钢架安装措施含吊装措.doc

CSPC Nanhai Petrochemicals ProjectSEPCO Electric Power Construction CorpCSPC NANHAI PETROCHEMICALS PROJECT南 海 石 化 项 目INSTRUCTION FOR ERECTION OF BOILER STEEL STRUCTURE锅炉钢架安装作业指导书WORKING INSTRUCTION： WI-8710-8100-2007SEPCO Electric Power Construction Corporation山东电力基本建设总公司SEPCOREVDATEREASON FOR ISSUEBYCHKDQAAPPRA1 NOV 2003Issued for ReviewJi ShenboGao HuamingZhao XieShi DepingB12 NOV 2003Issued for ApprovalJi ShenboGao HuamingZhao XieShi DepingC13 NOV 2003Reissued for ApprovalJi ShenboGao HuamingZhao XieShi Deping0020 NOV 2003Issued for UseJi ShenboGao HuamingZhao XieShi DepingTable of contents目 录1 purpose目的2 scope范围3 responsibilities职责4 project overview工程概述5 reference编制依据6 measuring instrument, tools and machines计量器具、工具、机械7 labor force organization劳动力组织8 construction process and construction technique施工工序和施工方法9 environment control measures环境控制措施10 attachments附件1 Scope范围 This instruction is applicable to the steelwork erection of 4 set fuel (gas) boilers in Nanhai peotrochemical steam & power unit.本指导书适用于南海石化汽电联产项目4台燃油（气）锅炉的钢架安装。2 Purpose目的 The purpose of the preparation of boiler steelwork erection specification and requirements of SEP2 is to direct the future erection and control the construction process and quality effectively in order to ensure the project completion on schedule with good quality.制订二公司（以下简称SEPC2）南海石化汽电联产项目锅炉钢架安装施工的规范及要求，作为以后安装的指导，以有效的控制施工过程及质量。确保工程高质量的按期完工。3 Responsibilities职责3.1 SEPC2 is responsible for the erection of the boiler steelwork.SEPC2负责锅炉钢架的安装。 3.1.1 SEPC2 Boiler Installation Team is responsible for the construction and control of the overall erection process of boiler steelwork.SEPC2锅炉工程处负责锅炉钢架安装全过程的施工、管理。3.1.2 SEPC2 CMD is responsible for the check of the steelwork WI. CMD also conducts supervision and give directs during the erection of the steelwork.SEPC2施工部对锅炉钢架的施工措施进行审核，并在作业过程中进行监督指导。3.1.3 SEPC2 HSE is responsible for the check of the safety instructions of the steelwork erection and inspection of the safety protection measures on jobsite.SEPC2 HSE部对锅炉钢架施工的安全措施进行审核，并检查现场安全防护措施。3.1.4 The related supervisors of SEPC2 should be on duty. If there are any abnormal problems, report immediately and adopt rescue measures.SEPC2相关管理人员应坚守岗位，发现异常问题，立即报告或采取救援措施。3.2 SEPC1 is responsible for the construction of the boiler foundation.一公司（以下简称SEPC1）负责锅炉基础的施工。3.3 SEPCO is responsible for the interface coordination of the SEPC1 and SEPC2.基建总公司（以下简称SEPCO）负责SEPC1与SEPC2施工的接口协调。4 Project overview工程概述Four set fuel (gas) boilers are the WGZ305/11.55-1 boiler designed and manufactured by WBCL. They are arranged in parallel. The distance between the centerlines of two adjacent boilers is 28m.四台燃油(气)锅炉由武汉锅炉有限公司设计、生产，呈并列布置，相邻两台锅炉中心线距离为28m。The boiler steelwork mainly comprises: column, beam, vertical bracing, horizontal bracing, roof framework, each floor plane, passage and other support structures. Main members (beams, columns and bracings, etc) adopt high strength bolt connection during site erection except otherwise stated on the drawing. Some members adopt welded connection on site. The roof steelwork will be a rigid plane-layer jointly constituted by main beam, secondary beam, gird and checkered plate. The steelwork of the boiler is made up of five erection layers. The first layer is from +0.2m(elevation) to +8.8m(elevation), the second layer is from +8.8m to +17.6m, the third layer is from +17.6m to +24.8m, the forth layer is from +24.8m to the top of the column, the fifth layer is roof steelwork layer. The first layer of boiler steelwork contains column baseplate. The lower elevation of the column baseplate is +0.2m. The datum 0.00 grade elevation is equivalent to HHD 6.70m. All elevation the instruction are relative elevation.