Lifting-Plan-吊装方案.doc

中中国南海工程有限公司 艺康（太仓）科技有限公司新工厂项目技术标China National Nanhai Engineering Co., Ltd. Technical Proposal for Ecolab Taicang Jade Project 16.2、Lifting plan吊装方案I、 Generals of Work工程概况There are 248 sets of equipment with different weights. Lifting of large equipments concerned is mainly concentrated in Production Building B, Mixing Pots T-202, T-210 are the heaviest equipments, with monomer weight of 27 tons. 120T Truck Crane Model ATF 120-5 shall be employed. 100T, 50T, 25T cranes may be used according to different volumes and weights respectively and forklift and chain blocks plus roller bars will also be used to locate equipment in place. The manufacturer shall be responsible for transporting equipment to the site of Ecolab Taicang Jade Project. The authorized party shall be responsible for mobilization of vehicle and personnel and coordination and communication with the Owner at site. We will pay highly attention to construction and get organized elaborately, arranged thoughtfully, work done carefully to ensure the lifting of equipment in place without any risks.本项目共有设备248台，设备重量不等，涉及的大型设备吊装主要集中在生产车间B，其中以混合釜T-202、T210为最重，单重为27吨。计划采用ATF 120-5型号的120吨汽车吊，其它设备根据体积和重量的不同分别采用100吨、50吨、25吨吊车或者采用叉车及配合用手拉葫芦加滚杠进行就位。由厂家负责运到艺康（太仓）科技有限公司新工厂项目工地，委托方负责组织车辆和人员的进场，负责现场协调和业主沟通。我们在施工时必须高度重视，要求做到精心组织、周密安排、谨慎施工，确保设备吊装就位万无一失。II、 The lifting work shall execute the following codes, specifications and requirements本吊装工程执行以下规范、规程和要求： Code of Lifting Work for Engineering Architecture 工程建设起重施工规范； Specification of Safe Operation for Lifting Work 起重吊装安全操作规程； Standard of Construction Technique for Large-sized Equipment Lifting Work 大型设备吊装工程施工工艺标准； Performance List of Conveying flatbed trucks, cranes 运输平板车、吊车性能表； Management System of Crane Safe Operation for Ecolab Taicang Jade Project. 艺康（太仓）科技有限公司新工厂项目有关吊车安全作业管理制度； All concrete requirements for lifting work specified by the Owner and Jones Lang Lasalle. 业主和仲量联行对吊装工程的各项具体要求。III、Heavy lifting parameters list大型设备吊装基 本参数一览表No.序号Equipment Tag No.设备位号Equipment Description设备名称Weight重量（t）Installation Elevation安装标高(m)Crane Type吊车选型1T-201Mixing Pot 混合釜100.350T2T-202Mixing Pot 混合釜270.3120T3T-203Mixing Pot 混合釜160.350T4T-205Mixing Pot 混合釜160.350T5T-206Mixing Pot 混合釜100.350T6T-207Mixing Pot 混合釜100.350T7T-210Mixing Pot 混合釜270.3120T8T-223Mixing Pot 混合釜160.350T9T-301Mixing Pot 混合釜240.3100T10T-302Mixing Pot 混合釜240.3100T11T-303Mixing Pot 混合釜240.3100T12T-304Mixing Pot 混合釜240.3100T13T-305Mixing Pot 混合釜230.3100T14T-306Mixing Pot 混合釜240.3100T15T-307Mixing Pot 混合釜240.3100T16T-308Mixing Pot 混合釜240.3100T17T-309Mixing Pot 混合釜240.3100T18T-310Mixing Pot 混合釜240.3100TIV、Lifting Method吊装方法It is recommended that large equipment will be delivered concentrically to minimize mobilization and demobilization time of large cranes. Taking the mixing pots T-202, T210 for example to describe the lifting method as follows: 建议大型设备集中到货，减少大型吊车进出厂次数，以下以混合釜T-202、T210为例说明吊装方法：Overall dimensions: 2615*2850mm，外形尺寸：2615*2850mm，equipment weight: 27T设备重量：27TLifting weight: G=（Q+Q）K=（27+0.5）1.1=30.25T吊装重量：G=（Q+Q）K=（27+0.5）1.1=30.25TIn the formula: 式中：G-lifting weight 吊装重量Q-equipment weight 设备重量 Q=27Tweight of hooks, guy wires and sling chains 钩头、吊索具的重量Q0.5Tk- Dynamic load factor =1.1 k-动载系数=1.1Locating height 就位高度：+0.3m V、Check and Calculation of Lifting Height吊装高度核算Lifting height with a radius of 11m 11米半径时吊装高度Length of pole: 21.65m 杆长：21.65mRadius: 11m 半径：11米Vertical height of jib 吊臂垂直高度：18.65mRated lifting weight: 37.5tons 额定吊装重量：35吨The max. equipment height shall be 6.65m, (height above ground 0.8m +guy wire and sling chain length 3m) smaller than the min. jib height above ground 18.65m.