二次吊装方案制作吊架

TableofContentsTOC\o"1-1"\h\z\u1.工程概况2WorkOverview22.吊装要求4LiftingRequirements43.施工程序5ConstructionProcedure54.吊装方法6BriefDescriptionofLiftingMethod65.层吊梁焊接66.挂设吊装用倒链77.PM21-FB002的二次吊装7The2ndLiftingPM21-FB00278.PM21-FB001的二次吊装10The2ndLiftingPM21-FB001109.PM21-FB003的二次吊装11The2ndLiftingPM21-FB0031110.现场清理16Clearsite1611.技术安全要求16Technical&SafetyRequirements1612.工机具及材料计划18Tools&Equipment,MaterialsPlan1813.吊装施工人力资源计划19LiftingConstructionManpowerPlan1914.吊架型钢受力分析19工程概况WorkOverview编制说明NotesforPreparation概述General为了使PM21-FB001/FB002/FB003三台设备的二次吊装就位正常有序地进行,保证起重工作的安全，根据力求施工成本最低、施工周期最短、确保技术可靠的方案编制原则，根据国家、业主的规范要求，特编制此吊装方案，以说明吊装施工方法、施工用料、吊装顺序。Inordertoensurenormalandproperfieldloading,2nd-timetransportationandliftingof3setsofequipmentPM21-FB001/FB002/FB003safetyandsuccessfulcompletionofthework,thisliftingprocedureisspeciallypreparedasperthenationalstandardsandtheOwner’sspecificationrequirementsintheprincipleoflowestconstructioncost,shortestconstructiondurationandreliabletechnologytoelaboratetheliftingconstructionmethod,constructionmaterialsandliftingsequence.我方于20007年7月19日用ATF110-5110t吊车将PM21-FB001/002/003连带运输鞍座水平的吊装到层，暂时存放在5/6轴线与A/D轴线之间，其具体放置位置如下图所示：OnJuly19,2007,CNI23liftedtheequipmentsPM21-FB001/FB002/FB003togetherwiththeirtransportationsaddlehorizontallytothefloor,placingthemtemporarilyaxis5/6andA/DbyusingATF110-5(110t)crane.Specificpositionisshownasbelow:图1第一次吊装放置平面示意图Sketch1Primaryliftingpositionplanview图2第一次吊装放置剖面示意图Sketch2Sectionviewfortheprimaryliftingposition编制依据References有关设计技术文件;Relevantdesigndocuments；设备到货后的实际参数重量Changedweightafterequipmentdeliverytosite;；国家及BAYER公司相关规程、规范、标准；Nationalcodes&standards,relevantBayerspecifications;化学工业建设起重施工规范HGJ201-83；ConstructionCodeforChemicalIndustryConstructionLifting HGJ201-83;我公司BAYER项目部所拥有的工具、索具；ToolsandriggingsownedbyourBayerprojectmanagement;吊装与运输任务Lifting&TransportationWork在本次施工中，需完成下表所列设备的装车、现场二次运输及吊装就位。Duringthisconstruction,theloading,field2nd-timetransportationandliftingoftheequipmentlistedinthefollowingtablearerequiredtobecompleted.设备参数：Equipmentparameters:TagNo.位号Inst.Elevation安装标高mLocation位置Dia.直径Length长度NetWt.净重tPM21-FB002B~D\5~6D=25005780PM21-FB001B~C\5~6D=28006600PM21-FB003B~C\5~6D=25005780设备位置如下图所示Theequipmentlocationsareshownasthefollowingsketch图3/设备就位位置图Sketch3:Equipmentin-positionsketch设备吊装顺序LiftingsequencePM21-FB002--→PM21-FB001--→PM21-FB003在进行二次吊装的时候，主要是确保PM21-FB001先于PM21-FB003吊装就位，否则PM21-FB003将没有翻转竖立的空间。During2ndlifting,thein-positionofPM21-FB001shouldbedonepriortoPM21-FB003,ortherewillbenospacefortheturnoverofPM21-FB003.吊装要求LiftingRequirements中建已经将的钢梁安装完毕。ThesteelbeamonelevationhasbeeninstalledbyCSCECandisqualifiedthroughacceptance.