锅炉钢架主要包括：柱、梁、垂直支撑，水平支撑，炉顶构架，各楼层平面、通道以及其它所需的支承结构。主要杆件(梁、柱及支撑等)除在图纸中另有说明外均在工地安装时采用高强度螺栓连接，部分杆件在工地采用焊接连接。炉顶钢架由主梁、次梁、小梁及满铺花纹钢板共同构成一个刚性平面层。锅炉构架共分五个安装层：第一层自标高+0.2m至+8.8m，第二层自+8.8m至+17.6m，第三层自+17.6m至+24.8m，第四层自+24.8m至柱顶，第五层为炉顶钢架层。锅炉钢架第一层含柱底板，柱底板下标高为+0.2m。注：相对标高的0m相当于绝对标高（黄海高程）的6700mm,本作业指导书中所有标高均为相对标高。The designed live load of boiler passage and platform is designed 2.5kN/m2, the designed live load of maintenance platform is 4kN/m2, the designed live load of ladder is 2Nkg/m2.锅炉通道、平台设计活荷载为2.5kN/m2，检修平台设计活荷载为4kN/m2，扶梯设计活荷载为2kN/m2。The performance grade of the high strength bolt of the boiler steel structure adopting is 8.8 grade (pressurized type). The main members adopt M22 bolt and secondary members adopt M16 bolt.本锅炉构架工地连接采用的高强度螺栓的性能等级为8.8级(承压型)，主要构件采用螺栓直径M22，次要构件采用螺栓直径M16。5 Reference编制依据5.1 Boiler steel structure drawing(the No. of volume:DT-SEPC-SEPC2-0058)锅炉钢架图纸（卷册号：DT-SEPC-SEPC2-0058）5.2 Electric power construction and inspection and acceptance technical specification (boiler unit) (DL/T 5047-95)电力建设施工及验收技术规范（锅炉机组篇）(DL/T 5047-95)5.3 Thermal power construction quality inspection and assessment standard (boiler) (Rev.1996)火电施工质量检验及评定标准（锅炉篇）（1996年版）5.4 Steel structure construction quality acceptance specification(GB 50205-2001)钢结构工程施工质量验收规范(GB 50205-2001)5.5 Compilation and implementation of WI and JSA (PR-8710-8100-0203C Rev.02)作业指导书及JSA的编制及实施(PR-8710-8100-0203C Rev.02)5.6 Electric power construction safety work specification (thermal power section) (DL-5009.1-2002)电力建设安全工作规程（火力发电厂部分）(DL-5009.1-2002)5.7 Electric power construction safety, health and environment control stipulation 电力建设安全健康与环境管理工作规定5.8 HSE Scaffolding（WI-8560-8100-0253C Rev.00）脚手架管理程序（WI-8560-8100-0253C Rev.00）5.9 Lift/transportation management procedure（PR-8710-8100-0201C Rev.00）起重运输安全管理程序（PR-8710-8100-0201C Rev.00）5.10 Portable Ladders Management Procedure（WI-8560-8100-0250C Rev.00）便携式梯子管理程序（WI-8560-8100-0250C Rev.00）5.11 Design change control (PR-8710-8100-0047 rev.02)现场设计修改控制(PR-8710-8100-0047 rev.02)5.12 Construction surveying (PR-8710-0000-0012 Rev.01)施工测量(PR-8710-0000-0012 Rev.01)5.13 Quality inspection (PR-8710-8100-0056 Rev.01)质量检验(PR-8710-8100-0056 Rev.01)6 Main measuring instrument, tools and machines主要计量器具、工具及机械序号No.机具名称name of tools and machines型号.规格model and specification单位unit数量quantity1电焊机electric welder/台set22经纬仪theodolite/台set13水准仪gradienter/台set14汽车吊truck crane50t台set15汽车吊truck crane25t台set16汽车吊truck crane16t台set17履带吊crawler craneCC1000台set18履带吊crawler crane50A台set19玻璃管水平带子level tape of glass tube/副off110钢卷尺steel tape50m把set111钢板尺steel ruler3m把set11m把set112软爬梯cat ladder/挂string6013差速自锁器speed differential self-locker/个piece407 Labor force organization劳动力组织序号No.名 称name数量/人quantity/ person序号No.