槽鋼基礎吊裝及安裝方案.doc

拜耳異氰酸酯和聚醚項目 TDI聯(lián)合裝置基礎設施BAYER ISOCYANATE & PET PROJECT TDI TRAIN-INFASTRUCTUREPCS樓C581、B551，C403R118盤柜槽鋼基礎吊裝及安裝施工方案PCS Building C581, B551, C403R118 Cabinet Channel Base Hoisting Construction Plan編 制： 陳 健Compiled by: Chen Jian審 核：Reviewed by:審 批：Approved by 中國核工業(yè)第五建設公司拜耳項目部China Nuclear Industry Fifth Construction Corporation Bayer Project Department 二九年十月十八日October 18, 200921Construction Plan Approval Form施工方案審批表Project Name工程名稱Bayer isocyanates and polyether project TDI combination unit Infrastructure拜耳異氰酸酯和聚醚項目TDI聯(lián)合裝置-基礎設施Structure Type結構類型Frame-wall, local steel框剪，局部鋼結構Construction Unit建設單位Bayer Polyurethanes(shanghai)Co.,Ltd拜耳（上海）聚氨脂有限公司ManagementCompany管理公司M+D ZANDER美斯威爾Supervision Unit監(jiān)理單位Construction Unit施工單位China Nuclear Industry fifth Construction Corporation中國核工業(yè)第五建設公司Compilation Section編制部門China Nuclear Industry fifth Construction CorporationBayer Project Department中國核工業(yè)第五建設公司拜耳項目部Compiled by編 制 人Jian Chen陳 健Compilation Date編制時間October 18, 20092009年10月18日Submission Date報審時間October 18, 2009 2009年10月18日ApprovalSection審批部門Approval Date審批時間Year Month Day 年 月 日 Approved by 審 批 人Program Name方案名稱Bayer Isocyanate & PET Project TDI Train InfrastructureHoisting Construction Plan 拜耳異氰酸酯和聚醚項目 TDI聯(lián)合裝置基礎設施吊裝及安裝方案審批意見：（填寫討論的主要結論 包括應修改的部分）Views of Approval:(Fill the main conclusions of the discussion, including the amended part)目 錄 Contents1. 工程概況General statement 2. 項目組織機構Project organization3. 編制依據(jù) Compilation basis 4. 槽鋼基礎運輸路線及吊機站位平面圖（見附圖）Drawing of channel base transportation routes and stations of cranes (see attached drawing)5. 吊裝步驟 Hoisting steps6. 索具選擇Rigging options 7. 施工機具配備 Construction equipment and tools 8. 吊裝操作流程 Hoisting operating process9. 吊裝工作應注意的安全事項 Safety matters of hoisting work10. 質量標準 Quality standards 11. 起重吊裝的指揮和吊裝工藝崗位的分工 Command & division of labor of hoisting process12. 吊裝作業(yè)風險評價報告 Risk assessment of hoisting work 13. 作業(yè)應急預案Emergency planPCS樓C581、B551，C403R118盤柜槽鋼基礎吊裝施工方案PCS Building C581, B551, C403R118 Cabinet Channel Base Hoisting Construction Plan1 工程概況General statement1.1本方案屬于拜耳異氰酸酯和聚醚項目TDI聯(lián)合裝置-基礎設施-PCS樓C581、B551，C403R118盤柜槽鋼基礎吊裝及安裝施工方案。配電柜基礎總共有大小120多個。所有配電柜基礎均為10#槽鋼制作，材質為碳鋼，外表采用聚氨脂涂料。采取場外預制，現(xiàn)場安裝。預制完成的槽鋼基礎大小不等，最大規(guī)格為8000*1000*800mm。重量為：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為三層框架結構，槽鋼基礎分別安裝在二層、三層。二層地面標高為7m，三層地面標高為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為四層框架結構，槽鋼基礎分別安裝在二層、三層、四層。二層地面標高為5.4m，三層地面標高為9.9m，四層地面標高為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 吊裝組織機構Hoisting OrganizationCommander: Chen Jian現(xiàn)場總指揮:陳健Material:WuXuefei 材料: 徐兵Equioment:YinHaihua設備: 印海華Tecnology:WuHaidong技術: 吳海東Safety:安全:程宗強Quality: Xu Bin質量:吳雪飛Hoisting commander:吊裝指揮: 徐永德:2.1.1 吊裝總指揮對吊裝工作的總體運行進行協(xié)調控制,提供資源保證。