吊装设备用的吊架制作完毕并检验合格。Liftingsupportsheavedfabricatedandinspectedrightly.将3个吊架安装到层钢梁上，吊架上的吊耳分别位于3个设备的就位中心。Liftingthethreeliftingsupportsonsteellayerbeamsandinstallationonbeams,maketheluglocateoneachequipmentpositioncenter.在每台设备吊装之前安装好顶部盲板吊具。Blindplateliftingtoolshouldbeinstalledproperlybeforeliftingequipment.层的钢梁与吊架上的倒链拴挂完毕。在钢梁与钢丝绳圈之间垫一层厚橡皮垫或者1/4圆钢管，胶皮垫与圆钢管用铁丝绑在钢梁上。Chainblockonthefloorhasbeenfixedproperly.Padalayerofrubbercushionor1/4roundsteeltubebetweenthesteelbeamandsteelrope;rubbercushionandroundsteeltubeisfixedtothebeambyironwire.图4钢梁上倒链挂设示意图Sketch4Sketchforthechainblocktobeusedonthebeamofelevation注：除了标明的2个20t与4个10t倒链外，其余的均为5t倒链，5t倒链可以在吊装就位完一台设备之后再安装吊装另一台设备的倒链。Note:Exceptthetwo20tandfour10tchainblocksindicated,otherchainblocksareall5t.The5tchainblockfortheliftingofnextequipmentcanbeinstalledafterthefirstequipmentisliftedin-position.在层钢梁上设置好生命索。Properlysetthelifelineonthebeamonthefloor.施工程序ConstructionProcedure设立吊装警戒线Setalarminglineforlifting↓层安装吊架Installliftingsupports↓层挂设倒链Fixchainblockonthefloor↓安装盲板吊具InstallblindplatetoolforLifting↓设备翻转竖立Liftequipmentupandturnitupright↓设备吊装就位Liftequipmentin-position↓安装弹簧吊架Installationspringhanger↓清理现场House-keeping吊装方法BriefDescriptionofLiftingMethod在设备的顶部与尾部两端连接倒链，倒链的另一端连接在拴挂在钢梁上的钢丝绳圈上，通过倒链将设备翻转竖立，然后移位到安装位置就位，等安装好弹簧吊具后，拆除倒链，完成整个设备的安装就位过程。Fixchainblocktotheequipmenttopandend;connecttheotherendofthechainblocktotheironroperingonthesteelbeam;turnandsettheequipmentuprightbychainblock,thenmovetheequipmenttotheinstallationlocation;afterthespringliftingtoolisinstalled,removethechainblock,thencompletetheentireequipmentinstallationandin-positionprocess.层吊架焊接Liftingsupportweldingatthefloor.待土建钢结构复位完成，检查合格以后，我们即可25t以上吊车将3个吊架吊到PM21-FB001/002/003钢结构基础的横梁上面，吊架距离5轴线1250mm平行摆放，将吊加立柱与钢梁段接固定。安装位置如图4所示，吊架的具体计算见后。Uponcompletionofsteelstructurerestorationanditisacceptable,lift3liftingsupportsontomainbeamsofstructurefoundationforPM21-FB001/002/003,fixthesupportonthesteelbeambywelding;puttheminparallelwithadistanceof1250mmtotheaxis5.Seethesketch4.BearingforcecalculationofliftingsupportintheendoftheplanPM21-FB003的临时吊架需要从已经安好的钢结构支架间穿入安装，它们之间的尺寸间距如下图所示。TheliftingsupportforPM21-FB003needthroughinthesteelsupportinstalledonlayerbeams,spacebetweenofthemasthefollowingsketch.图5PM21-FB003钢结构支撑与临时吊架之间间距示意图Sketch5spacebetweenofsteelsupportandliftingsupport挂设吊装用倒链Fixchainblockforlifting按照图4所示挂设二次吊装用倒链，除了标明的2个20t与4个10t倒链外，其余的均为5t倒链，5t倒链可以在吊装就位完一台设备之后再安装吊装另一台设备的倒链。Fixchainblockusedfor2ndliftingaccordingtosketch4;Exceptthetwo20tandfour10tchainblocksindicated,otherchainblocksareall5t.The5tchainblockfortheliftingofnextequipmentcanbeinstalledafterthefirstequipmentisliftedin-position.PM21-FB002的二次吊装The2ndLiftingPM21-FB002拆除N1法兰的盲板，安装盲板吊具，。