名 称name数量/人quantity/person1工程负责人project responsible袁怀民 张传国Yuan Huaimin Zhang Chuanguo2技术负责人technical responsible 王 强Wang Qiang3班长、技术员foreman, technician王友敏、冀慎波、于强Wang youmin, Ji shenbo,Yu Qiang4质检员quality inspector1人15安全员safety supervisor4人46安装工fitter40人407电 工electrician1人18电焊工welder4人49架子工scaffolder8人810起重工rigger10人108 Construction process and construction technique施工工序和施工方法 8.1 Construction process施工工序 Overall sequence: #1, #2，#3，#4 boiler be lifted and erected in turn. The erection sequence of each boiler: construction preparation, boiler foundation handover, erection and inspection and acceptance of first layer steelwork, second grouting of column pedestal, erection and inspection and acceptance of second layer steelwork, erection and inspection and acceptance of third layer steelwork, erection and inspection and acceptance of forth layer steelwork, erection and inspection and acceptance of roof steelwork, overall recheck and alignment of boiler steelwork and quality supervision station activity before steelwork load bearing.整体顺序：#1，#2，#3，#4锅炉依次吊装。每台锅炉安装顺序：施工准备；锅炉基础交接；第一层钢架安装验收；柱脚二次灌浆；第二层钢架安装验收；第三层钢架安装验收；第四层钢架安装验收；炉顶钢架安装验收；锅炉钢架整体复查找正，钢架承载前质监站活动。8.2Construction technique施工方法8.2.1 Construction preparation施工准备8.2.1.1 Be familiar with drawing, make a review of the drawing and put forward material plan according to the drawing.熟悉图纸，进行图纸会审，根据图纸提出所需材料计划；8.2.1.2 Make a corresponding training to all personnel taken part in construction对所有参加施工的人员进行相应培训；8.2.1.3 Compile construction instruction and make technology clarification编制施工措施，并进行施工技术交底；8.2.1.4 Check equipment 设备检查a. Check the appearance and certificate of steelwork and high strength bolt and report for High strength bolt spot-checked(selectively check 5 set per lot).检查（钢架、高强螺栓）外观、出厂证明书、高强螺栓抽检报告（每批次抽查5套）；b. Check the levelness of the steel plate and shaped steel at the connection of the high strength bolt. If there are any deformation and deflection of the connecting plate, adjust it. The burrs of the plate edge and hole edge should be removed by hand grinding wheel to ensure closely contact of the surface. Rectifying should be taken during adjustment in order not to damage the surface.检查高强度螺栓连接处的钢板或型钢是否平直，如发现连接板有变形、挠曲等都进行校正，板边、孔边的毛刺需用手提砂轮清除，以保证摩擦面的密贴接触，校正时应采取措施防止损伤摩擦面；c. Check the surface whether disposed according to the requirement before members to be lifted and erected. And check the cleanliness of the surface. If there are any soil, oil, paint, etc, they should be removed. The rust on the surface joint should be removed by wire brush.在构件吊装前应检查摩擦面是否按要求处理，检查摩擦表面是否干净，如有泥土、油污、油漆等应予以清除，并用钢丝刷清除接头摩擦面的浮锈。d. Recheck the size of the main members (such as column and main beam) before erection.主要构件(如立柱、主梁)安装前必须对其尺寸进行复验。8.2.1.5 Prepare of tools and machines, entering the site of the requisite material and information arrangement.准备工器具及需用材料的入厂及资料整理。8.2.1.6 Marking off of one layer steelwork column(1m elevation line and centerline).Weld bolt (M22*140) on the column bottom plate and prepare for the supporting steel plate which thickness is 10mm.一层钢架立柱划线（1m标高线及中心线）。在柱底板上焊接螺栓（M22*140），并准备支撑该螺栓用的厚10mm的钢板（100*100mm）。8.2.1.7 Crane arrangement吊车布置 The roadbed of the cranes traveling route shall be firm in order to keep the crawler belt on the same level. All lifting will be within 90% of crane capacity.吊车行走路线路基应坚固，以便使吊车履带保持在同一水平面。所有起重量必须控制在吊车满负荷的90%以内。8.2.2 make pre-construction handover work through CMD personnel.通过SEPCO施工部人员，进行施工前交接工作。8.2.2.1 recheck the reference cross centerline of boiler by isosceles triangle method用等腰三角形法复核SEPC1提供的锅炉基准纵横中心线。 Allowable deviation:a. Relative to the turbine house centerline: 20mmb. Relative to the actual boiler foundation centerline 1 mm允许偏差： a. 相对于汽机房中心线偏差 20 mmb. 