履带吊安装方案

拜耳材料科技（中国）有限公司扩建5万吨/年HDI和3万吨/年IPDI项目履带吊安装方案 Contents目录一、 References编制依据 1二、 PreparationStatement编制说明 1三、 GeneralInformation吊机概况 13.1 BasicDimensions基本外形尺寸 13.2 DimensionandWeightofMainTranspotationComponents主要运输部件外形尺寸及重量 23.3 MainPerformanceParametersofQUY200QUY200主要性能参数表 63.4 BoomCompositionTable吊臂组成组合表 7四、 ProjectFeaturesAnalysis工程特点分析 7五、 ConstructionArrangements施工安排 7六、 ConstructionProcedures施工流程 7七、 SiteLayout现场布置图 7八、 ConstructionMethods施工方法 88.1 RelevantPreparationsinAdvance前期相关准备 88.2 HostUnloading主机卸车 98.3 TrackedUnloadingandAssembly履带卸车及组装 108.4 Counterweight,BottomUnloadingandAssembly配重及底板卸车及组装 118.5 BoomUnloadingandAssembly臂架卸车及组装 128.6 MainBoomandJibInstallation主副臂安装 138.7 TieRopeandHookInstallation拉杆钢丝绳及吊钩安装 138.8 BoomElevation臂架提升 148.9 CommissioningandTesting调试及检测 14九、 ProductionSafetyMeasures安全生产措施 159.1 PrinciplesandGoalsofSafetyProduction安全生产的原则和目标 159.2 SiteSafetyRequirementsforMandatory施工现场强制性安全要求 15References编制依据Documentsprovidedwithcranebymanufacturer履带式起重机随机资料；OperationInstructionfor200TCrawlerCrane《200T履带吊使用说明书》；

JGJ/T189-2009TechnicalSpecificationonSafetyAssessmentofBuildingCraneonConstructionSite《建筑起重机械安全评估技术规程》；GB/T5972-2009Cranes-Wireropes-Care,Maintenance,Installation,ExaminationandDiscard《起重机钢丝绳保养、维护、安装、检验和报废》；GB50278-2010CodeforConstructionandAcceptanceofCranesInstallationEngineering《起重设备安装工程施工及验收规范》；JGJ33-2012TechnicalSpecificationforSafetyOperationofConstructionMachinery《建筑机械使用安全技术规程》；BayerShanghaiSiteRoadLayoutPlanandrelatedspecifications拜耳上海基地现场道路布置图及相关规范。PreparationStatement编制说明ThisplanispreparedforthepurposetoinstructtheinstallationofQUY200crawlercrane,andavoidimpactsonconstructionprogresscausedbyunfamiliaritywithworkprocesses.为了指导QUY200履带式吊机安装工作，预防出现各种因不了解各工序施工方法而影响施工进程，特制定本方案。GeneralInformation吊机概况ThecrawlercraneQUY200mainlyconsistsofhost,counterweight,boom,hooketc..Specificationsofeachpartarelistedasfollows.QUY200履带式吊机主要分为主机、配重、吊臂、吊钩等部分组成，各部分规格参数如下图所示。BasicDimensions基本外形尺寸DimensionsandWeightofMainTransportationComponents主要运输部件外形尺寸及重量Host48t主机—48吨TrackFrameAssembly23t×2履带架总成—23t×2CounterweightBottom15t×1配重底板—15t×1Counterweight4.45t×10配重—4.45t×10Counterweight2.94t×2配重—2.94t×230THook1.1t×130T吊钩—1.1t×1BottomPartofMainBoom2.2t×1主臂底节臂—2.2t×1TopPartofMainBoom2.9t×1主臂顶节臂—2.9t×13mPartofMainBoom0.5t×1主臂3m节臂—0.5t×16mPartofMainBoom0.9t×1主臂6m节臂—0.9t×19mPartofMainBoom1.3t×1主臂9m节臂—1.3t×1BottomPartofLuffingJib0.8t×1变幅副臂底节臂—0.8t×1TopPartofLuffingJib0.9t×1变幅副臂顶节臂—0.9t×13mPartofLuffingJib0.2t×1变幅副臂3m节臂—0.2t×16mPartofLuffingJib0.4t×1变幅副臂6m节臂—0.4t×19mPartofLuffingJib0.6t×1变幅副臂9m节臂—0.6t×1FrontStrutofLuffingJib1t×1变幅副臂前撑杆—1t×1BackStrutofLuffingJib1.2t×1变幅副臂后撑杆—1.2t×1MainPerformanceParametersofQUY200QUY200主要性能参数表项目Items数值Value备注NoteMaxWeight×Range最大起重量×幅度t×m200×5BasicElbowWeight基本臂时自重t196MainBoomLength主臂长度m20~83FixedJibLength固定副臂长度m12~30MaxWeightofFixedJib固定副臂最大起重量t32InstallationAngleofFixedJib固定副臂安装角度°10,30MainBoom＋MaxLengthofFixedJib主臂＋固定副臂最大长度m71＋30JibTowerLength塔式副臂长度m21~51MaxWeightofJibTower塔式副臂最大起重量t55BoomWorkingAngleunderTowerConditions塔式工况主臂工作角度°65、75、85MainBoom＋MaxLengthofJibTower主臂＋塔式副臂最大长度m59＋51Rollingspeedofsinglerope卷筒单绳速度MainLifting主起升m/min102Thefourthlayerofroll卷筒第四层ViceLifting副起升m/min102Thefourthlayerofroll卷筒第四层RangeofChange变幅m/min45Thefourthlayerofroll卷筒第四层SwingSpeed回转速度rpm0~1.39WalkingSpeed行走速度km/h0~0.98CrawlingCapability爬坡能力％30GroundPressure接地比压MPa0.1Dimensionslength×width×height总外形尺寸长×宽×高m10.6×7.2×3.9MastBoomnotIncluded不含桅杆臂架Engine发动机Ratedpower/speed额定功率/转速kW/rpm256/2100228/2100Maxoutputtorque/speed最大输出扭矩/转速Nm/rpm1750/12001505/1400Emissionstandards排放标准EUStageIITierⅢTrackgauge×groundinglength×creeperwidth履带轨距×接地长度×履带板宽度mm6000×7935×1400BoomCompositionTable吊臂组成组合表number序号Condition工况Numberofmainbooms主臂节数NumberofJibs副臂节数Note备注135mmainboom+27mjib35m主臂+27m副臂3m*1+6m*23m*1+6m*12辆247mmainboom+36mjib47m主臂+36m副臂3m*1+6m*1+9m*23m*1+6m*1+9m*12辆ProjectFeaturesAnalysis工程特点分析Becauseofthesmallsiteanddifficultperformance,coordinationsforroadsclearingandclosingareneeded;现场场地狭小，操作难度大，需要协调场内道路疏通及道路封闭；Theheavycrawlercraneneedshighfoundationbearingcapacity,soroadsshouldbehardenedandlayedfoundationboardsandboxes;履带吊自重较大，需要地基承载力较高，因此需要对路面进行硬化处理及铺设路基板及路基箱；Becauseofthegreatweightofcomponents,truckcranesareneededforcooperationduringinstallation,sotheoperationisverydifficult.各部件自重大，安装需要汽车吊进行配合，操作难度大。ConstructionArrangements施工安排Accordingtothesiteconstructionschedule,HDI5unitisexpectedtotransfertostructuralsteelconstructionattheendofJune.Weintendtostartcrawlercraneinstallationworkon20thJune.Crawlercranedismantlingworkwillbecarriedoutafterfinishingstructuralsteelbodylifting.Thedismantlewillbephrasedandthedatewilldependonsiteinstallationschedule.根据现场施工进度安排，预计HDI5单元6月底移交钢构施工，我司拟在6月20日开始进行履带吊的安装工作。钢结构主体吊装完成则进行履带吊拆除工作，预计后期会分阶段拆除，具体拆除日期根据现场安装进度确定。ConstructionProcedures施工流程Craneapproaching→craneinspection→transportationroutechecking→installationsitechecking→craneunloading→crawlertrackcounterweightself-installation→truckcranecooperatingwithboominstallation→cranecommissioningandtesting→craneacceptance→layingmeasuresforfoundationboards→liftingoperations.吊机进场→吊机检验→运输路线查看→安装场地查看→吊机进场卸车→履带吊自行安装履带配重→汽车吊配合安装吊臂→调式检测吊车→吊车验收→路面铺设路基板措施→吊装作业。SiteLayout现场布置图CranecomponentsshouldbetransportedoutsideBayersiteandtoliftingareaafteracceptance.Routesfortrucksinsiteareasfollows:吊车部件运输至拜耳基地场外，在场外验收完成后运至吊装区域，场内货车行走路线如下所示：Structuralsteelyard1#2#1#2#4#3#Seeattachments1and2forsitecraneassemblylayouts.吊机现场拼装布置图见附件1、2。Assemblyorderforthe4cranesis:first1#crane,then3#crane,next2#crane,andatlast4#crane.4辆吊机的拼装顺序为：先拼装1#吊车，再拼装3#吊车，尔后拼装2#吊车，最后拼装4#吊车。Constructionmethods施工方法Relevantpreparationsinadvance前期相关准备Transportroadsshouldbecheckedbeforecrawlertracktransportation.Theroadsmustbesolid,smoothandwithnolargepotholes.Eachroadcurvemustbeabletoensurethesmoothcornering.Thereshouldbenoobstaclesovertheroads.Clearanceshouldmeettherequirementsofaccessandsoon.Ensuresafeandsmoothtrafficduringtransport.