在N1法兰面与盲板吊具之间需垫上一层薄胶皮，防止损坏N1法兰面。盲板吊具用28个M30的镀锌螺栓安装，锁紧垫圈与螺母。在拆除N1法兰盲板到盲板吊耳安装完毕的过程中注意不要污染设备内表面。RemovetheblindplateofflangeN1,andinstalltheblindplateliftingtool.PadalayerofthinrubbercushionbetweentheflangeN1faceandblindplateliftingtooltopreventdamagetoflangeN1face.Theblindplateliftingtoolisinstalledby28galvanizedM30bolts.使用爬梯，在设备顶部的位于水平方位（设备0°与180°方位）的两个吊耳上分别各连接2个5t倒链，在盲板吊耳上连接一个20t倒链，在设备的尾部吊耳上连接一个10t倒链。Useladdertofixtwo5tchainblockstoeachofthetwohorizontalliftinglugs(atdirectionof0°and180°oftheequipment)ontopoftheequipment;fixone20tchainblocktotheliftinglugoftheblindplate,andfixa10tchainblocktotheliftinglugattherearoftheequipment.图6PM21-FB002倒链连接示意图Sketch6:chainblockfixingforequipmentPM21-FB002拆除设备与运输鞍座之间的紧固绳。Removethefixingropebetweentheequipmentandthetransportationsaddle.拉紧与设备本体连接的4个5t倒链与1个10t倒链，将设备提起200mm，移走运输鞍座。Tightthefour5tchainblocksandone10tchainblockfixedtotheequipmentbodytolifttheequipment200mmupandremovethetransportationsaddle.图7PM21-FB002提起200mm移走鞍座示意图Sketch7:LiftingequipmentPM21-FB002uptoremovethesaddle通过5个倒链的配合，将设备翻转竖立。稍微拉紧20t倒链。Turnandsettheequipmentuprightthroughthejointhandlingofthefivechainblocks.Tightthe20tchainblockslightly.图8PM21-FB002翻转竖立示意图Sketch8:SettingtheequipmentPM21-FB002upright拆除尾部翻转倒链。Removetheturningchainblockattherear通过连接在设备顶部的4个5t倒链使PM21-FB002的中心位于安装中心。PuttheequipmentPM21-FB002centerinpositionbyfour5tchainblocksfixedontheequipmenttop拉紧20t倒链，使其逐步承受PM21-FB002的全部重量。Tightthe20tchainblocktomakeitbearalltheweightofPM21-FB002gradually.调整设备方位与设备标高，使其施工图纸上的要求相一致。Adjusttheequipmentlocationandelevationaccordingtotheconstructiondrawing.在设备上的两外两个吊耳上（设备90°与270°方位）安装弹簧吊具。Fixspringliftingtoolstothetwoliftinglugs(atthedirectionof90°and270°)ontheequipment.挂设好安全带，拆除连接在PM21-FB002设备本体吊耳上的4个5t倒链。Fixtheliftingbeltssecurelyandremovethefour5tchainblocksfixedtothefourliftinglugsontheequipmentPM21-FB002body.拆除安装在层钢梁上吊装PM21-FB002的5个倒链。RemovethefivechainblocksonthebeamusedtoliftequipmentPM21-FB002onthe25.63floor.图9PM21-FB002就位时倒链剩余长度示意图Sketch9:RemainingchainblocklengthwhenPM21-FB002isin-positionPM21-FB001的二次吊装The2ndLiftingPM21-FB001按照图4所示挂设好吊装PM21-FB001的倒链，由于设备重量为，连接在设备盲板吊具上倒链载荷量为10t。FixchainblockusedtoleftequipmentPM21-FB001asshownonthesketch4;astheequipmentweights8.5t,theloadofchainblockfixedtotheblindplateliftingtoolis10t.按照吊装PM21-FB002的方法完成PM221-FB001的二次吊装就位。Completethe2ndliftingandin-positionforequipmentPM221-FB001throughthewayusedtoliftPM21-FB002.图10PM21-FB001就位时倒链剩余长度示意图Sketch10:RemainingchainblocklengthwhenPM21-FB001isin-positionPM21-FB003的二次吊装The2ndLiftingPM21-FB003按照图4所示挂设好吊装PM21-FB003的倒链。