相对于实际锅炉基础中心线偏差 1 mm8.2.3 Erection inspection and acceptance of steelwork 钢架安装验收8.2.3.1 Column erection立柱安装a. The column and the connecting beam erection is one of the most dangerous work during steelwork erection. According to our past construction experience, we shall adopt the scheme of hanging soft ladder on the top of the column to work overhead. At the same time, speed differential self-locker shall be adopted as protection measures to ensure the safety of the overhead construction (the detailed use of the soft ladder see soft ladder execution plan). Vertical column and beam of the first floor shall be hoisted by using 50A crawler crane according to different areas. The 50A crawler crane shall travel back and forth alone the central line of column 2 and column 3 and hoist the column E, D, C, B, A successively from front side to the back side of the boiler. After the hoisting of the first floor, erect the steel frame of the 2nd, 3rd and the 4th floor. During hoisting of the column，for each column connect 2 sets of 4.75t American arc ouch with the bolt hole of the frame and then hoist them, fasten the beams to wire rope and then hoist them. The boiler frame shall be assembled with each other according to the field construction requirement; the weight of the assembly parts shall be controlled within the lifting capacity of thr crane.After assembling on the specified field of boiler 0m ground, use the CC-1000 crawler crane to hoist the assembly parts into position. The scaffold used for frame erection shall apply Scaffold Management Procedure. While using portable ladders, operators shall obey Portable Ladders Management Procedure. Execute Lifting Transportation Management Procedure in the transportation of lifting equipment.立柱和其间连梁安装是钢架安装过程中最危险的作业之一，根据我们以往的施工经验，采用在立柱顶端拴挂软爬梯进行高空作业的方案，同时采用速差自控器作为防护措施，以确保高空作业的安全性。（软爬梯的使用详见附件软爬梯实行计划）。一层立柱、横梁用50A履带吊分区域进行吊装，50A履带吊沿2、3列柱之间锅炉中心线前后方向行车，从炉前向炉后依次吊装E列柱、D列柱、C列柱、B列柱、A列柱及其相连的横梁斜撑。一层吊装完毕后，用CC-1000履带吊吊装2、3、4层钢架。立柱吊装时，每一个立柱用两个4.75t美式弓形卸扣直接与钢架螺栓孔连接起吊，锅炉钢架横梁直接用钢丝绳拴紧,吊装。锅炉钢架根据现场施工需要，进行适当的组合，组合件重量控制在10t以内，组合件在锅炉零米组合场地组合完成后，由CC-1000履带吊吊装就位。锅炉钢架安装用的脚手架应符合脚手架管理程序，便携式梯子使用时应符合便携式梯子管理程序，设备的起重运输执行起重运输安全管理程序。b. When the column is installed, the end surface of the column must be tightened. The maximum allowable clearance on the butt joint contact surface of the column is no more than 0.5mm. When erection, contact the butt joint surfaces first, then join them by high strength bolt.钢柱安装时，柱的端面必须顶紧，钢柱对接接触面允许的局部间隙最大不超过0.5mm。安装时应让对接端面先接触，然后再用高强螺栓连接。c. When the first layer column is put into position, the column baseplate centerline and foundation centerline must be aligned, Adjust the elevation of column by bolt jack. The bolt welded on the baseplate shall be used to assist the stability of the column. Then tighten the nut and standby nut of the anchor bolt, draw the cable rope. Anchor the upper end of the cable rope on the top of the vertical column or the steel member placed on the field (prier to lifting). Anchor the lower end on the column end of the foundation and tighten it with 2t/3t chain blocks. unhook and remove the cable rope after steady framework is formed (made up by each four columns and their connecting beam).第一层立柱安装就位时，必须将柱底板中心线与基础中心线对正，用焊接在柱底板上的螺栓辅助稳定立柱，用螺栓千斤顶调节好立柱标高，然后拧紧地脚螺栓的螺帽和备帽，再拉好板线，板线上端固定在立柱顶端，下端固定在基础柱头或地面摆放的钢构件上，并用2t或3t倒链拉紧，摘钩，待形成稳定框架（每四根立柱及其间连梁构成）后再将板线拆除。