E-1501ABE-1502AB吊装施工技术方案.

1、上海化学工业区项目部Shanghai Chemical Industry Park Project Department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 Ethylene Plant of Shanghai 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 Lin Originated By:施工技术审核： 李春法 Chunfa Li Tech.

2、 Reviewed By: 质量保证审核： 戴东明 Dongming Dai QA Reviewed By : 安全技术审核： 边长刚 Changgang BianHSE Reviewed By: 审 定： 徐庆海 Qinghai Xu Checked by:批 准：褚振辉 Zhenhui Chu Approved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Shanghai Chemical Industry Park Project Department of TCCS1 概况 Project introduction

3、SECCO乙烯装置急冷区设备， 1号急冷水冷却器(E-1501A/B)，外形尺寸为2070（外径）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）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9725），(E-1502A/B)位于混凝土基础上（基础标高2280），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。In quench area of SECCO ethylene, wide si

4、ze of Quench Water Coolers No.1 is 2070(O.D)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)13650(total length), net weight of the equipment is 77.7 tons, four equipments are horizontal , E-1501A/B locate above platform of No.

5、1 steel structure (elevation of cradle 9725), E-1502A/B locate above concrete foundation (elevation of foundation 2280). Will adopt “single crane lifting” to lift the four equipments, the type of crane is crawler crane LR1280. In order to ensure safe of lifting, authorize the scheme specially.2编制依据

6、reference2.1化工塔类设备安装施工及验收规范Construction and acceptance specifications for chemical towers HGJ211-832.2 化工工程建设起重施工规范Construction specifications for lifting in chemical engineering construction HGJ201-832.3.大型设备吊装工程施工工艺标准Construction process standards for heavy equipment lifting SHJ515-902.4 石油化工施工安全技

7、术规程Security technology regulations for petrochemical construction 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File No.：E-10856-00428A2.7 LR1280型吊车性能表 The load table of cr

8、ane LR12802.8 1号急冷水冷却器(E-1501A/B)施工图 Drawing of Quench Water Coolers No.12.9 2号急冷水冷却器(E-1502A/B)施工图 Drawing of Quench Water Coolers No.23.工序 procedure吊装施工工序如图-1。Construction procedure of lifting is figure-1.方案编制场地地基处理地基处理验收吊车进场组装设备进场、验收吊装用具（卸扣、索具）的采购、验收试吊、测吊装重量正式吊装吊车退场图-1 施工工序Authorize schemeFoundat

9、ion treatmentAccept foundationMain crane entranceEquipment entrance And inspect Balance beam and shackle and sling purchase and inspecttrial lifting and measure weight of equipmentLifting Crane outFigur-1 construction procedureAssist crane entrance4.吊装前的准备工作 prepare works before lift4.1设备吊装对No.1框架的预

10、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&B轴线钢结构延缓施工。The steel structure of axial A&B of No.1 steel structure shall be postponed before equipment lifting.4.2 E-1501A/B吊装技术参数 Main technical 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）1

11、1088（全长），设备净重80吨，鞍座标高9725，吊装重量确定如下：Quench Water Coolers No.1 is 2070(O.D)11088(total length), net weight of the equipment is 80 tons, elevation of cradle is 9725, the lifting weight is as follows:吊装重量Weight of Lifting G=设备重量weight of equipment G1+吊钩重量weight of hook G2+索具重量 weight of rigging G3=80+3.

