E-1501ABE-1502AB吊装施工技术方案.

1、档案号File No:上海赛科石油化工有限公司90万吨/年乙烯装置900 kt/a Ethyle ne Pla nt of Sha nghai SECCO Petrochemical Co. LtdE-1501A/B和E-1502A/B吊装施工技术方案Methods Statement For E-1501A/B and E-502A/B Lifting编制:林土金Tujin LinOrigi nated By:施工技术审核：李春法Chunfa LiTech. Reviewed By:质量保证审核：戴东明Dongming DaiQA Reviewed By :安全技术审核：边长刚Changga

2、ng BianHSE Reviewed By:审定:徐庆海Qin ghai XuChecked by:批准:褚振辉Zhen hui ChuApproved编制时间：2003年12月26日Date:2003-12-26中国石化集团第十建设公司上海化学工业区工程项目部Shan ghai Chemical In dustry Park Project Departme nt of TCCS中国石化集团第十建设公司THE TFNTH CONSTRUCTIONX gliClPFC上海化学工业区项目部Shan ghai Chemical In dustry Park Project Departme nt

3、1 概况 Project introductionSECCOS烯装置急冷区设备，1号急冷水冷却器（E-1501A/B），外形尺寸为 2070（外径）X 11088 （全长），设备净重80吨；2号急冷水冷却器（E-1502A/B），外形尺寸 为1943 （外径）X 13650 （全长），设备净重77.7吨。这四台设备均为卧式设备， E-1501A/B位于No.1钢结构框架平台上（鞍座标高 V9725伽），（E-1502A/B）位于混凝 土基础上（基础标高02280伽），拟采用单机吊装的吊装工艺进行安装，使用LR1280型履带式吊车(280t)吊装，为保证设备吊装的顺利进行及安全，特编制本方案。I

4、n quench area of SECCO ethylene, wide size of Quench Water Coolers No.1 is 2070(0.D) X 11088(total length) , net weight of the equipment is 80 tons, Wide size of E-1502A/B Quench Water Coolers No.2 is 1943(O.D) X 13650(total length), netweight of the equipme nt is 77.7 tons, four equipme nts are hor

5、iz on tal , E-1501A/B locate above platform of No.1 steel structure(elevation of cradle 、9725 mm), E-1502A/Blocate above concrete foundation (elevation offoundation 2280 m). Will adopt“ si ngle crane lifti ng to lift th” four equipme nts, the type of crane is crawler crane LR1280.In order to ensure

6、safe of lifting, authorize the scheme specially.2编制依据referenee2.1化工塔类设备安装施工及验收规范Con structio n and accepta nee specificati onsfor chemical towers HGJ211-832.2 化工工程建设起重施工规范Construction specifications for lifting in chemicalengin eeri ng con structi on HGJ201-832.3.大型设备吊装工程施工工艺标准Construction process s

7、tandards for heavyequipment lifting SHJ515-902.4石油化工施工安全技术规程Security technology regulations for petrochemicalcon struction SH3505-19992.5乙烯装置设备总平面布置图 档案号：E-10856-00010B Equipment plot plan of Ethylene Complex 档案号 File No.: E-10856-00010B2.6乙烯装置地下管道布置图Underground piping layout of Ethylene Complex 档案号

8、 File No.: E-10856-00428A2.7 LR1280 型吊车性能表 The load table of crane LR12802.8 1 号急冷水冷却器(E-1501A/B)施工图 Drawing of Quench Water CoolersNo.12.9 2 号急冷水冷却器(E-1502A/B)施工图 Drawing of Quench Water CoolersNo.23. 工序 procedure吊装施工工序如图-1Construction procedure of lifting is figure-1.图-1施工工序Figur-1 con structi on