FixchainblockusedtoleftequipmentPM21-FB001asshownonthesketch4拆除N1法兰的盲板，安装盲板吊具，。在N1法兰面与盲板吊具之间需垫上一层薄胶皮，防止损坏N1法兰面。盲板吊具用28个M30的镀锌螺栓安装，锁紧垫圈与螺母。在拆除N1法兰盲板到盲板吊耳安装完毕的过程中注意不要污染设备内表面。RemovetheblindplateofflangeN1,andinstalltheblindplateliftingtool.PadalayerofthinrubbercushionbetweentheflangeN1faceandblindplateliftingtooltopreventdamagetoflangeN1face.Installtheblindplateliftingtoolby28galvanizedM30bolts,andthenfixthewashersandnuts.PayattentioninordernottocontaminatetheinnersurfaceofequipmentintheprocessofremovingblindflangeN1andinstallingliftinglugforblindflange.使用爬梯，将挂设在层横梁上的4个倒链与设备本体90°与270°方位的两个吊耳连接，将挂设在吊架上的20t倒链与盲板吊具连接。Useladdertoconnectthefourchainblocksfixedtothebeamonthefloortothetwoliftinglugsatthedirectionof90°and270°oftheequipmentbody,andconnectthe20tchainblockfixedtoHW175andtheblindplateliftingtool.图11PM21-FB003倒链连接示意图Sketch10:ChainblockfixingforPM21-FB003拆除设备本体与设备鞍座之间的紧固绳。Removethefixingropebetweentheequipmentbodyandthesaddle.拉紧连接在设备顶部的4个5t倒链，配合第一次吊装时留在尾部的1个10t倒链，将PM21-FB003提起200mm，移走设备运输鞍座与临时道木。Tightthefour5tchainblocksontopoftheequipment,andalsousethe10tchainblockontheequipmentrearusedinthefirstliftingtoraisetheequipmentPM21-FB003200mmupandremovethetransportationsaddleandtemporarysleeper.图12/Sketch12PM21-FB003提升200mm移走运输鞍座示意图Sketch12:raisetheequipmentPM21-FB003200mmupandremovethetransportationsaddle通过连接在设备顶部吊耳上的4个5t倒链与第一次吊装时的10t倒链，将PM21-FB003向C轴方向移动。Usethefour5tchainblocksfixedtotheliftinglugontopoftheequipmentandthe10tchainblockusedinthefirstliftingtomoveequipmentPM21-FB003towardsaxisC.图13PM21-FB003向C轴移出示意图Sketch13:movetheequipmentPM21-FB003outofaxisC通过上述5个倒链与连接在设备尾部吊耳上的另一个10t倒链，将PM21-FB003翻转45°。Usetheabove-mentionedfivechainblocksandanother10tchainblockfixedtotheequipmentreartoturntheequipmentPM21-FB003forty-fivedegree.图14PM21-FB003翻转45°示意图Sketch14:turn45°fortheequipmentPM21-FB003拉紧连接设备尾部吊耳上靠近B轴的10t倒链，使其承受溜尾载荷，拆除第一次吊装时保留的10t倒链。Tightthe10tchainblockfixedtotheliftinglugattheequipmentrearandclosetoaxisB,tobearthetailingloadandremovethe10tchainblockleftoverbythefirstlifting.继续起升设备顶部的倒链，通过溜尾倒链的配合将PM21-FB003完全翻转。Continuetoliftthechainblockontopoftheequipment,andalsousethetailingchainblocktoturntheequipmentPM21-Fm003.图15/Sketch15PM21-FB003翻转竖立示意图setandturntheequipmentPM21-FB003upright拆除溜尾用10t倒链。Removethe10ttailingchainblock.通过连接在设备顶部吊耳上的4个5t倒链将设备向5轴移动，使PM21-FB003的中心距离5轴1250mm。Usethefour5tchainblockfixedtoliftinglugontopoftheequipmenttomovetheequipmenttowardaxis5,tomakethecenterofequipmentPM21-FB003hasadistanceof1250mmtoaxis5.图16PM21-FB003中心就位示意图Sketch16:EquipmentPM21-FB003centerin-position同时拉紧连接在盲板吊具上的20t倒链，使其承受PM21-FB003的全部载荷。