The commander in chief coordinates and controls the overall hoisting operation and provides resources.2.1.2 吊裝現(xiàn)場指揮負責組織吊裝方案的實施應由有實踐經(jīng)驗、技術水平較高、組織能力較強的人擔任，應充分了解并嚴格執(zhí)行起重施工技術文件的規(guī)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 材料負責人根據(jù)吊裝工作所需要的器具和材料及時供應,并做到質量保證. The one who is responsible for materials should timely supply the required hoisting equipment and materials and ensure the quality.2.1.4設備負責人負責對進場施工設備的狀況進行核實確，負責設備的日常維護管理,參與風險評估工作. 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技術人員負責吊裝技術指導,參加技術交底,參加技術攻關工作,參與風險評估和吊裝的檢查確認. Technical staff is responsible for hoisting technical guidance, participates in technical disclosure and research work and engages in risk assessment.2.1.6質量負責人負責審查、確認特殊作業(yè)人員上崗資格，參加到貨設備的檢查和驗收，組織設備基礎的驗收、檢查確認施工質量。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. 編制依據(jù)Compilation Basis3.1 浙江美陽國際石化醫(yī)藥工程設計有限公司繪制的施工圖 Drawings of Zhejiang Meiyang International Petrochemical Pharmaceutical Engineering Co., Ltd. 3.2 電氣裝置安裝施工及驗收規(guī)范Specifications of electrical installation construction and acceptance.3.3 鋼結構工程施工及驗收規(guī)范 GB 50205-2001 Steel Structure Construction and Acceptance Norms GB 50205-20013.4 建筑施工高處作業(yè)安全技術規(guī)范JGJ80-91 Building Construction Height Works Safety Technical Code JGJ80-913.5 實用起重吊裝手冊Practical Hoisting Manual4.0 設備進場路線 Equipment Delivery Route5.0 吊裝步驟 Hoisting steps施工方案編制（批準）施工準備（場地、路線、機索具）機索具的檢查吊裝前交底設備方位確認吊車的就位設備進入吊裝位置卸車吊裝設備就位吊車脫鉤吊車退場清理場地 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 根據(jù)本項目的槽鋼基礎參數(shù)、結構特點和施工現(xiàn)場條件，用機械吊裝能滿足設備吊裝要求。經(jīng)過反復計算和論證后，采用16噸汽車吊。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噸汽車吊站位在C581、B551東側，設備運輸車開到指定位置。The 16-ton truck crane locates in east of C581 and B551 and equipment vehicles drive to the specified location.5.1.3 16噸汽車吊，吊車伸20米臂桿到槽鋼基礎中心位置，吊鉤緩緩放下。使用兩根12mm麻繩做設備溜繩起吊時控制設備的穩(wěn)定性。吊裝區(qū)域拉上警示帶掛上警示牌有專職安全員負責管理，無關人員不準入內。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 吊裝準備工作結束檢查無誤后準備起吊，先車同時拉緊吊帶慢慢起鉤讓設備離車20cm停下觀察每一根吊帶的受力情況、卸扣是否完全站立、吊車的穩(wěn)定性如何。當一切檢查正常后聽從指揮吊車慢慢起鉤，讓設備平穩(wěn)的吊起來。把設備吊運指定位置有安裝工慢慢松鉤、摘鉤，吊裝結束。注：在進行汽車吊室外設備吊裝是一定要設置吊裝區(qū)域保護拉上警戒線，非吊裝人員嚴禁入內。有專職安全員負責安全警戒。保證工作安全順利進行。?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 施工現(xiàn)場吊裝繩采用合成纖維吊裝帶，或者扁平型的吊裝帶，計算校核：a)槽鋼基礎參數(shù) 最大設備規(guī)格：8000*1000*800 設備重量: 0.54T 安裝標高： C581 EL+7.0 00m，+11.800m；B551 +5.4m，+9.9m，+14.4m。 b). 1.合成纖維吊裝帶合成纖維繩的破斷拉力為(僅為數(shù)據(jù)估算用,非規(guī)范公式) Sp=110d2 其許用拉力為 P=Sp/K 式中P許用拉力，N; Sp破斷拉力，N; d合成纖維繩直徑，mm; K安全系數(shù)，合成纖維繩的安全系數(shù)可根據(jù)工作時用狀況的重要程度選取，但不得小于6。 現(xiàn)取K=7，P=mg=540kg*9.8N/kg=5292N，則Sp=PK=5292*7=37044N，計算： d=18.35mm故：合成纖維繩可取25mm。2.扁平型的吊裝帶扁平吊帶（索）webbing sling ： 織帶寬度： 25mm 拉力能力500kg，最小破斷力1000kg 織帶寬度： 35mm 拉力能力1000kg，最小破斷力2000kg 織帶寬度： 50mm 拉力能力2500kg， 最小破斷力5000kg 織帶寬度： 75mm 拉力能力3500kg，最小破斷力7000kg 可取35mm寬度的吊裝帶。栓掛方式:1彎2股受力分析 S=G/n*1/sin式中:G-設備、吊索、吊鉤及重量,取G=0.6T -吊索之間的夾角, =60 n- 繩索的股數(shù),n=2 S-每根吊索的拉力S=(0.6/1)*(1/sin60)=0.346 T受力計算 T= Sp /K式中 T-吊裝帶的容許拉力 Sp -吊裝帶的破斷拉力 K-安全系數(shù),K=7合成纖維吊裝帶T=3.7/7=0.529T S符合扁平型的吊裝帶T=2/7=0.286T S 符合C).