的岗位(即：索具监管员、机械和运行主管工程师)5.0REQUIREMENTS要求Allcraneswhicharriveon-sitewillreceiveaninitialinspectioninaccordancewithConstructionProcedurePR-8710-0000-0009,CraneUseandOperation.Onceasatisfactoryinspectioniscomplete,loadtestingperthisproceduremayproceed.所有到达现场的起重机要根据施工程序PR-8710-0000-0009（起重机使用与操作）接受初步的检查。一旦检查合格，即按本程序进行载荷试验。CraneoperatorshallbequalifiedperPR-8710-0000-0007,CraneOperatorQualification起重机驾驶员要符合程序PR-8710-0000-0007（起重机驾驶员资格）的要求。Note:Ifthecranehasreceivedasatisfactoryloadtestwithinthepast12monthsandisrecordedwiththeequipmentfile,thenaninitialloadtestisnotrequired.注：如果起重机在过去十二个月内接受过满意的载荷试验，并记录在设备档案中，就不需要初始载荷试验。LoadTestPrerequisites 载荷试验必备条件Setupcraneaccordingtomanufacturersrecommendationsinasuitableareaclearofobstructions.根据制造商的建议在没有障碍物的合适区域安置起重机。Ensurealloperationmanualsandloadchartsapplicabletothecrane,areproperlylocated.确保用于该起重机的所有操作手册和负荷图表放置在适当的地方。Performafullcraneinspection（ReferPeriodicInspectionChecklist）toassesstheoperationalandmechanicalconditionofthecrane.进行全面的起重机检查（参照定期检查表）以评估起重机的运行和机械状况。Barricadethetestareaanderectnoentrysignswithappropriatecranetestwarnings.在试验区域设置路障，竖立“禁止进入”的牌子警示起重机试验。Performchecksofalloperationalandsafetysystems.进行操作和安全系统的检查Eachcraneshallbetestedbythemanufacturerand/ortheowner/usertotheextentnecessarytoensurecompliancewiththeoperationalrequirements.Theseoperationalfunctionsincludethefollowing:每台起重机要由制造商和/或使用者进行试验达到必要的程度，保证符合操作要求。这些操作功能包括：Loadliftingandloweringmechanisms.载荷物起升机构Boomliftingandloweringmechanisms起重臂起升机构Boomextensionandretractionmechanism起重臂伸缩机构Swingingmechanism回转机构Travelmechanism迁移机构Safetydevices安全装置Wherethecompleteproductioncraneisnotsuppliedbyonemanufacturer,suchtestsshallbeconductedatfinalassembly.完整的起重机产品不是由一家制造商提供时，试验在最终组装后进行。Loadbrakesshallbetestedandadjustedtomanufacturerspecificationspriortoanymachineloadtestbeingperformed.Themanufacturersspecificationsgenerallycallforasinglepartlinetobeutilizedforthesebrakecheckstopreventamulti-partlinefrommaskinganypotentialproblems.ThePreliminaryBrakeCheckProcedureusingSinglepartlineallhoistingdrumsisasfollows:在进行任何机械负荷试验前，负载制动器要按制造厂说明进行试验和调节。制造厂说明通常要求用单条绳索进行制动器检查，防止多条绳索掩盖了任何可能的问题。初步的制动器检查程序如下：a)OnHydraulicCraneswithspringappliedhydraulicallyreleasedbrakes.对于弹簧应用于制动器的液压起重机Checkbrakesaspermanufacturerrecommendationsfoundinservicemanualsorpublishedbulletins.按照服务手册或说明书中制造商的建议检查制动器；Determinethemaximumloadratingforthebrakes.确定制动器的最大额定负载；Determinethemaximumsafeworkingloadofthewireropeinstalledonthecrane.确定起重机钢缆的最大安全工作负荷；Note:Thelowerofthetwocapacitiesabovewillbethelimitingfactorinplanningthetest.注：两倍能力以上的下降是计划试验时的限制因素；Determinethetestweightneededtakingintoaccountallloadingthebrakeswillbesubjectedto.确定需要的试验重量要考虑制动器将承受的所有载荷；Thistestmustbecarriedoutataboomlengthandradiuswellwithintheratedcapacityofthecrane.执行本试验起重臂长度和回转半径要在起重机的额定能力之内；Lifttheloadapproximately6inchesofftheground.起升起吊物离开地面约六英寸；Movethehoistcontroltotheneutralpositionallowingthebraketoset.将起升控制放于空挡位置，使制动器能够调整；Holdtheloadwiththebrakesonly.只用制动器保持起吊物Theloadshouldremainsuspendedwiththebrakessetaccordingtomanufacturerspecifications.