设备最大高度为6.65 米(含基础离地高度0.8米吊索具长3米)小于吊臂最小离地高度18.65米Therefore, lifting height can achieve lifting requirement.因此，吊装高度能满足吊装要求VI、Calculation of Lifting load rate吊装负荷率计算A、Parameters of 120-ton truck crane 120吨汽车吊参数 Lifting weight: 27.5T(equipment weight + guy wire and sling chain weight)吊装重量：27.5 T(设备重+吊索具重) Working radius: 11m作业半径：11米 Rated lifting weight: 35 tons额定吊重量：35吨 Load rate: 78.6%负荷率：78.6%VII、Check of Lifting Guy Wires and Sling Chains 吊装机索具校核 Steel wire rope: 32-6x37+1钢丝绳选用32-6x37+1 Max. allowable pull 68 tons允用最大拉力68吨 Single loop double strand lifting 单圈双股吊装 Max. equipment weight: 27 tons 设备最大重量：27吨 Decrement factor takes 0.8 折减系数取0.8 68*4*0.8/27=8.06Safety coefficient: 8.06安全系数：8.06 Safety 安全 2 relief shackles of 20 tons each shall be used. 卸扣采用20吨卸扣 2个.VIII、Work Procedure施工步骤 1、Field and foundation treatment 场地及地基处理 After the ground bearing surface for truck crane is compacted and treated, a steel plate of 25mm thick shall be spread to guarantee the crane legs with sufficient bearing area and reaching 25 tons per square meter.在吊车支腿承压地面经夯实处理后再铺设厚度为25的钢板以保证吊车支腿有足够的承压面积并达到25吨/平米。 2、120-ton crane approaches to the site and stands at its place according to diagram. (See attached diagram)120吨吊车进入现场，按图站位。（见附图）3、 Lifting lug of Mixing Pots T-202, T210 shall be within the working radius of crane. 混合釜T-202、T210吊耳应在吊车工作半径内。4、 Hang hooks of 120-ton crane lifts. When the Mixing Pot leaves the bracket for about 50mm, keep it standstill for 3 minutes, observe crane supporting legs, ground surface, wire rope, relief clamp and the equipment body, and continue to lift only after confirmation without error. Then lift the equipment upward 500mm over the bracket. 120吨吊车挂钩，起吊，当混合釜离开托架50mm时，静止3分钟，观察吊车支腿、地面、钢丝绳、卸扣以及设备本体，确认无误后，继续起吊，将设备抬高距托架500mm。5、Turning radius of boom moves to 11m, lifts the equipment to its locating place and set in place. 趴杆旋转半径至11米，将设备吊至就位点，落点就位。6、After completion, lifting work shall be approved and signed by the Owner. 吊装结束以后，业主签字确认7、Schedule arrangement of crane 吊车台班时间安排 Schedule of crane mobilization and demobilization shall be arranged according to the time of equipment delivery. Detailed plan shall be prepared before the equipment delivery. 根据设备到货时间安排吊车进场时间和吊装时间，设备到货前编制详细吊装方案。IX、Layout Plan and Section Plan 平面、立面布置 Please refer to Construction Layout Plan and Section Plan参见施工平面、立面图X、Labor Arrangement劳动力安排S.N.序号Type of Work工种Number (unit: person)人数(单位：人)1Commander指挥12Rigger 起重23Helper 力工64Crane driver 吊车司机25Lifting Engineer起重工程师16Administrator 管理人员27Safety officer 安全员18Mechanic 钳工2XI、Main Construction Tools and Riggings主要施工机索具S.N.序号Description名称Model型号Place of Origin产地Unit单位Qty.数量1120-ton truck crane120吨汽车吊ATF 120-5Set台12Steel wire rope钢丝绳32mm6mHebei Juli河北巨力Piece根23Relief shackle 卸扣20THebei Juli河北巨力Piece只24Pad timber 道木Standard标准Piece块20XII、Safety and Technical Measures安全技术措施1、We are responsible for inspection of the employees work permit issued by the labour bureau 我公司负责检查所有参加施吊人员的劳动局颁发的职工上岗证。2、We shall organize all lifting participants to understand construction plan and define their own responsibility and obey commander.