9、procedure4. 吊装前的准备工作 prepare works before lift4.1 设备吊装对 No.1 框架的预留要求 The postponing requirement of equipment lifting to No.1 steel structure设备吊装前要求No.1框架A&Btt线钢结构延缓施工。The steel structure of axial A&B of No.1 steel structure shall be postponed before equipme nt lift ing.4.2 E-1501A/B 吊装技术参数 Main tech

10、nical parameters of E-1501A/B4.2.1 1号急冷水冷却器(E-1501A/B)，外形尺寸为2070 (外径)X 11088 (全长)，设 备净重80吨，鞍座标高 9725伽，吊装重量确定如下：Quench Water Coolers No.1 is 2070(O.D)X 11088(total length), net weight of the equipment is 80 tons, elevation of cradle is 9725 mm, the lifting weight is as follows:中国石化集团第十建设公司THE TENTH C

11、ONSTRUCT 1X glMDPFC：上海化学工业区项目部Shan ghai Chemical In dustry Park Project Departme nt吊装重量 Weight of LiftingG=S备重量 weight of equipment G1+吊钩重量 weightof hook G2+ 索具重量 weight of rigging G3=80+3.3+0.7 =84t吊车钩头(100t级)以下总载荷 G0为807KN，使用52-6 X 37+1 (1700 MPa等 级)、长度为30米/根的钢丝绳两根作为吊装索具，对吊装钢丝绳进行受力分析，如图-2, 可以得知 F=

12、 (tg -/2) 2+ (tg：/2) 2+1 1/2x G0/4= (tg10/2) 2+ (tg10/2) 2+1 1/2X 807/4=203.5KN。The total load under the hook of crane is 808 KN, two slings the diameter 52-6X 37+1(class 1700 MPa) and length 30 meters will be used for lifting. Analyze the load of sling,221/20202refer to figure-2, F= (tg /2) + (tg：

13、/2) +1X G0/4二(tg10 /2) + (tg10 /2) +11/2X 807/4=203.5KN.吊装参数 Crane parameters型号 type： LR1280作业半径 working radius : R=12m 主杆长 length of boom： L=31.7m 额定载荷 rated load : 94.1t吊装载荷 lifting load : 84t负荷率 load rate： 89.3%4.2.2 索具 rigging选用规格为52-6X 37+1 (1700 MPa等级)、长度为30米的钢丝绳两根，作为吊装索具，共四股受力，其安全系数为Two sling

14、s the diameter 52-6X 37+1(class 1700 MPa) and length 30 meters will beused. The safe modulus is as follows:N=No/F3=1398100- 203.5- 103 =6.87 6安全！ Acceptable4.3 E-1502A/B 吊装技术参数 Main technical parameters of E-1502A/B4.3.1 2号急冷水冷却器(E-1502A/B)，外形尺寸为1943 (外径)X 13650 (全长)，设 备净重77.7吨，基础标高为2280伽，吊装重量确定如下：W

15、ide size of E-1502A/B Quench Water Coolers No.2 is 1943(O.D) X 13650(total length) , net weight of the equipment is 77.7 tons, elevation of concrete foundation iR2280 mm, the lifting weight is as follows:吊装重量 Weight of LiftingG=S备重量 weight of equipment G1+吊钩重量 weightof hook G2+ 索具重量 weight of riggin

16、g G3=77.7+3.3+0.7 =81.7t吊车钩头(100t级)以下总载荷 G0为784KN，使用52-6 X 37+1 (1700 MPa等 级)、长度为30米/根的钢丝绳两根作为吊装索具，对吊装钢丝绳进行受力分析，如图-2, 可以得知F= (tg-/2)2+(tg：/2)2+1 1/2XG0/4= (tg10/2)2+(tg10/2)2+1 1/2X784/4=198KN。The total load under the hook of crane is 808 KN, two slings the diameter 52-6X 37+1(class 1700 MPa) and le