履带吊运输前需先查看运输沿线道路情况，道路必须坚实平整无大型坑洼。道路各弯道必须保证车辆能够顺利进行转弯行驶。道路上空无障碍物，净空是否满足通行等。确保运输过程中安全顺利通行。Installationsitechecking.Sincetheweightofcrawlertrackafterassemblyisabout210t,thefoundationbearingcapacityshouldbehighandthereshouldbenounstablesoilorlaminatedsiltetc.underground.Thefoundationbearingcapacitymustnotbelessthan10T/㎡.Inviewofthese,theroadsshouldbelayedwithfoundationboardsandthewestlawnbackfillareashouldbecompactedandleveledwithhardconstructionmaterials.Thebestmethodistopourconcretefirstandthenlaysteelboardsonit.查看安装场地，由于履带吊组装完成后自重约210T，要求地基承载力高，安装场地不得有不稳定土质，下层不得有淤泥夹层等，地基承载力必须≥10T/㎡。因此需要在原路面上铺设路基板，且西侧草地回填区域要用硬质施工材料夯实整平，最好是浇筑砼，尔后在面上铺设钢板。Thediagramisasfollows:示意图如下：Diagramforroadteethprotectionnodes:路牙保护节点示意图：HostUnloading主机卸车Whencrawlertrackarrivesinsite,legswillliftfromthetopofthehost.Thenthetrackdriveoutthesitealongtheroad,withthespeednotmorethan25km/h.履带吊运输至现场后，主机顶升支腿，货车沿道路前行驶出现场，时速不超过25km/h。Thediagramisasfollows:示意图如下所示：TrackedUnloadingandAssembly履带卸车及组装Crawlercraneapproachingisafterthehostcomestoitsplace.Crawlersareunloadedbyhostandassembledontheirownbythebalancearmofthehost.Mainboominstallationiscarriedoutaftercrawlersandcounterweight,andthelegscanbebackonlyafterpassingtheinspectionsofprofessionals.主机就位后则开始进场吊机履带，履带用主机卸车，且自行组装履带，自行组装采用主机平衡臂，履带及配重完成后进行主臂安装，经专业人员检测合格后方可收支腿。Thediagramisasfollows:示意图如下所示：Counterweight,BottomUnloadingandAssembly配重及底板卸车及组装Counterweightboardsandblocksinstallationiscarriedoutaftercrawlerinstallation.Thetracktransportsthebottomboardstothehostattachment.Thenthehostunloadsthemtotheelevationplacebehind.Next,placethecounterweightblocksonebyoneonthebottomboards.Afterthat,rotatethehosttoinstallthecounterweightbypowerpin.履带安装完毕后则开始进行配重底板及配重块的安装，货车运输底板至主机附件，由主机卸车至主机后侧提升处，尔后把配重块依次放置在底板上，待配重放置完成后回转主机，用动力销轴把配重重安装完成。Thediagramisasfollows:示意图如下所示：BoomUnloadingandAssembly臂架卸车及组装Theinstallationofbottompartofmainboomiscarriedoutafterfinishingcounterweightsysteminstallation.Thisisdonebyhostitselfafterunloading.配重系统安装完成后则开始安装底节主臂，底节主臂由主机自行卸车安装。Thediagramisasfollows:安装示意图如下：MainBoomandJibInstallation主副臂安装Mainboomandjibneed25ttruckcraneforunloadinginstallation.Unloadrelevantcomponentstothebottomforconnection,andmakeslightadjustmentbyworkers.Alignthepinholesofthetwobooms,paintthelubricant,insertthepinfromoutsideandfixit,then,installothercomponentsinorder.主副臂节需要用25T汽车吊进行卸车安装，将相关部件卸车至底节位置进行对接，且采用人工进行微调，两节臂的销孔对齐，涂抹润滑油，由外向内插入销轴，并固定，尔后依次安装其他部件。Thediagramisasfollows:安装示意图如下：TieRopeandHookInstallation拉杆钢丝绳及吊钩安装Theinstallationoftrolleywireropeandhookiscarriedoutafterthatofmainboomandjib.Thehookshouldbea30tonewith2*2pulleyblocks.Putthehookattheendofthemainboom,flameoutthecrawlerhostfromoperation,releasethehoistandthenorderworkerstoconnectthehookwithhostbywireropesaccordingtotherequirements,andfixtheendsofwireropeswithsnaprings.