吊機吊裝計算吊機性能選用16噸汽車吊回轉半徑9m 臂桿長度25m 起吊最大能力3.3T臂桿傾角計算 a=arc cos (S-F)/L =arc cos (9-1)/25 =71式中: S-吊車回轉半徑,選S=9m F-臂桿底鉸盤至回轉中心的距離,F=1m L-吊車臂桿長度,選L=25m7.0 吊裝操作流程 Hoisting operating process7.1 由項目部有關部門會同吊裝專業(yè)有關人員進行聯(lián)合檢查，全部確認后聯(lián)合（包括項目經(jīng)理）簽發(fā)起吊后才可進行吊裝。Carrying out hoisting after being inspected and confirmed by relevant departments and professional personnel of the project and signed together (include PM).7.2 所有各項準備工作完備后進行試吊，試吊要求吊耳點抬高200-500mm，檢查內容為： 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 所有索具情況,吊車負荷情況,地基變化情況,吊耳及殼體情況. Include rigging, crane loads, ground changes, lug and shell conditions.7.4 試吊如出現(xiàn)問題則及時放回原位針對這些問題進行整改，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 現(xiàn)場吊裝指揮協(xié)調主吊吊車的變幅度速度，要求始終保持主吊車吊臂與設備在水平面上投影相垂直，吊鉤始終保持與地面相垂直,然后再提升至安裝位置。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 槽鋼基礎吊至安裝高度后，一端放在手動液壓車上，另一端放在滑輪上，進行水平運輸，運到安裝位置后用龍門架就地放下。對于比較小的槽鋼基礎，用液壓車水平運輸?shù)轿缓螅斯ぬ隆?.7 槽鋼基礎安裝前，先按施工圖紙所標位置，進行施工放線，放線完成后，將預制好的基礎型鋼架放在正確位置上，用水準儀或水平尺找平、找正。用12膨脹螺栓固定。找平過程中，需要用墊鐵的地方最多不能超過三片。然后，將墊鐵用電焊焊牢?；A型鋼安裝允許偏差下表。基礎型鋼安裝允許偏差 項目允許偏差mm/mmm/全長不直度13水平度13位置誤差及不平行度58.0 吊裝工作應注意的安全事項: Safety matters of hoisting work8.1吊裝施工準備和實施過程中安全質量保證體系必須要保證正常運轉,以確保吊裝工程達到安全優(yōu)質的要求.吊裝前必須進行安全質量檢查,并要符合化工工程建設起重施工規(guī)范(HGJ201-83)以及其他規(guī)程、規(guī)范的規(guī)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 起重作業(yè)人員應熟知施工方案、起重設備性能、 操作規(guī)程、指揮信號和安全要求。Hoisting operators should be familiar with the construction plan, lifting equipment performance, operational procedures, command signals and safety requirements. 8.3 起重機械和索具應具有出廠合格證. Lifting machines and riggings should have the factory certification. 8.4 起吊作業(yè)前,應在重物上系以牢固的溜繩,防止吊裝過程中重物擺動、旋轉或碰撞其他建、構筑物。Before hoisting, weights should be wrapped with solid slide ropes to prevent swinging, rotating or colliding other built structures.8.5 吊起的重物不得長時間空中停留,嚴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吊裝用吊帶應受力均勻,在使用過程中應經(jīng)常檢查吊帶有無斷絲、扭結、彎折、磨損、而引起的損壞等現(xiàn)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 吊裝性能應滿足吊裝工藝要求,警報和液壓系統(tǒng)必須可靠. Hoisting performance should meet the technical requirements. Alarm and hydraulic systems must be reliable.8.9 吊鉤偏角不應大于30The deflection angle of the drop hanger should not be more than 30.8.10 禁止用吊車在地面上直接拖拉設備. Prohibit using cranes to haulage equipment directly on the ground.8.11 設備吊裝前應進行試吊,試吊前,參加吊裝的人員應按分工,嚴格檢查吊耳,機械及索具的裝設情況,達到要求后試吊,試吊時重物離地面200500mm,應觀測吊裝凈距及吊車支腿處地基變化情況,發(fā)現(xiàn)問題應先把設備放回地面,故障排除后重新起吊,方可正式吊裝. 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 吊裝過程中,應保持動作平穩(wěn),待設備就位后應及時找正找平,設備未固定前不得解開吊裝索具. 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 吊裝時,任何人不得隨同設備或吊裝索具上下. During hoisting, nobody can go up and down accompanying the equipment or hoisting rigging.9.0 質量目標與質量保證措施Quality objectives and assurance measures9.1 質量目標Quality objectives精心組織、精心施工、爭創(chuàng)優(yōu)良工程Careful organization and construction and striving for excellent project9.2 質量保證措施Quality assurance measures9.2.1建立以項目部總工程師領導的質保體系,認真搞好”五關”圖紙會審關、方案編制關、設備驗收關、施工工序質量檢查關和資料收集關。