17、ngth 30 meters will be used for lifting. Analyze the load of sling, refer to figure-2, F= (tg 72) 2+ (tg：/2) 2+1 1/2 X G/4= (tg10O/2) 2+ (tg10O/2) 2+1 1/2 X 784/4=198KN.吊装参数 Crane parameters型号 type： LR1280作业半径 working radius : R=12m主杆长 length of boom： L=31.7m额定载荷 rated load : 94.1t吊装载荷 lifting load

18、: 81.7t负荷率 load rate： 86.8%4.3.2 索具 rigging选用规格为52-6X 37+1 (1700 MPa等级)、长度为30米的钢丝绳两根，作为吊装索具，共四股受力，其安全系数为Two slings the diameter 52-6X 37+1(class 1700 MPa) and length 30 meters will beused. The safe modulus is as follows:N=No/F3=1398100- 198- 103=7.0 6安全！ Acceptable5. 吊装布置图 Lifti ng pla n and elevati

19、 on5.1吊装平面布置图 Lifti ng plan viewE-1501A/B吊装平面布置图见图-4, E-1502A/B吊装平面布置图见图-5Lifti ng plan view for E-1501A/B refer to figure-4, lifti ng plan view for E-1502A/B refer to figure-5.5.2 吊装立面图 Lifting elevation viewE-1501A/B吊装立面图见图-6, E-1502A/B吊装立面图见图-7Lifting elevation view for E-1501A/B refer to figure-

20、6, lifting elevation view for E-1502A/B refer to figure-7.6. 施工计戈 U con struct ion pla nE-1502A/B将于2004年1月12日左右进行吊装，E-1502A/B的吊装施工计划将根 据No.1框架的安装进度进行，具体吊装时间另行确定。E-1502A/B will been lifted on Jan 12 2004. E-1502A/B will been lifted according to the schedule of No.1 steel structure installation. Detai

21、l time is hold.7 JHA分析及安全技术措施 HSE management measures7.1施工过程中可能发生的安全事故风险分析JHA during con struction施工现场地质条件差，易发生吊车倾覆事故；Bad ground condition on site will easily cause crane overturn;设备吊装施工属于高空作业，易发生高空坠落事故；Equipme nt lift ing n eeds work at heights, and falli ng accide nt is easily occurred;物体打击；Strick

22、en by objects;设备运输事故；Tran sportati on accide nt;钢丝绳、卡具不合格；Unq ualified wire rope and shackles;吊装作业过程中，发生吊装物件倾倒，损坏吊车等；Equipme nt overtur ns and crane damage duri ng lift ing;在平台和坑、洞口旁作业或路过时发生坠落事故；Falli ng accide nt from platform, pit, hole duri ng work ing or pass ing by;吊耳和平衡梁制作、焊接不合格，发生坠落事故。Unquali

23、fied lifting lug and compensating beam cause falling accident;7.2 相应对策 Corresponding measures加强安全教育，严格执行班前安全讲话和周一安全活动制度，有针对性地交代近 期工作中的安全注意事项；Enhance safety training, strictly carry out the system of tool box meeting and routine Mon day safety meet ing, make safety clarificati on accord ing to rece n

24、t work;凡参加大型设备吊装的工作人员，如安全监督、吊装指挥、配合吊装作业的起重 工人、吊车操作员等，必须持有国家有关部门颁发的上岗证。设备吊装前，对所有参加 吊装的作业人员进行安全和技术交底。All participated pers onnel such as safety supervisor, lift ing comma nder, rigger and crane operator etc. shall have qualification certificate issued by related national authority, tell all pers ons t

25、ake part in lift ing real inten ti ons about safe and tech ni cal parameters.针对物体打击和高空坠落事故的原因，采取下列措施：Follow ing measures shall be take n to avoid object strik ing and falli ng from height:1）戴好安全帽，系好安全带，高空作业时做到安全带高挂低用，使用安全带前仔细检查安全带有无损坏。高处作业、交叉作业应张挂安全网，有高处作业处下方12米必须有安全网，否则不得施工。Correctly use safety hel