主臂及副臂安装完成后则开始安装拉杆钢丝绳以及吊钩，吊钩采用30T吊钩，选用2*2滑轮组，将吊钩放置在主臂端头，履带吊主机熄火，停止运转，将卷扬机制动放开，用人工将钢丝绳按照要求将吊钩与主机连接起来，并有卡环将钢丝绳端头固定。Thediagramisasfollows:安装示意图如下：BoomElevation臂架提升Afterassemblingbooms,checkthepintomakesureitisfixedandthewireropesqualified.臂架组装完成后，检查销轴是否紧固完成，穿绕钢丝绳是否合格。Crawlerhostcanonlybestartedafterhookinstallation.Liftthepole,elevatethemainboomandjibasawholeandthehoistwilltensilethewireropesslowly.Stopfor5minuteswhentheangleofmainboomandtrolleyjibgetsstable.Thencheckthewireropesandboomagain.Elevatethemtotheworkingangleiftheyarequalified.吊钩安装完成后，方可启动履带吊主机，指挥起杆，主臂跟副臂整体提升，卷扬机缓慢拉伸钢丝绳，主臂与拉杆副臂形成稳定夹角后停止5分钟，再次检查钢丝绳及臂架后完全符合要求后再次提升至工作角度。Thediagramisasfollows:安装示意图如下：CommissioningandTesting调试及检测Docheckafterinstallation.Forexample,whethereverypininstallationisqualifiedornot,whetherthepinsarefixedornot,whetherjibluffing,hookliftinganddropping,hookinsurancecards,anti-overturningdevices,slewingmechanism,U-ropesettingandothermechanicalactionsarecorrectandstableornot,whetherthesafetydevicesareflexibleandreliableornot,whetherthetorquedisplayingisflexibleornot.Makeadjustmentstimelyifthereareanyproblems.Checkthebrokenwireinwireropesling,hookwearing,U-shapedringwearing.Aftertheself-testisrunningnormally,inviterelevantinspectionstaffforthewholedetectionandissuingtheliftingoperationlicense.完成安装后检查每个销轴安装是否到位，别针是否牢固，检查吊臂变幅、升降吊钩、吊钩保险卡、防后倾覆装置、回转机构、U型绳卡设置等机构动作是否正确平稳，安全装置是否灵敏可靠。力矩显示是否灵敏。如若发现问题及时进行调整。吊具钢丝绳的断丝、吊钩磨损、U型吊环磨损的检查。经各项自检运行正常后，申请相关检测人员前来进行整机检测并出具吊装作业许可证。Thediagramofworkingconditionisasfollows:工作状态示意图如下：ProductionSafetyMeasures安全生产措施PrinciplesandGoalsofSafetyProduction安全生产的原则和目标Principles原则ResolutelyobeytherelevantrequirementsofBayerIntegratedSiteShanghai;坚决服从拜耳上海一体化基地相关要求；Adheretotheprincipleofsimultaneousimplementationofproductionandsafety;坚持生产与安全同步实施的原则；Adheretotheprincipleofsafetyfirst.坚持安全第一原则。Goals目标ShanghaiConstructionandstrictlyinaccordancewiththeorganizationofcivilizationonbuildingconstructionsiteconstructionsitestandardizeregulationstoeliminateallon-sitesafetyhazards.严格按照上海市有关建筑工程施工现场标准化管理规定组织施工和现场文明施工，消除一切现场安全隐患。SiteSafetyRequirementsforMandatory施工现场强制性安全要求Projectsafetyplansandproceduresshouldbereportedtotheownerssupervisingengineertoreviewandaccepttheproposedadditionalrequirementsunplanned.Constructionsitemustperformthefollowingmandatoryrequirements:项目安全计划及程序应报业主监理工程师审查，接受计划外提出的附加要求。现场施工必须执行下述强制性要求：Notwearingprotectiveequipment(helmets,workshoes,etc.)ofemployees(includingvisitor,supplierrepresentatives,materialtransportmember)shallnotentertheconstructionsite;没有穿防护用品(安全帽、工作鞋等)的职工(包括来访者、供方代表、材料运送员)不得进入施工现场；Aerialseatbeltwhenever2maboveshouldbeprotectedwithinthescopeoflanding;高空作业系安全带，无论何时在2m以上的降落范围内应有保护；Participatedinoperationspersonnelmustundergosafetytraining,examination;参加作业人员必须经过安全培训，考试合格；Liftingcommandtocommandbyap