上海某工程反应釜吊装方案教学提纲.doc

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PROJECT EXECUTION PROCEDURES施工方案33.1 Large Scale Equipment Lifting Plan大型设备吊装方案33.1.1 General编制说明33.1.2 Applicable Codes and Standards引用的标准和规范33.1.3 Lifting Overall Design吊装总体设计43.1.4 Heavy Lifting Table大型设备吊装清单53.1.5 Lifting Plan of DG workshop 甲类厂房设备吊装73.1.6 Lifting Plan of AT workshop丙类厂房设备吊装143.1.6.1 General总体说明143.1.6.2 M020304 lifting plan 设备吊装143.1.6.3M020212C Lifting Plan设备吊装223.1.7Lifting Device List吊装机具一览表283.1.8 Safety Technology Requirements安全技术措施283. Project execution procedures施工方案3.1 Large Scale Equipment Lifting Plan大型设备吊装方案3.1.1 General编制说明XXX Project Phase has 363 equipments.xxx项目二期工程，共有设备363台。The equipments which are more than 10T are about 13 sets. The workshop is the concrete framework structure and the equipments are heavy so we need to prepare the Lifting Plan to guide the project equipment lifting and all project coordination.超过10吨的重型设备有13台。由于车间属于混凝土框架结构，并且设备重量较大，必须编制吊装方案，用于指导项目的设备吊装工作和整个工程的施工协调。3.1.2 Applicable Codes and Standards引用的标准和规范Construction technical drawings supplied by OWNER业主提供的施工技术图纸Equipment plot plan layout设备平面布置图Construction standard for large-size equipment hoisting engineering大型设备吊装工程施工工艺标准SH/T 3515-2003Safety specification for hoisting installation起重机械安全规程 GB6067.1-2011Lifting construction specification for petrochemical engineering石油化工工程起重施工规范 SH/T3536-2002 Specification for hoisting of installation project of construction engineering工程建设安装工程起重施工规范 HG20201-2000 Technical code for safety of working on higher in construction建筑施工高处作业安全技术规范 JGJ80-91Technical code for safety of steel tubular scaffold with couplers in construction建筑施工扣件式钢管脚手架安全技术规范 JGJ130-2011Site construction condition现场施工条件Capacity diagram for relative cranes吊车性能表3.1.3 Lifting Overall Design吊装总体设计The normal equipment weighs above 20Tand under 30T. The 100T track crane can lift it. Even though the speed is not fast, it suit for the lift alone. When the goods arrived and installed immediately. The cost is low. The equipment weigh under 20T, the 50T track crane can lift it. The unloading and transportation are very convenient. Due to the numbers the track are large, the equipments can be lift concentrated.Crane and a scooter to focus to use, can maximize labor efficiency, saving construction cost.一般30吨以下20吨以上的设备，属于100吨以上汽车吊的能力范围，吊装过程比较慢，单台吊装比较适宜，到货后立即安装，可以节省二次运输费用。20吨以下的设备，是50吨以下汽车吊的能力范围，卸车和运输都比较方便，由于台数比较多，适合于多台设备一起吊装。吊车和板车集中使用，可以最大限度地提高工人的劳动效率，节约施工成本。This scheme gives all heavy equipment ( 10t) of the lifting scheme, need crane are listed in the large scale equipment lifting list. After that, he painted out of the 13 sets of equipment assembly drawings, are representative.本方案给出了全部重型设备（10吨）的吊装方案，所需要的吊车均列在大型设备吊装清单里。在此之后，还画出了13台设备的吊装图纸，均具有代表性。3.1.4 Heavy Lifting Table大型设备吊装清单Heavy Lifting Table 重型设备吊装一览表ITEM单项Description 名称描述Main specifcation主要规格U.M. 