12、3+0.7=84t吊车钩头（100t级）以下总载荷G0为807KN，使用52-637+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=（tgb/2）2+（tga/2）2+11/2G0/4=（tg10O/2）2+（tg10O/2）2+11/2807/4=203.5KN。The total load under the hook of crane is 808 KN, two slings the diameter 52-637+1(class 1700 MPa) and length 30 meters will be use

13、d for lifting. Analyze the load of sling, refer to figure-2, F=（tgb/2）2+（tga/2）2+11/2G0/4=（tg10O/2）2+（tg10O/2）2+11/2807/4=203.5KN.FG3000图-2F211613760mma=10Ob=10O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

14、rate：89.3%4.2.2索具 rigging选用规格为52-637+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 52-637+1(class 1700 MPa) and length 30 meters will be used. The safe modulus is as follows:N=NO/F=1398100203.5103=6.876安全! Acceptable 4.3 E-1502A/B吊装技术参数 Main technical parameters of E-1502A/B4

15、.3.1 2号急冷水冷却器(E-1502A/B)，外形尺寸为1943（外径）13650（全长），设备净重77.7吨，基础标高为2280，吊装重量确定如下：Wide size of E-1502A/B Quench Water Coolers No.2 is 1943(O.D)13650(total length), net weight of the equipment is 77.7 tons, elevation of concrete foundation is 2280, the lifting weight is as follows:吊装重量Weight of Lifting G=

16、设备重量weight of equipment G1+吊钩重量weight of hook G2+索具重量 weight of rigging 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52-637+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=（tgb/2）2+（tga/2）2+11/2G0/4=（tg10O/2）2+（tg10O/2）2+11/2784/4=198KN。The total load under the hook of crane is 808 KN,

17、 two slings the diameter 52-637+1(class 1700 MPa) and length 30 meters will be used for lifting. Analyze the load of sling, refer to figure-2, F=（tgb/2）2+（tga/2）2+11/2G0/4=（tg10O/2）2+（tg10O/2）2+11/2784/4=198KN.FG3000图-3F194313760mma=10Ob=10O吊装参数 Crane parameters型号 type：LR1280作业半径 working radius ：R=1

18、2m主杆长 length of boom：L=31.7m额定载荷 rated load ：94.1t吊装载荷 lifting load：81.7t负荷率 load rate：86.8%4.3.2索具 rigging选用规格为52-637+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 52-637+1(class 1700 MPa) and length 30 meters will be used. The safe modulus is as follows:N=NO/F=1398100198103

19、=7.06安全! Acceptable 5.吊装布置图 Lifting plan and elevation5.1吊装平面布置图 Lifting 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-5。Lifting plan view for E-1501A/B refer to figure-4, lifting 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-7。Liftin

20、g elevation view for E-1501A/B refer to figure-6, lifting elevation view for E-1502A/B refer to figure-7.6.施工计划 construction planE-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

21、No.1 steel structure installation. Detail 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 construction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；Equipment lifting needs work at heights, and falling acci

22、dent is easily occurred;物体打击；Stricken by objects;设备运输事故；Transportation accident;钢丝绳、卡具不合格；Unqualified wire rope and shackles;吊装作业过程中，发生吊装物件倾倒，损坏吊车等；Equipment overturns and crane damage during lifting;在平台和坑、洞口旁作业或路过时发生坠落事故；Falling accident from platform, pit, hole during working or passing by;吊耳和平衡梁制

23、作、焊接不合格，发生坠落事故。Unqualified 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 Monday safety meeting, make safety clarification acc

24、ording to recent 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 personnel such as safety supervisor, lifting commander, rigger and crane operator etc. shall have qualification certificate issued by related national authority, tell all

25、persons take part in lifting real intentions about safe and technical parameters.针对物体打击和高空坠落事故的原因，采取下列措施：Following measures shall be taken to avoid object striking and falling 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 harness. Harness 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 forbidden.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，作业前应认真检查所用

27、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, hanger, ladder, gangplank, guardrail, toe board and harness shall be used during working at height. Carefully check if all the safety facilities are fixed and reliable before working. Scaffold shall be checked and labeled by saf

28、ety inspector, and used only after procedure hand-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 during work at height to avoid falling and striking accident.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, equipment m

29、ust be fixed carefully and transport route shall be ascertained 5）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 accident area

30、 must be isolated and closed to irrelevant person.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 lifting accident, chain block shall be checked before using, and overload and over-tension shall be forbidden. Ch