Allowable deviation of column erectionCenterline of column baseplate: 5mmColumn elevation: 5mmRelative elevation of each column: 3mmDistance of each column: 1 column distance and 10mmDiagonal of column top: 1.5 diagonal length and 15mmDiagonal on 1m elevation: 1.5 diagonal length and 15mmColumn verticality: 1 column length and 15mm立柱安装允许偏差：柱脚中心线： 5mm立柱标高： 5mm各立柱间相互标高： 3mm各立柱间距： 1柱距且10mm柱顶对角线： 1.5对角线长度且15mm1米标高处对角线： 1.5对角线长度且15mm立柱垂直度： 1立柱长度且15mm8.2.3.2 Erection of members, such as horizontal beam and bracing横梁及支撑等构件安装The vertical bracing and horizontal bracing of the boiler steelwork are the main force bearing members of the steelwork system and the main structures that cannot be lacked during the erection and use to maintain the structures steady and to ensure the safety. They cannot be installed subsequently or cancelled without an approved FCR by SEPCO and W.B.C.L.本锅炉构架的垂直支撑和水平支撑均为构架系统中的主要受力构件，是安装和使用过程中维持结构稳定和确保安全不可缺少的主要结构，未经SEPCO和武锅厂正式同意，不得任意缓装和取消。The both ends of the boiler main beam adopt strip pedestal put on the top of the column. The connecting bolt is used to position. The nut should not be tightened during erection. For the members connected by high strength bolts, the contact surface has been blast treated in the factory. The rust should be removed according to the construction code during erection and connection.锅炉主梁两端采用条型支座支搁于柱顶，连接螺栓作定位用，安装时不应将螺母拧紧。采用高强度螺栓连接的构件，其连接的接触面均在工厂经喷砂（或喷丸）处理，安装连接时，应按施工规程除锈。During erection, the clearance between the surfaces caused by plate tolerance or fabrication deflection should be treated as following:在安装过程中，对因钢板公差或制作偏差引起的摩擦面接触间的间隙，按如下处理：间隙大小(mm)clearance处理方法treatment method1mm1mm以下不作处理The clearance below 1mm will not be treated13mm将较厚一侧作成向较薄一侧过渡的缓坡或填入垫板以1：10坡度过渡A gentle slope will be made from the thicker side to the thinner side or a shim plate be inserted.The slope ratio is 1:103mm以上填入垫板，且垫板要与摩擦面用同样处理Insert a shim plate and the shim plate has been treated by the same treatment method of the friction surface.Allowable deviation of horizontal beam erection:Elevation: 5mmlevelness: 5mmCenterline: 5mm横梁安装允许偏差：标高：5mm水平度：5mm中心线：5mm8.2.3.3 Erection and marking of roof plate beam炉顶板梁安装划线Vertical flexibility of plate beam: upward 30mm；downward 5mm板梁垂直挠度：向上，30mm；向下5mmSide flexibility of plate beam: 1 of space between columns and 10mm板梁旁弯度：1柱距且10mmThe vertical flexibility of plate beam shall be test before erection, before loading, before hydraulic test and after water is filled during hydraulic test respectively.板梁垂直挠度在安装前、承载前、水压前、水压上水后分别测量一次。8.2.3.4 Erection of ladder platform梯栏平台安装Under the availability of conditions, the ladder platform should be erected with the steelwork members. After each layer steelwork erection is finished, the main passage of the ladder platform should also be finished. Thus facilitate the overhead construction and ensure the safety of the overhead working personnel.在具备条件的情况下，梯栏平台应随钢架构件一起安装，在每层钢架安装完毕，梯栏平台的主要通道也应安装完，以便为高空作业提供方便，进一步保证高空作业人员的安全。栏杆柱子间距应均匀，符合设计，横杆平直，无明显凹凸不平，栏杆接头应光洁、无毛刺。8.2.3.5 Requirements to the welding对焊接的要求a. The welding work can only be done by qualified welder.焊接工作由取得考试合格证明书的焊工担任。b. The paint, moisture, rust, scale, gas cut slag surface soil, etc. in the welding area must be removed before members be put into position.构件安装定位前，必须清除其焊接区域的油漆，油污、水分、铁锈、氧化皮、气割熔渣面及泥土等杂物。c. Check and adjust tacked spot before welding. The slag and spatter should be removed after welding.施焊前应检查和修整定位焊点。焊接完毕