计量单位Quantity数量Unloading卸车Loading&Transport装车和运输Main Crane主吊车Tailing Crane遛尾吊车Remarks备注1Table C-2 A-Class Plant 甲类厂房1.135m聚酯多元醇稀释釜(带搅拌)1.材质:S304082.35005200 V=35m3.电机N=45kW, U=380V4.单重:10300kg台125T Mobile Crane 25T Mobile Crane+15T Vehicle300TMobile Crane 25T Mobile Crane1.2.35m聚氨酯反应釜(带搅拌)1.材质:S304082.35005200 V=35m3.电机N=45kW, U=380V4.单重:10300kg台125T Mobile Crane 25T Mobile Crane+15T Vehicle300TMobile Crane25T Mobile Crane2Table C-7 C-Class Plant 丙类厂房2.1.2000L真空捏合机1.720033002500 2.单重：23000kg3.电机N=195kW, U=380V台170T Mobile Crane 70T Mobile Crane+30T Vehicle100T Mobile Crane N/A2.2.1000L真空捏合机1.720033002500 2.单重：23000kg3.电机N=195kW, U=380V台170T Mobile Crane 70T Mobile Crane+30T Vehicle100T Mobile Crane N/A2.3.1000L真空捏合机1.480023502500 2.单重：15000kg3.电机N=130kW, U=380V台450T Mobile Crane 50T Mobile Crane+20T Vehicle70T Mobile Crane N/A2.4.100L密炼机1.407527123580 2.单重：12000kg3.电机N=90kW, U=380V台350T Mobile Crane 50T Mobile Crane+20T Vehicle160T Mobile Crane N/A2.5.真空耙式干燥机1.6.8m 2.单重：22000kg3.电机N=37kW, U=380V台170T Mobile Crane 70T Mobile Crane+30T Vehicle350T Mobile Crane N/A2.6.捏合机1.单重：12000kg2.电机N=110kW, U=380V台150T Mobile Crane 50T Mobile Crane+20T Vehicle160T Mobile Crane N/A3.1.5 Lifting Plan of DG workshop 甲类厂房设备吊装3.1.5.1Equipment Data设备参数Equipment Name: 35m3polyamin reactorEquipment tag: R040204Equipment specification: 3500*5200mmEquipment net weight:10.3t.设备名称：35m3聚胺脂反应釜设备位号：R040204设备规格：3500*5200mm设备净重：10.3吨。3.1.5.2Lifting Plan & Profile吊装平面图和立面图3.1.5. 3Main Crane Working Condition主吊车工况计算Crane name: 300 t mobile craneCrane type:QAY300Crane condition: main boom conditionCrane body weight: 65tCounter weight:98.2tMain boom length: 61 metersCrane working radius: 32 metersCrane load permitted rate: 85%吊车名称：300吨汽车吊吊车型号：QAY300吊车工况：主臂工况主机重量：65吨悬挂配重：98.2吨主臂长度：61米吊车工作半径：32米吊车允许负载率：85%Equipment weight: 10.3tHook weight:0.7tSling weight: 0.1 tLifting gross weight: 11.1tCrane capacity: 13.4tCrane load rate:82.8%设备重量：10.3吨钩头重量：0.7吨吊索重量：0.1吨吊装总重：11.1吨吊车能力：13.4吨吊车负载率：82.8%3.1.5.4Wire Rope主吊索计算Main cable name: harness ropeSingle length: 10metersSling quantity: 2 rootAllow safety factor: 6Main cable specifications: 5TBreaking force: 30tStress root number: 4Sling safety factor: 9.9主吊索名称：吊带单根长度：10米吊索数量：2根允许安全系数：6主吊索规格：5T破断力：30吨受力根数：4吊索安全系数：9.93.1.5.5Tailing Crane Working Condition溜尾吊车工况计算Crane name: 25t craneCrane type: QY25K-5Crane condition: Main boom conditionCrane body weight: 31tMain boom length: 22.5 metersCrane working radius: 9 metersCrane load permitted rate: 85%吊车名称：25吨汽车吊吊车型号：QY25K-5吊车工况：普通工况主机重量：31吨主臂长度：22.5米吊车工作半径：9米吊车允许负载率：85%Equipment weight: 10.3 tHook weight: 0.3 tSling weight: 0.1 tLifting gross weight: 5.6tCrane capacity: 7.8tCrane load rate:71.8%设备重量：10.3吨钩头重量：0.3吨吊索重量：0.1吨吊装总重：5.6吨吊车能力：7.8吨吊车负载率：71.8%3.1.5.6Capability of crane 吊装性能表见下页。