我公司组织参加施吊人员熟悉详细施工方案，并明确各自的岗位职责，服从指挥。3、Prior to work, safety officer shall organize the personnel concerned to inspect the machine and tools. No mechanical trouble and unacceptable tools shall be allowed.施工前安全员负责组织有关人员对施工机械和工具检查，严禁机械带故障作业及使用不合格的工具。4、When wind force 6, working at night, and under stormy and foggy weather. Stop lifting work.风力6级、夜间、大雨大雾或能见度低天气，停止吊装作业。5、Enclose the working area with flag rope and provide warning signboard. 2 guards shall be appointed to stop personnel with no access permission. 在作业区域用旗绳围栏，并设禁行警告牌，设2名警戒人员，严禁无关人员进出。6、Lifted load shall not rest on the air for a long time. Standing under the jib shall be strictly forbidden.起吊重物，不得长时间停留在空中，吊车起重臂下严禁站人。7、Establish safety guarantee system for equipment lifting建立设备吊装安全保证体系。8、Operators working at elevated height shall require regularly physical examined. Personnel who are not suitable for elevated work shall not be allowed to work at height.从事高空作业人员要定期体检，凡不适合从事高空作业的人员，不得从事高空作业。9、Safety helmets should be prepared when entering into construction site and safety belts or harness should be prepared when working at height. 进入施工现场必须戴好安全帽,高处作业系牢安全带。10、All cranes (including assisting crane) shall not be allowed to overload work . 所有吊车(包括溜尾吊车),严禁超负荷作业。11、Prior to lifting, confirm uniform commanding signal. When commanding, flag and whistle should be prepared completely with clear signal, timely cooperation and uniform commanding. 吊装前统一指挥信号,指挥时旗哨齐全.信号明确,配合及时,服从统一指挥。XIII、Risk Evaluation风险评估Preparation method编制方法JSA (Job Hazard Analysis) shall be prepared by safety engineers, safety officials, technicians, and construction staffs who are experienced with similar works according to the specific condition at site. Danger shall not be overstated nor hidden trouble be ignored, in order to evaluate and control risk objectively, thoroughly and effectively.JSA（工作危险性分析）由安全工程师、安全员、技术员以及对该项工作具有丰富经验的施工人员，结合施工现场的具体情况统一编制，不夸大危险，不忽略隐患，使风险得到客观、充分、有效地评估和控制。2.0 Risk Evaluation风险评估For this item, likelihood, seriousness and risk value shall be evaluated. Value and meaning of analysis shall be as follows:该项就每一步骤各项危险发生的可能性、严重性和风险值进行评估，其分析价值和意义如下：Likelihood 可能性：1- Accident seldom to happen 事故很少发生； 2- Accident possible to happen but not often 事故可能发生但不经常发生； 3- Accident very likely to happen 事故很可能发生。S (Serious): subsequence of accidents or danger严重性S(Serious)：事故或危险时间发生引起的后果1- the subsequence may be slight harmful which shall not affect performance of work对人员造成不会影响工作的微小伤害；2-the subsequence may be flesh wound, slight harmful to health, small economic loss, slight pollution, such as working without work permit for crane operator or lifting worker.可能导致轻伤、对健康有轻微伤害、较小的财产经济损失、轻微污染，如吊车操作人员无证上岗, 起重作业人员无证上岗等；3-the subsequence may be badly injured, deathful, serious harmful to health, big economic loss, serious pollution, such as personnel suffering from squeezing hurt, knock hurt or fall.可能导致重伤、死亡、严重危害健康、重大财产经济损失、严重环境污染，如挤伤、撞伤人员、人员摔落等。R (Risk): Risk Value = likelihood value x seriousness value, i.e. R=LS风险值R(Risk)： 风险值=可能性值严重性值，即：R=LSRisk Value shall be: 风险值为：1，2- low-level danger L低度危险L；3，4- medium level danger M中度危险M；6，9- high-level danger H高度危险H。According to analysis above, likelihood, seriousness and risk value of each danger listed in the table above shall be revealed, e.g. when the control brake system lose effectiveness because of defect of equipment, serious harm may be made on human health without protection measure - thus the seriousness value shall be 3, and the likelihood of causing harm is “very likely” -thus the likelihood value shall be 3, and the risk value in total shall be 9, as shown in the table Risk Evaluation Value.根据以上分析，可以得知上表各项危险的可能性、严重性及其风险值，如设备缺陷，控制制动系统失灵时，若不采取防护措施将会对人体健康构成“严重危害”-严重性值为3，造成危害的可能性也“很可能”-可能值为3，则风险值为9，如表中“风险评估值”所示。Note: In fact, there are some dangers with high seriousness value and low likelihood value, and, on the other hand, there are also some other dangers with high likelihood value and low seriousness value. In view of that, all dangers shall be evaluated one by one when practical evaluation is performed.注：鉴于是有的危害严重性较高，但可能性较小（需要指出的是，这些危害，由于可能性很小，往往不会引起人们的重视，而事故往往就起源于这些人们忽视的危险），而有的危害可能较高，但严重性较小，在实际评估时可以对各项危害逐一进行评估。3.0 Control Method of Danger 危险控制方法 For risk existing in each work and risk evaluation value, control method of danger shall be indicated. Refer to the item Control Method of Danger in the form.针对各项工作中存在的风险及风险评估值，指出控制危害的方法。见表中“对危害的控制方法”一栏。4.0 Remaining Danger 剩余危险 Dangers which still remain after danger control shall be listed in this item to remind workers paying special attention during construction. Dangers which has been reduced to an acceptable level or almost removed do not have to be listed.本项将列出经过危害控制后仍然存在的部分无法控制的危险，以提请作业人员在施工时特别注意。如果通过采取控制措施，风险已经减低到人们可以接受的程度或已基本消除，则剩余危险不用列出。5.0 Review and Approval for Risk Control Measures 风险控制措施审批After signed by preparation personnel and principal of this work (team leader or group leader), completed JSA shall be submit to HSE manager to inspect and approve with construction method. It can also be treated as an attachment of construction method.编制好的JSA经编制人员和该项工作负责人（组长或伙长）签字后与施工方案一起送交HSE经理审批，也可以做为施工方案的附件同时进行审批。6.0 Execution 执行 JSA返回后下发所在施工班组执行。After issuance, JHE shall be executed by the construction team concerned.Before construction, technicians shall carry out safety presentation to make every workers get acquainted with danger existing in construction and pay attention to it during construction. After completion of presentation, all members of construction team shall sign on the back of JSA to ensure execution of JSA safety measures.施工前，技术员作安全交底，使每位作业人员知道、熟悉施工中存在的危险并在工作时注意，交底完成后，所有班组人员须在JSA背面签字，以保证按JSA安全措施执行。During construction, JSA shall be hanged near construction site to facilitate readings for construction workers.施工期间，JSA应挂在施工位置附近，以方便施工人员翻阅。JSA shall be content to be studied in safety activities on every Monday and toolbox meeting every day.将JSA作为每周周一安全活动和每天班前会的学习内容。Safety department shall inspect execution condition of JSA.安全部门将对JSA执行情况进行检查。It can be said that by execution of JSA and relative protection measures, every workers shall fully know dangers existing in their working and handle them calmly and smoothly in case they happen.可以说，通过实行JSA并采取相应防范措施，可以让每位作业人员对自己从事工作所存在的危险做到心中有数，即使有意外发生也能沉着应对。Danger Analysis Report 危险性分析报告Job type: lifting & hoisting work工作项目：起重吊装作业序号No隐患或风险Potential Danger orRiskL/可能性S/严重性R/风险值对危害的控制方法Control Method of Danger剩余危险RemainingDanger一、起吊设备存在缺陷 Defects of Lifting Equipment1性能达不到要求Function not meeting requirement2361、按施工技术方案要求选择起重吊车。Crane shall be selected according to construction method.2、起重吊车按期参加年检且合格。Annual inspection shall be necessary for cranes and shall be approved.3、吊车有劳动部门核发的有效作业许可证。