Tightthe20tchainblocksfixedtotheblindplateliftingtooltomakethembearalltheloadfromPM21-FB003.拆除与设备本体吊耳连接的4个5t倒链，将靠近6轴线两个5t倒链中的一个与盲板吊耳连接。Removethefour5tchainblocksconnectedtothelugsofequipment,connectoneofthe5tchainblocksthatisclosetotheaxis6withblindplatelug.通过连接在设备盲板吊耳上的两个倒链将PM21-FB003拉向6轴线，偏移距离约800mm，以满足设备顺时针旋转90°不碰撞5/B轴上的立柱。GetthePM21-FB003closetotheaxialline6withtheassistanceoftwochainblocksconnectedtotheblindplatelugsofequipmentabout800mmnottotouchtheposton5/Baxiswhenrotatingclockwise90°图17/Sketch17PM21-FB003向6轴偏移800mm示意图在层，用爬梯在设备上拴牵引绳，将PM21-FB003顺时针旋转90°，使设备方位满足安装要求。在旋转的时候，要注意避免设备接管嘴与PM21-CA001、立柱相碰撞。Fixcontrolropetotheequipmentonthe16.4floortoturnit90°inanticlockwisedirectiontomeettheinstallationrequirement.TurningshouldbedonewhileliftingtopreventcollisionofequipmentoutletwithPM21-CA001.将PM21-FB003再次移到设备就位中心。PutPM21-FB003centerin-positionagain.通过20t倒链提升PM21-FB003，使其标高满足安装要求。ContinuetoliftPM21-FB003totheappropriateelevationbyusing20tchainblocktomeettheinstallationrequirement.在设备本体90°与270°方位的两个吊耳上安装弹簧吊具。Installspringliftingtooltothetwoliftinglugsatthedirectionof90°and270°withtheequipmentbody.拆除连接在层的4个5t倒链。Removethefour5tchainblocksonthefloor.现场清理Clearsite用三防布包裹好挂设在吊架上的2个20t倒链和1个10t倒链。Parceltwo20tchainblocksandone10tchainblockhangoverliftingsupportswiththreeguardcloths.拆除其他所有的倒链。Removeotherchainblocks.恢复第一次吊装时拆除的灯具与报警器。Resumethelumpsandalarmremovedforthefirstlifting.清理吊装现场，整理清理吊装工机具设备。Clearliftingsite,cleanupliftingtools.注：吊架与挂设在其上的3个倒链需要等到PM21-FB001/002/003上的管道安装完毕之后才能拆除。Notice:liftingsupportsandchainblockshangoverthemdon’tremoveuntilPM21-FB001/002/003connect技术安全要求Technical&SafetyRequirements钢丝绳圈与棱角接触处必须根据具体情况垫上胶皮或半圆钢管,半圆钢管上打孔,穿孔用铁丝固定住；Wrapthecontactlocationofwireropewithedgeandsharpcornerusingrubbersheetorsemi-roundsteeltubeoncase-by-casebasis.Drillholeonsemi-roundsteeltubeandfixthetubewithironwire;吊装过程中必须根据分工,有专人控制设备在空中的方向。控向人员必须恪守职守，绝对不能发生设备碰触混凝土立柱及其它物体现象；Duringlifting,assignspecialpersonneltocontrolequipmentorientationintheairaccordingjobdivision.Theorientation-controllingpersonnelmustfulfillhisduty.Collisionofequipmentwithconcretecolumnorotherobjectisabsolutelyforbidden.吊装过程中发现问题则进行处理直到保证安全继续起吊，无问题再由总指挥发出命令，无关人员撤离吊装区，继续起吊；Ifanyproblemfoundduringlifting,carryouttreatmentuntilthesafetyisguaranteed.Thecommandofnoproblemshallbeissuedbythechiefcommanderandthepersonnelirrelevanttoliftingshallwithdrawfromliftingarea,thentheliftingcontinues.起重工通过爬梯摘掉抬尾吊索，爬梯必须有人扶住；Theriggerpicksofftailingslingthroughaccessladderandtheaccessladdermustbeheldbyotherperson.设备安装就位后，起重工登高摘倒链时，必须系好安全带；Afterequipmentinstallationinposition,safetybeltshallbewornwhenriggerclimbshightopickoffchainblocks.