26、met and harn ess.Har ness shall be hung at height and used at lower level, and checked carefully prior to using. Safety net shall be used during work at height and cross work, and shall be provided 12m under work position, otherwise, work is forbidde n.2）高处作业应使用合格的脚手杆、吊架、梯子、脚手板，防护围栏，挡脚板和安全带，作业前应认真检查

27、所用安全设施是否坚固、牢靠，脚手架应经安全员检查认可后，挂牌标识，并办理工序交接手续后，方可使用。Qualified scaffold pole, han ger, ladder, gan gpla nk, guardrail, toe board and harn ess shall be used during working at height. Carefully check if all the safety facilities are fixed and reliable before work ing. Scaffold shall be checked and labeled

28、 by safety in spector, and used only after procedure han d-over.3）高处作业使用工具、材料等应放在安全、不易失落处，防止砸伤下方人。Tools and other materials shall be put at safe place duri ng work at height to avoid falli ng and strik ing accide nt.4）为防止设备运输事故的发生，必须认真封车，运前探路，小心谨慎，确保安全。To ensure safety and avoid transport accidents,

29、 equipment must be fixed carefully and tran sport route shall be ascerta ined5）吊装作业区应设置明显的警告牌，并设专职安全员负责安全监护。作业前，将 可能发生事故的区域隔离，无关人员不得入内；Warning board shall be set up at eye-catching position in lifting area, and full-time safety inspector shall be arranged for supervision. Prior to lifting, potential

30、 accident area must be isolated and closed to irreleva nt pers on.6）为防止发生吊装事故，手拉葫芦使用前应检查是否完好，不得超载使用，严禁 强拉硬拽；检查钢丝绳、卡具是否合格。吊装作业时，人员不得站在重物正下方，吊装中国石化集团第十建设公司1 THE TENTHOF gIMDPFC上海化学工业区项目部Shan ghai Chemical In dustry Park Project Departme nt指挥穿着由SECCO公司指定的指挥人员服装进行指挥，指挥信号应统一、明确。安装 的设备应及时固定，确保稳固性。To avoid

31、 lift ing accide nt, cha in block shall be checked before using, and overload and over-tension shall be forbidden. Check if wire rope and shackle are qualified. During liftingpers onnel shall not stay below the lifted equipme nt, the comma nder shall wear the uniform designated by SECCO. The equipme

32、nt shall be fixed timely.7）在坑、洞、平台边缘等“四口五临边”处设置护栏，防止高空坠落事故。Guardrail shall be set up at the edges of pit, hole and platform to avoid falling from height.8）施工场地是由填海形成的，遇到阴雨天气易积水，因此应作好场地的排水措施。 阴雨天气不进行吊装作业，雨天过后，应对场地进行检查，确认条件具备后，才能进行 吊装作业。Con structi on site is formed by sea reclamati on, and easily acc

33、umulate water in rainy days, so dewateri ng measures shall be take n. Lifting work shall be stopped in rainy days, and can be proceeded only after the ground con diti on is acceptable.9）针对每一步工序作业前，组织由总指挥、工程技术部、质量部门、安全部门、 供应部门、施工班组等联合参加的吊装JHA分析专题会议，制定合理、有效的保障措施。 如发生安全事故，应及时抢救受伤人员，保护现场，并对事故原因加以分析，防止同类

34、事故再次发生。According to the characteristic of each working procedure, organize the lifting JHA meeting participated by chief commander, relative personnel from engineering dept., QA dept., HSE dept., procureme nt dept. and con structi on groups, and make reas on able and effective protect ion measures.