按照制造厂说明，起吊物用制动器保持悬空；Ifrequired,replaceorrepairbrakingsystemtocomplywithmanufacturer'sspecifications.如需要，按制造厂说明更换或修理制动器系统；b)OnConventionalfrictiontypecranes.对于传统的摩擦力起重机Adjustfrictionbrakesaspermanufacturerrecommendationsfoundintheservicemanualsorpublishedbulletins.按照服务手册或说明书中制造商的建议调节摩擦力制动器；Determinethemaximumloadratingforthebrakes.确定制动器的最大额定负载；Determinethemaximumsafeworkingloadofthewireropeinstalledonthecrane.确定起重机钢缆的最大安全工作负荷；Note:Thelowerofthetwocapacitiesabovewillbethelimitingfactorinplanningthetest.注：两倍能力以上的下降是计划试验时的限制因素；Determinethetestweightneededtakingintoaccountallloadingthebrakeswillbesubjectedto.确定需要的试验重量要考虑制动器将承受的所有载荷；Thistestmustbecarriedoutataboomlengthandradiuswellwithintheratedcapacityofthecrane.执行本试验起重臂长度和回转半径要在起重机的额定能力之内；Lifttheloadapproximately6inchesofftheground.起升起吊物离开地面约六英寸；Applythebrake.使用制动器；Holdtheloadwiththebrakesonly.只用制动器保持起吊物；Theloadshouldremainsuspendedwiththebrakessetaccordingtomanufacturerspecifications.按照制造厂说明，起吊物用制动器保持悬空；Ifrequired,re-adjustorrepairthebraketocomplywithmanufacturer'sspecifications.如需要，按照制造厂说明重新调节或修理制动器。Locatesuitabletestweight.Theweightmusteitherbeastampedcertifiedweightorweighedwithacertifiedand/orcalibrateddynamometerorscale.IflocalJurisdictionalcodes,standards,orregulationsaremorestringent,andrequirea"certifiedweight",thenonemustbeused.确定合适的试验砝码。该砝码或者是批准的经鉴定的砝码，或者是用经鉴定和/或校准的量具称过的砝码。如果当地法规标准更严格，并要求‘经鉴定的砝码’，则必须采用。Note:Commonsensemustprevailwhenchoosinga"suitabletestweight".Itshouldhavereadilyavailablepickpointsandnotbeofageometrywhichwouldrequirespecialriggingfixturesandcalculationstodeterminethecenterofgravity.Ifapieceofequipmentisused,itshouldberiggedsuchthattheslingsandriggingwillnotdamagethe"testweight".注：选择一个‘合适的试验砝码’时应使常识可以应用。砝码应有吊点，且不能是特殊的几何结构以致需要特殊的夹具并且计算来确定重心。如果使用一个装置，安装索具不能破坏‘试验砝码’。Usecertifiedriggingforallloads(i.e.,slings,shackles,spreaders,etc.).对所有起吊物使用合格的索具(即吊索、吊钩等)。Whileitisnotrequired,documentationofcraneloadtestsusingphotographshasproventobeaneffectivemediumtocommunicatewhattranspired.虽然不要求，但是起重机载荷试验文件使用照片被证明是一种有效的媒介表示所发生的事。RatedLoadTest 额定负荷试验Priortoinitialuse,annually,and/orwhenmaintenanceoncranesinwhichloadsustainingpartshavebeenaltered,replaced,orrepairedaloadtestistobeconductedby,orunderthedirectionof,aqualifiedperson.Thereplacementoftheropeisspecificallyexcludedfromthisrequirement.However,afunctionaltestofthecraneunderanormaloperatingloadshouldbemadepriortoputtingthecranebackinservice.最初使用前、每年、或者起重机维修时负荷支撑部件被改变、更换或修理的情况下，载荷试验要由合格人员进行或在其指导下进行。绳索的更换在本要求之外。但是，起重机正常运行负荷下的功能试验应在其投用前进行。Caution:Thecraneshallnotbeloadedtomorethan100%ofitsratedchartcapacitywithoutpriorwrittenapprovalfromthecranemanufacturer.Ifa110%loadtestisrequiredbytheproject,thenmanufacturersapprovalandtestplanshallbeobtained.注意：没有制造商的预先书面批准，起重机不能负载超过其额定能力的100%。如果项目要进行110%的载荷试验，要获得制造商的批准和试验计划。AwrittenliftplanmustbegeneratedforapprovalinaccordancewithPR-8710-0000-0008,ConstructionRiggingWorkOperations书面吊装方案必须根据程序‘PR-8710-0000-0008施工索具操作’获得批准。Determine/confirmdeductionsfromthegrosscapacitychartforthefollowing:确定/确认从净起重能力图表中扣除：Manufacturerapprovedattachments制造商认可的附件Loadblock滑轮Overhaulball检查球Wirerope钢缆Rigging索具Determinetestloadrequiredbaseduponavailableweightsandloadchartstoachieve100%capacity.