起重机司机、起重工及其它参吊人员必须遵守国家有关安全规定、操作规程；Craneoperator,riggerandotherlifting-relatedpersonnelmustobserverelevantnationalsafetyrulesandoperationregulations;5级风以上、大雨、大雾天气禁吊；Noliftingisallowedincaseofwindoverlevel5,heavyrainandfog;指挥人员对吊装不同的设备时各倒链的动作先后顺序和步骤及吊索连接方式必须熟悉；Thecommandingpersonnelmustbefamiliarwithactionsequenceandstepsofeachchainblockandslingconnectionmethodduringliftingdifferentequipment;设备正式吊装前必须移走吊装路径上及地面各种障碍物Allobstructionsintheroadandonthegroundshallberemovedfromequipmentslocationsbeforeactuallifting;所用工、机具及起重机用前先检查，确保使用性能良好；Thetools&machinesandcranesshallbeinspectedinadvancetoguaranteegoodperformance;在吊装过程中，各参吊人员必须坚守岗位，严禁擅离职守；在操作过程中，必须服从统一指挥，严禁各行其是；Duringlifting,allpersonnelinvolvedinliftingshallholdtheirrespectivepositions;duringlifting,allthepersonnelshallabidebytheuniformcommanding.在施工区域周围应设立警戒线，无关人员禁止进入；Warninglineshallbesetuparoundtheconstructionareaandthepersonnelnon-relevantwithliftingshallbedenied;指挥人员观察要周密，信号要清晰Thecommandershallobservethoughtfullyandgiveclearsignal;；在吊装过程中，应尽量避免冲击和震动；Impactandshakingshallbeavoidedtothefurthestextentduringlifting;吊装前，所有参吊人员应参加吊装技术交底。Allthepersonnelinvolvedinliftingshallparticipateinliftingtechnicalinstructionspriortolifting.现场应备有良好的气割工具、足够气割用氧气、乙炔气等Thereshallbeenoughoxygenandacetylenegasesonsite;吊装前请通知相关施工单位撤离警戒线范围外；Priortolifting,informrelevantconstructionpartiestowithdrawouttheareaaroundbywarningline;施工现场附近应配有符合国家消防要求的灭火器。Fireextinguisherscomplyingwithnationalfirefightingrequirementsaroundconstructionspots.工机具及材料计划Tools&Equipment,MaterialsPlan序号.No名称Description规格Spec.数量Qty.单位Unit备注Remarks警戒绳Guardline100m米指挥哨Commandingwhistle3Ea.个盲板吊具Blindplateliftingtool3Ea.个配备84个M25×85镀锌螺栓84M25×85galvanizedbolts吊架Liftingsupport3个EA吊车CraneTR250M25tMobileCraneTR250M25t吨轮胎式起重机1Set台专用路基板，25吨吊钩Specialroadbedplate,50thook直梯Ladder6m1个Ea摘抬倒链Forpickingoffchainblock麻绳Hempropeφ12200m米控制设备在空中方向Controllingdirectionofequipmentintheair吊装带LiftingBelt5t×6m6Ea.根吊装带LiftingBelt1t×1m2Ea.根道木Sleeper20Ea.根卡环Shackle15t4Ea.个卡环Shackle5t6Ea.个卡环Shackle1t2Ea.个倒链Chainblock20tX6m（或6m以上）2台主吊用Formaincrane倒链Chainblock10tX6m（或6m以上）3台抬尾用Fortailingcrane倒链Chainblock5tX6m（或6m以上）4台钢丝绳WireropeΦ32x2根挂20t手拉葫芦Hung20thandchainblock钢丝绳WireropeΦ26x4根挂10t/5t手拉葫芦Hung10t/5thandchainblockRubberSheet胶皮适量保护吊带和设备、倒链与钢梁Protectliftingbeltandequipment、chainblockandsteelbeam跳板Board5块吊装施工人力资源计划LiftingConstructionManpowerPlan起重工Rigger6persons人吊装Lifting钳工Fitter2persons人配合监控与吊、安装焊工Welder1persons人制作吊具Fabricationofspreaderbar&liftingcage其它Other4persons人监控与配合Monitoring安检Safetyinspector2persons人安检Safetyinspector吊架受力分析CalculationofBearingForceofliftingsupport吊具材料表MaterialListforblindplate