35、If accide nt occurs, save the in juries timely, protect the accide nt site, and an alyze accide nt reas ons to avoid same accide nt.10）吊车站位处地面的地耐力应满足吊装工艺要求，吊装过程中应随时检查吊车支 腿处地基的变化情况，如发现异常，应立即停止吊装作业。The bearing capacity of ground must be satisfied with the requirement of lifting. Check the complexi on

36、of ground duri ng lift ing at any mome nt. Stop the lift ing if the ground is out of way.11）卧式设备吊装过程中应设溜尾绳，以防设备偏转碰撞吊车杆。In order to preve nt destro ying boom of crane from the equipme nt deflexi on, must set up traili ng rope whe n lift horiz on tal equipme nt.1SECCO Project 赛科项目1.1Hazard Assessment

37、Worksheets 险源分析报告Company 公司中国石化第十建设公司TCC of SINOPECJob 工作： E-1501A/B 和 E-1502A/B 吊装 E-1501A/B andE-1502A/B Lifting。Number编号Date 日期：E-1502A/B on Jan 12 2004, E-1501A/B hold序 号Step of LOSS工作步骤Chance of Loss可能的危害或损失Risk Ran ki ng作业条件危险性评价法Method of Con trol对危害的控制方法Residual Risk剩余危险1工作准备1、工作人员不熟悉施工方案和相

38、关的要求；不能按照标准正确操 作。SPR1、1、施工前，对所有的作业人员进行施工方案和安全 技术交底，确保每一名施工人员都了解施工程序和作业 方法。2、 对自制的吊装横梁，对所有的焊点进行100%着 色检查；检查吊车和吊装索具是否捆扎牢固；吊装前进 行共检，统一对讲机的频道和联络方式，并进行试吊。1224 22设备吊装1、吊车和钢丝绳选型不当，在吊 装过程中发生吊车倾覆、钢丝绳断 裂等恶性事故。2361、吊车和钢丝绳选型要经过仔细的受力计算，根据吊 装设备的最大重量选择吊车和钢丝绳的型号；吊装钢丝 绳要有合格证并不得小于 6倍的安全系数。2、吊车要合理占位，地基耐压力要经过计算满足吊装 要求。

39、3、 吊车的最大荷载不得其额疋何载的90% ;吊车的支 腿要全部打开，下面铺好钢垫板。1JHA prepared by :JHA拟定：Construction safety manager:施工单位安全经理：DateConstruction responsible person : 施工负责人：DateSupervisor reviewed 监理审核：:SECCO HSE marSECCO HSE 经理lagerDateSECCO Construction manager:Date里：赛科项目经理：DateNQ序号Step of LOSS工作步骤Chance of Loss可能的危害或损失Ri

40、sk Ran ki ng作业条件危险性评价法Method of Con trol对危害的控制方法Residual Risk剩余危险2设备吊装2、在吊装过程中发生人员伤害事故。2361、专人指挥，在吊车的吊装范围内设立警戒绳；严禁无关人 员进入作业区域；2、所有的作业人员在作业过程中要穿戴好劳动保护用品；在 起吊过程中不得站在吊车的起重臂下。把设备顶部和周边的杂物清理干净，防止在吊运过程中杂物掉落伤人。13设备吊装绑扎方法不正确导致吊物 倾斜。SPR按照方案要求正确绑扎，并画出绑扎点的位置图。1224起重工绑扎钢丝绳作业时 伤手。133戴好防护手套，注意与吊车指挥人员的协调配合。钢结构移动时碰伤

41、作业人 员或其他人员。2241、专人指挥，无关人员不得进入作业区；2、设备移动时用溜绳或搭钩进行辅助移动、固定。恶劣的天气或恶劣的工作 条件使作业风险增大。224禁止在夜间，大雨，雷电，风速大于10.8米/秒的情况下进行吊装作业。设备在就位时挤伤铆工或 起重工的手。2361、设备就位时用溜绳或搭钩进行辅助固定。2、吊车指挥人员要看清情况后进行指挥，设备就位时要缓慢 进行。1设备安装过程中发生偏移 等事故。133设备在安装完成，上好地脚螺栓以后再摘吊车的吊钩。18质量保证措施QA measures8.1严格物资采购和管理制度，施工所用全部主、辅料均需有合格证，并应保证合 格项目齐全和符合设计要求