31、eck if wire rope and shackle are qualified. During lifting personnel shall not stay below the lifted equipment, the commander shall wear the uniform designated by SECCO. The equipment 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 plat

32、form 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。Construction site is formed by sea reclamation, and easily accumulate water in rainy days, so dewatering measures shall be taken. Lifting work shall be stopped in rainy days, and can be

33、proceeded only after the ground condition 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，防止同类事故再次发生。According to the characteristic of each working procedure, organize the lifting JHA meeting participated by chief commander

34、, relative personnel from engineering dept., QA dept., HSE dept., procurement dept. and construction groups, and make reasonable and effective protection measures. If accident occurs, save the injuries timely, protect the accident site, and analyze accident reasons to avoid same accident.10）吊车站位处地面的

35、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 complexion of ground during lifting at any moment. Stop the lifting 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 prevent destroying

36、 boom of crane from the equipment deflexion, must set up trailing rope when lift horizontal equipment. 9上海化学工业区项目部Shanghai Chemical Industry Park Project Department1 SECCO Project 赛科项目1.1 Hazard Assessment Worksheet 危 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-1501

37、A/B and E-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 Ranking作业条件危险性评价法Method of Control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、 2、对自制的吊装横梁，对所有的焊点进行

38、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。12242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。3、吊车的最大荷载不得其额定荷载的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： D

39、ate Construction responsible person : 施工负责人： Date Supervisor reviewed： 监理审核： Date SECCO HSE manager Date SECCO HSE经理：SECCO Construction manager： 赛科项目经理： Date No序号Step of LOSS工作步骤Chance of Loss可能的危害或损失Risk Ranking作业条件危险性评价法Method of Control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

40、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

41、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。1 10上海化学工业区项目部Shanghai Chemical Industry Park Project Department8 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。Enhance the management of material procure

42、ment. Qualification 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 technical and quality requirements.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，

43、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 recording timely which to be confirmed by quality inspector. For co-inspection item, inspection record with completed signature shall be prepared timely and exactly.8.4严格工序交接制度，自

44、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 pro

45、grams issued by TCCS, collect related data timely and exactly to ensure the veracity and integrity.8.6施工所用计量器具要定期送检，确保准确有效。Measurement apparatus shall be calibrated termly to ensure 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 lifting, pe

46、rsonnel shall not stay below the lifted equipment; the command 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 person, full-time safety inspector is responsible for site security.8.8做好

47、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 fulfill construction requirements. Strictly choose the slings will been used during lifting according to the lifting scheme,

48、and QA Department and HSE Department check the slings before lifting, The slings can not been used if find six steel wires are broken.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 procedures only after chief commander endorses the lifting order, meanwhile, tria

49、l lifting shall be carried out before lifting.质量管理部SECCO公司、齐鲁监理十公司项目管理部项目经理质量经理项目总工程师工程管理部物资装备部计划经营部调度室吊装工程师设备安装工程师质量检查员起重班测量员图8 质量管理体系8.10质量管理体系见图-8。QA control organization refers to figure-8.QA departmentSECCO、QPECProject manage departmentProject managerQA managerChief engineerEngineering departme

50、ntMaterial departmentOperation departmentCoordination officeLifting engineerEquipment engineerQA inspectorRiggerMeasurerFigure-8 QA control organization9. 应遵循的主要质量文件Quality documents followed9.1 QG/P4441.30.05-2001施工技术文件管理程序；“Management procedure for construction technical documents”;9.2 QG/P4441.30

51、.06-2001工程竣工技术文件管理程序；“Management procedure for technical documents for engineering completion”;9.3 QG/P4441.30.07-2001物资采购管理程序；“Management procedure for material procurement”;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/P4441.30.09-2001用户提供物资管理程序；“M

52、anagement procedure for material supplied by owner”;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；“Management 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 for equipment”;9.10 QG/P4441.30.21-2001工序质量