3.1.6 Lifting Plan of AT workshop丙类厂房设备吊装3.1.6.1 General总体说明For reducing costs and being restricted by site conditions, C-Class plant equipment installation must work closely with civil construction. The heavy equipment installation of ground floor should be completed before construction of steel structures in the region. The lifting of rest heavy equipments should be completed after steel structure basement construction. The west side of the wall should leave passage space for equipments and materials of each floor. The heaviest equipment that is required to be lifted after completion of steel structure construction basement is: vacuum rake dryer (M020304), weight 22 tons.为了降低成本以及受到现场条件的限制，丙类厂房设备安装必须与土建施工紧密配合，一楼地面重型设备安装应在该区域钢结构施工前完成，其余重型设备吊装应该在钢结构基础施工完成后进行。西侧墙面应留出各楼层设备、材料进出通道。本装置中需要在钢结构基础施工完成后进行吊装的最重的设备为：真空耙式干燥机（M020304），重量22吨。3.1.6.2 M020304 lifting plan 设备吊装3.1.6.2.1Equipment Data设备参数Equipment Name: vacuum rake dryerEquipment tag: M020304Equipment specification: 6.8m3Equipment net weight: 22t.设备名称：真空把式干燥机设备位号：M020304设备规格：6.8m3设备净重：22吨。3.1.6.2.2Lifting Description吊装概述The equipment is located in the AT PLANT 11 m layer framework 2-3/KJ axis area, using 350T mobile crane to lift the device.该设备位于AT厂房11米层框架内2-3/K-J轴线区域内，采用350T汽车吊吊装该设备。3.1.6.2.3Lifting Plan& Profile吊装平面图和立面图Detailed visible below the lifting plan and elevation详细可见下图吊装平面图和立面图3.1.6.2.4Main Crane Working Condition主吊车工况计算Crane name: 350 t mobile craneCrane type: QAY350Crane condition: main boom conditionCrane body weight: 84tFixed counter weight: 107tMain boom length: 51.4 metersCrane working radius: 26 metersCrane load permitted rate: 85%吊车名称：350吨汽车吊吊车型号：QAY350吊车工况：主臂工况主机重量：84吨固定配重：107吨主臂长度：51.4米吊车工作半径：26米吊车允许负载率：85%Equipment weight: 22tHook weight:0.6tSling weight: 0.1 tLifting gross weight: 22.7 tCrane capacity: 28tCrane load rate: 81.1%设备重量：22吨钩头重量：0.6吨吊索重量：0.1吨吊装总重：22.7吨吊车能力：28吨吊车负载率：81.1%3.1.6.2.5 Wire Rope主吊索计算Main cable name: harnesses slingSingle length: 12 mSling quantity: 2 rootAllow safety factor: 6Main cable specifications: 10TBreaking force:60tStress root number: 4Sling safety factor:9.4主吊索名称：吊带单根长度：12米吊索数量：2根允许安全系数：6主吊索规格：10T破断力：60吨受力根数：4吊索安全系数：9.43.1.6.2.6 Detailed Lifting Process详细吊装过程Single crane hoisting process, from 350 t mobile crane is responsible for ascension, Formal lifting began, the equipment from the ground 500 mm, static. To observe the crane and wire rope state, make sure no abnormalities, the Main crane lifting equipment, when the bottom of equipment more than level + 21.5m, the Main crane in load cases turn bar,move EQP to the foundation.When the equipment is looking for qualified, the Main crane loose hook.单吊车吊装工艺，由350t汽车吊负责提升。正式起吊开始，设备离开地面500mm后，静止。观察各吊车和钢丝绳状态，确认无异常后，主吊车提升设备，当设备底部超过标高+21.5m后，主吊车在负载情况下转杆，将设备送入基础上方。当设备找正合格后，主吊车松钩。