Effective construction permit issued by Labor Authority shall be necessary for cranes.4、定期对起重机进行年度、每月和每日检查。Regularly annual, monthly and daily inspection shall be necessary for crane.5、定期进行动（静）载荷试验，试验结果作好记录建档备查。Regular dynamic (static) load test shall be performed and test result recorded and filed.6、禁止超负荷运行。Overload operation shall be prohibited.7、设备定机、定人，吊车司机每日班前进行自检、自查。 Operator shall be fixed for equipment. Crane driver shall perform self-inspection every day before work.8、Two cranes for lifting shall be consistent in type. 双机抬吊应尽可能型号一致。9、2台以上吊车抬吊，每台设备不得超过额定负荷75%。When more than 2 cranes for lifting together, load of each crane shall not exceed 75% of rated load.10、大件吊装作业前，对设备要进行全面检查。Thorough inspection of equipment shall be necessary before heavy and large lifting work.2传动系统运转不正常Abnormal running of transmission system.2361、吊车司机每日班前按规定要求进行自检、自查，设备定期检查，发现隐患及时消除。Crane driver shall perform self-inspection before work every day according to specification. Equipments shall be inspected regularly. Any discovered potential danger shall be removed in time.2、在现场检查时及时修复与调整还原。 Immediate repair, adjustment and restore shall be required during site inspection. 3、加强日常养护，保持车况良好。Daily maintenance shall be reinforced to keep crane in good condition.4、吊车带病更不得超负荷作业。Crain with malfunction shall not be allowed to run under overload.3控制系统失灵、失效Defectiveness of control system 2361、 定期检查设备安全防护装置、电路电控开关、液、气动系统。Safety protection device of equipment, electric circuit switch, hydraulic & pneumatic system shall be inspected regularly.2、 制动轮表面无明显凹缘。 No obvious sunken edge is allowed on surface of braking wheel.3、 制动瓦（带）无开裂现象，制动瓦和制动轮接触面大于50%。No cracking is allowed on braking band. Contact surface between braking band and braking wheel shall exceed 50%4Surface abrasion of rope slot of pulley and reel滑轮与卷筒的绳槽表面磨损2361、 滑轮凸缘无破裂。No damage is allowed on flange pulley.2、 齿轮齿厚磨损量不超过原厚的10%。Abrasion of tooth of gear shall not exceed 10% of original thickness.5Out of effect of limiting device and switch 限位及开关失效2361、 选择的开关与限位装置、力矩限制器等符合设计要求。Selected switch, limiting devices, and moment limiter shall meet design requirement.二、吊车操作和起重作业人员资质不符合要求Qualification of Crane Operators and Lifting Worker not Meeting Requirement.1No drivers permit 司机无证上岗2361、 按要求参加培训、取证，按期复审，持证上岗。Attend training, obtain license according to requirements, rechecked on time, and work with permit.2、 定期参加业务技能培训，进一步提高业务素质和技能。 Take part in skill training regularly to further improve operation capacity and skill.2No riggers permit 起重工无证上岗 2361、 按要求参加培训、取证，按期复审，持证上岗。Attend training, take license according to requirements, rechecked on time, and work with permit.2、 定期参加业务技能培训，进一步提高业务素质和技能。Take part in skill training regularly and further improve operation capacity and skill.3方案不符合要求Method Not Meeting Requirements1331、 吊装技术方案必须由有资格人员编制，并按规定审批。Lifting technical method shall be prepared by qualified personnel and inspected and approved according to specification.2、100t以上（含100t）及特殊环境条件下吊装方案，本单位自审后按规定必须报公司审批。 Lifting method under the condition of loads exceeding 100t (including 100t) or special surroundings shall be submitted to company for inspection and approval after self-inspection.2、 作业前组织进行联合检查确认并办理作业票，签发起吊令。Before work, joint inspection shall be organized to confirm, handle working permit, sign and issue lifting-start order. 三、吊索具存在缺陷 Defect of Sling Chain1索具断裂 Ruptur