42、。Enhance the man ageme nt of material procureme nt. Qualificati on certificate for all main and auxiliary materials used for construction shall be available.8.2做好技术交底工作，使参与施工的人员对施工的技术要求和质量标准有明确的 认识。Make technical clarification to ensure all construction personnel is familiar with the tech ni cal and

43、 quality requireme nts.8.3施工班组长负责组织工程质量自检，及时做好自检记录，并应得到质检员的确 认。对需要共检的项目应及时、准确地做好签字完备的检验记录。Construction group leader is responsible for organizing quality self-inspection and record ing timely which to be con firmed by quality in spector. For co-i nspect ion item, in specti on record with completed s

44、ig nature shall be prepared timely and exactly.8.4严格工序交接制度，自检、专检、互检相结合，确保工序质量从而保证工程质 量。Strictly perform work procedure hand-over system, implement self-inspection, special inspection and mutual inspection to ensure procedure quality, and consequently ensure project quality as well.8.5严格执行十公司制定的有关程序文

45、件，及时、准确地采集相关数据，确保数据 的准确性和完整性。Strictly abide by the related programs issued by TCCS, collect related data timely and exactly to en sure the veracity and in tegrity.8.6施工所用计量器具要定期送检，确保准确有效。Measureme nt apparatus shall be calibrated termly to en sure accuracy.8.7吊装作业时，人员不得站在重物正下方，指挥信号应统一、明确。作业前，将 可能发生事

46、故的区域隔离，设立吊装作业专用区，设围栏，与吊装工作无关人员严禁入 内，专职安全员负责现场安全工作。During lift ing, pers onnel shall not stay below the lifted equipme nt; the comma nd shall be uniform and clear. Prior to lifting, potential accident area must be isolated and lifting area shall be surrounded with guardrail and closed to irrelevant p

47、erson, full-time safety inspector is resp on sible for site security.8.8做好吊装机具的维护、保养，保证施工车辆完好，满足施工要求。吊装使用的 钢丝绳严格按照方案中要求进行选用，使用前应经质量、安全部门检验，如发现一个捻 距内断丝超过6根钢丝，则不得用于本方案涉及到的设备吊装。Keep lifting machine and tools in good condition through good maintenance to fulfillcon struct ion requireme nts.Strictly choo

48、se the sli ngs will bee n used duri ng lifti ng according to the liftingscheme, and QADepartment and HSEDepartment check theslings before lifting. The slings can not been used if find six steel wires are broke n.8.9每次吊装前均应在吊装总指挥签发吊装令后，方可以按程序进行，同时吊装前 应进行试吊。The lifting can be proceeded according to pr

49、ocedures only after chief commander en dorses the lift ing order, mea nwhile, trial lift ing shall be carried out before lift ing.图8质量管理体系Figure-8 QA con trol orga ni zati on129.应遵循的主要质量文件Quality docume nts followed9.1 QG/P4441.30.05-2001施工技术文件管理程序；“ Management procedure for con struct ion tech ni c

50、al docume ntS ;9.2 QG/P4441.30.06-200工程竣工技术文件管理程序；“ Management procedure for technical documents for engineering completion ;9.3 QG/P4441.30.07-200物资采购管理程序；“ Management procedure for material procuremenf;9.4 QG/P4441.30.08-2001物资保管、发放管理程序；“ Management procedure for material storage and issue ;9.5 QG

51、/P4441.30.09-2001用户提供物资管理程序；“ Management procedure for material supplied by owne” ;9.6 QG/P4441.30.10-2001标识管理程序；“ Management procedure for identification ” ;9.7 QG/P4441.30.13-2001安装施工管理程序；“ Ma nageme nt procedure for installation” ；9.8 QG/P4441.30.19-2001 隐蔽工程管理程序；“ Management procedure for concealed work ” ;9.9 QG/P4441.30.20-2001设备管理程序；“ Management procedure fo