确定需要的试验负荷要基于已有的重量和负荷以达到100%的能力。Refertoincabloadchartsandselectaradiusatwhichthetotaltestloadwillbe100%ofgrosscapacity.参考驾驶室内的负荷图，选择一个半径，试验负荷要达到净能力的100%。Forcraneswithautomaticsafeloadindicatorsandalarms,inordertoachievea100%lift,Theseloadmomentindicatorsmayneedtobeoverridden.Thesystemsaregenerallyequippedwithoverrideswitchestoaidintheperformanceoftheseloadtests.对于有自动安全指示和报警的起重机，为了达到100%，这些指示器可能需要过载。通常系统安装了过载开关以辅助载荷试验的进行。Measurethetestradiusandplaceasuitablemarker.测量试验半径并做适当的标记。Positionthetestloadinsidethetestradiuswellwithinthecapacityofthecraneasconfigured.在试验半径内确定试验负荷在起重机设定的能力之内。Liftthetestloadandallowittostabilize.起升试验起吊物并使其稳定。Maintaintheloadnomorethanonefootfromtheground.保持起吊物离地面不超过一英尺。Boomdowntothepredeterminedtestradiuswiththeguidanceofagroundsignalman.起重臂按地面指挥的指示降至预先设定的试验半径。Measurethedistanceofthetestweightheightfromtheground.测量试验砝码距地面的高度。Applyallbrakesandshutdowntheengine.使用所有制动器并关闭发动机。Observetheloadfor5minutestocheckforloaddrift.观察五分钟，检查载荷的漂移距离。Restartthecraneandswingthetestload360degreesifpermittedbytheloadchartworkareadiagram.重新启动起重机，如果负荷图、工作区域图许可，转动试验起吊物360度。Ifduringtheexecutionoftheloadtesting,correctivemaintenanceorrepairsarerequired,theProjectEquipmentMaintenanceandOperationsTeam(PEMOT)isresponsibletoassurecorrectiveactionsareperformed.如果在进行载荷试验期间需要保养或修理，项目设备维修与操作组负责保证保养的进行。Duringtheexecutionofanycorrectionactions(maintenanceorrepairs)ifanyloadsustainingpartsarealtered,replaced,orrepaired,thenaloadtestwillberequired.在保养(维护或修理)时，如果有载荷支撑部件被改变、更换或修理，要进行载荷试验。Allrepairsandmaintenancearetoberecordedandplacedintheequipmentfile.所有修理和维护要记录并放入设备档案中。AtthecompletionofasuccessfulloadtestallresultsaretoberecordedandplacedintheEquipmentfile.RefertoattachmentAforasampleLoadTestform.在成功的载荷试验完成时，所有结果要记录并放于设备档案。参考附件A载荷试验表示例。Writtenreportsshallbereviewedandfiledbyanappointedorauthorizedperson,showingtestproceduresandconfirmingtheadequacyofrepairsoralterations.书面报告要由指定或授权的人审核并归档，说明试验程序并确认修理或改变适当。ProjectSpecificLoadTesting 项目特殊载荷试验ShouldtheProjectorClienthaveaspecificloadtestrequirement,thisloadtestshallnotexceed100%oftheCraneorLiftingDeviceloadchartcapacity.ThesetestneedsareusuallyaresultofaHeavyorCriticalliftwherea"pre-lift"verificationofthecraneismandatedbytheproject.TheseTypesofprojectspecificloadtestsareinadditiontotherequired"ratedloadtests"previouslydiscussed.若项目或业主有特殊的载荷试验要求，该载荷试验不能超过起重机或提升装置负荷这些试验图能力的100%。这些试验需要通常是起因于大重量或关键吊装，项目指令进行起重机预吊装验证。这些项目特殊载荷试验是前面讨论的“额定载荷试验”以外的。6.0REFERENCES参考ApplicableJurisdictionalCodesandStandards适用的法规标准ConstructionProcedurePR-8710-0000-0009,CraneuseandOperation施工程序PR-8710-0000-0009，起重机使用与操作ConstructionProcedurePR-8710-0000-0007,CraneOperatorQualification施工程序PR-8710-0000-0007，起重机驾驶员资格ConstructionProcedurePR-8710-0000-0007,ConstructionRiggingWorkOperations施工程序PR-8710-0000-0007，施工索具操作7.0ATTACHMENTS附件AttachmentA-"Example"LoadTestForm附件A-载荷试验表示例

ATTACHMENTA(Form8710-0000-0010-A-Rev02)附件A(表格8710-0000-0010-A-Rev02)“EXAMPLE”LOADTESTFORM载荷试验表-示例WitnessSignature 见证人签宇DateCraneConfiguration&OperationDescription起重机构造及操作