使質量在各個環(huán)節(jié)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,技術人員應認真對施工班組進行技術交底,要有追蹤性,在施工過程中要嚴格執(zhí)行”三檢查”原則. 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在施工過程中,要嚴格按照方案、規(guī)程規(guī)范進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 起重吊裝的指揮和吊裝工藝崗位的分工Hoisting command and labor division10.1 起重吊裝的指揮協(xié)調工作Command and coordination (1)凡參加吊裝的施工人員,必須堅守崗位,并根據(jù)指揮者命令進行工作. Workers participating in hoisting construction must stick to their posts and work under the commanders order. (2)指揮者應把信號向全體工作人員交代清楚,明確各人的崗位職責.哨音必須正確、響亮、旗語應清楚. 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）在吊裝作業(yè)中，為了保證正確，及時地下達信號，可在指揮者領導下，各吊裝崗位的指揮工作，必須分工明確，緊密配合。, 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）指揮者應站在能看到吊裝全過程并被所有施工人員全能看到的位置上，以利直接指揮各個工作崗位，否則應通過助手及時傳遞信號。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）指揮者及操作人員應使自己的視覺、聽覺不受阻礙。The commander and operators should make their own vision and hearing not impeded.（6）吊裝過程中，任何崗位出現(xiàn)故障，必須立即向指揮者報告，沒有指揮者的命令，任何人不得擅自離開崗位。 During lifting process, find any failure must immediately report to the commander. No one can leave their posts without commanders permission.（7）吊裝工藝崗位的分工 labor division of hoisting technology序號Serial No. 崗位號Post no. 崗位名稱 Posts職責Responsibility11-0吊裝指揮Hoisting commander具體指揮吊裝全過程的工藝操作。Command the whole process1-1吊車司機Crane driver執(zhí)行吊裝指揮命令、準確、平穩(wěn)操作、吊車動作。Carry out the commanders order and operate the crane correctly and stablely.1-2設備就位Equipment 負責設備的就位找平找正,做好安裝記錄aligning and leveling equipment and make installation record1-3預備隊Reserve team執(zhí)行吊裝指揮命令,排除吊裝故障. Carry out the commanders order and eliminate the hoisting failure。11.0 起重施工安全技術措施如下: Safety technical measures are as follows:1 凡參加施工的人員，必須熟悉起吊方法的工程內容，按方案要求進行施工，并嚴格執(zhí)行規(guī)程規(guī)范。Workers involved in the construction must be familiar with the lifting contents, construct according to program requirements and strictly implement the specifications.2 在施工過程中，施工人員必須具體分工，明確職責，在整個吊裝過程中，要切實遵守現(xiàn)場秩序，服從命令聽指揮，不得擅自離開工作崗位。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 在吊裝過程中，應使用國家統(tǒng)一規(guī)定的指揮信號，參加施工的全體人員必須熟悉此信號，以便各操作崗位協(xié)調動作。 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 吊裝時，整個現(xiàn)場由總指揮調配，各崗位分指揮應正確執(zhí)行總指揮的命令，做到傳遞信息迅速、準確，并對自己負責的范圍內負有責任。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 在整個施工過程中要做好現(xiàn)場清理，清除障礙物，以利操作。Do the on-site clean-up. Remove obstructions to facilitate the operation.6 施工中凡參加登高作業(yè)的人員，必須經(jīng)過身體檢查并合格，操作時要佩戴安全帶，并系在安全可靠的地方，工具應有保險繩，不準隨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 施工人員必須頭戴安全帽。如冬季施工，應將護耳放下，以使聽覺不受阻礙。Wear helmets. If it is winter construction, put down earmuffs so that hearing is not impeded. 8 帶電的電焊線和電線要遠離鋼絲繩，帶電線路距離