3.1.6.2.7Capability of crane 吊装性能表Mobile crane350 tQAY350起重特性表配重107T支腿跨距9m工作半径臂 长(m)工作半径15.620.9263136.141.246.351.456.5613350*17533.5260*1741593.54235*17215844.52151701561304.5519816715413056175156148125110671571391401231058370781381261261181008067588912011511511095766458910110105105105907261554540101290888890806556524537.51214757478705650484235.514165764686551454338331618525658584440403430.618204850524037353228.8202243453634323026.8222438403331302824.92426323630282826232628322826252421.82830262624242220.33032242422222118.932342120202017.634362119181816.536381918191715.6384016161614.7404215151513.84244131412.9444612.513124648121211.6485011.41150521110.452549.854569.3563.1.6.3M020212C Lifting Plan设备吊装3.1.6.3.1Equipment Data设备参数Equipment Name:100L banbury mixerEquipment tag: M020212CEquipment specification: 4075 * 2712*3580 mmEquipment net weight: 12t.设备名称：100L密炼机设备位号：M020212C设备规格：4075 * 2712*3580 mm设备净重：12吨。3.1.6.3.2Lifting Plan & Profile吊装平面图和立面图3.1.6.3.3Main Crane Working Condition主吊车工况计算Crane name: 160 t mobile craneCrane type:QAY160Crane condition: main boom conditionCrane body weight: 70tCounter weight: 32tMain boom length: 43.5 metersCrane working radius: 18 metersCrane load permitted rate: 85%吊车名称：160吨汽车吊吊车型号：QAY160吊车工况：主臂工况主机重量：70吨悬挂配重：32吨主臂长度：43.5米吊车工作半径：18米吊车允许负载率：85%Equipment weight: 12 tHook weight: 0.9tSling weight: 0.2 tLifting gross weight: 13.1tCrane capacity: 17tCrane load rate:77%设备重量：12吨钩头重量：0.9吨吊索重量：0.1吨吊装总重：13.1吨吊车能力：17吨吊车负载率：77%3.1.6.3.4Wire Rope主吊索计算Main cable name: harnesses slingSingle length: 10 metersSling quantity: 2 rootAllow safety factor: 6Main cable specifications: 5tBreaking force: 30tStress root number: 4Sling safety factor: 8.7主吊索名称：吊带单根长度：10米吊索数量：2根允许安全系数：6主吊索规格：5吨破断力：30吨受力根数：4吊索安全系数：8.73.1.6.3.5Capability of crane 吊装性能表QAY160全地面起重机起重性能表支腿全伸(8.7m) ，悬挂32t平衡重幅度m臂长m13.617.8722.1426.4130.6834.9439.2143.4847.7552.0256.296031603.5124116411210898834.5103100927965.559795857562.553.868280786857.549.642.677271706252.545.739.833.386264625648.542.33731.427.59565553514539.434.529.426.122.6104846454541.536.832.227.624.721.518.815123635.5363532.328.624.522.119.617.214.31428272828.52725.42219.917.815.913.3162222.523222219.818.116.214.612.31817.51818.218181716.514.913.511.52014.51515.515.415.215.113.712.510.52212.212.512.812.712.612.612.611.69.82410.811.311.511.411.411.210.79.1269.29.59.61010.210.1108.42888.28.48.48.38.57.83077.27.47.67.57.67.3326.26.56.66.56.76.5345.8666.26.23655.25.25.35.2384.64.74.84.74044.24.44.34244.23.7443.53.53.24632.8482.52.5502.2521.8倍率14 10 8 7 6 5 4 3 3 2 2 2 3.1.7Lifting Device List吊装机具一览表No.Device ListSizeQuantityRemark1350t crawler craneQUY3501 shift2350t mobile craneQAY3501 shift3250t mobile craneQAY2501 shift4160t mobile craneQAY1601 shift5100t mobile craneQY100H-31 shift670t mobile craneQY70V5321 shift750t mobile craneQY50K1 shift8100t trailer1 shift950t trailer1 shift