龙门架吊装施工方案2011-3-26.doc

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Bayer TDI Train HCL-OX Plant
拜耳异氰酸酯和聚醚项目TDI联合装置盐酸氧化装置

Steel Lift Construction Plan
钢结构吊装施工方案

Approved by/批准：
Checked by/审核：
Prepared by/编制：

中国南海工程有限公司
Mar 26th, 2011
Content
目 录

一.General 概况
二.Reference 编制依据
三.Lift procedure吊装施工程序
四.Safety measures 安全措施
五.Labor force arrangement 劳动力组织
六.List of construction machines and tools 施工机具一览表
七. Calculation of cable wire吊索具计算
八.Risk Evaluation风险评估
九.Properties of crane吊车性能表

一、General 概况：
本工程为拜耳TDI联合装置盐酸氧化装置行车梁钢结构改造工程，其目的是为盐酸装置压缩机厂房南面增加钢结构龙门架。由于本项目是属于装置区内的吊装作业，出于安全考虑，必须做好必要的吊装风险评估，吊装时注意避免原有设备和仪器遭到损坏。在进行吊装前对运输通道、电源、消防设施、主要材料和机具及劳动力应有充分准备和安排。
现根据现场勘查，在地面上进行钢梁柱组对后，拟采用50吨汽车吊进行一次性吊装就位的方案。
二、Compilation reference编制依据
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：
① Code for Construction of Lifting Work for Engineering Architecture
工程建设起重施工规范；
② Specification of Safe Operation for Lifting Work
起重吊装安全操作规程；
③ Performance List of Conveying flatbed trucks, cranes
运输平板车、吊车性能表；
④ Management System of Safe Operation of Cranes Issued by Bayer Company
拜耳公司有关吊车安全作业管理制度；
⑤ All concrete requirements for lifting work set out by the Owner and Engineering Supervisor.
业主和工程监理对吊装工程的各项具体要求。
三、Lifting execution procedure 吊装施工程序
3.1、Construction procedure施工步骤
1、Field and ground base treatment 场地及地基处理
a、The main road for the Plant shall keep unblocked. 装置的主干道始终保持通畅。
b、Ensure the crane legs have sufficient bearing areas. Bayer provide the area and the concealed work document.保证吊车支腿有足够的承压面积（业主提供此区域隐蔽工程资料）。
2、Crane shall enter into site and be in position as per drawings. (see lifting drawings for details)
汽车吊车进入现场，按图站位（详见吊装示意图）。
3、Written consent by the owner and management company shall be obtained before removing existent iron balustrade if necessary. 需要拆除原有铁围栏或其它原有设施前要经过由业主及管理公司方面的书面许可。
4、钢结构组对施工程序。
4.1首先将两根钢柱按照施工图顺序平放至平整的地面上进行竖立，两端用三角形Φ48钢管做好临时支撑。
4.2将钢梁用吊车吊至两钢柱中间组对，然后进行穿螺栓紧固。
4.3绑扎好龙门架钢结构吊点，进行起吊就位。（见吊装示意图）
5、The hoist spreading position should be approved by Bayer & TJU.
吊车的站位应得到业主及管理公司的确认。
6、Crane shall be hooked and start lifting. Lift the steel apart from the truck to the work area radius and stay for 5 minutes. Inspect the support of crane, ground, cable wire, clamp and body of container. Lifting shall be continued after written confirmation with the owner.
汽车吊车挂钩，起吊，当钢结构离开车体后将设备吊至吊装的工作半径，静止5分钟，观察吊车支腿、地面、钢丝绳、卸扣以及设备本体，经业主确认无误签字后，继续起吊。
7、After finishing of lifting work, the Owner shall sign and approve. 吊装结束以后，业主签字确认。
8、Arrangement of period for crane application 吊车台班时间安排。
One working period of crane is 1 days. 汽车吊吊车工作台班为1天.
3.2 Technical presentation already done and prepared lifting plan approved by the owner.
已经进行吊装施工技术交底工作，并编制吊装施工方案已报得业主批准。
3.3 龙门架钢结构吊装就位
龙门架钢结构吊装就位后，先不要立即卸扣，让吊带带上劲，将两边钢柱用垫铁垫实后，将中间行车大梁螺栓拧紧，然后再缓慢降落卸钩。立即进行二次灌浆，等混凝土达到一定强度后对两端钢柱受损螺栓进行更换。
3.4. 50t lifting Parameters 70t吊装参数
3.4.1 Steel parameters钢结构参数
Overall dimensions 外形尺寸： 10.8x6.9x1.0 m
Steel Weight重量：4t
Lifting weight吊装重量：G=Q+Q’)=4+0.5=4.5t
In the formula 式中：
G- Lifting weight吊装重量
Q- Steel weight重量：Q=4t
Q’– Weight of hooks, guy wire and sling chains 钩头、吊索具的重量Q’＝0.5t
Locating height 就位高度：-1.000m
3.4.2 Check Calculation of Lifting Height 吊装高度核算
Lifting height at a radius of 15m 15米半径时吊装高度
Length of pole 杆长：21.6m
Radius 半径：15m
Vertical height of jib 吊臂垂直高度：15.5m
Lifting height 起重高度：15.5m
Crane height 吊车自身高度：1.8米
Therefore, lifting height can meet lifting requirement. (see attachment 1 and 2)
因此，吊装高度能满足吊装要求。（见附图1、2）
3.4.3 Calculation of Lifting load rate 吊装负荷率计算
3.4.4Parameters of70-ton hydraulic crane (see attachment 1 and 2)70吨液压吊参数（见附图1、2）
① Lifting weight:4.5t (steel weight + guy wire and sling chain weight)
吊装重量：4.5t (钢结构重+吊索具重)
② Working radius 作业半径： 15米
③ Rated lifting capacity 额定吊装重量：11吨
④ Load rate 负荷率：41%
See Attachment- 1/2 见附图-1、2
四、Safety Measures 安全措施
1、 We are responsible for inspection of the employee’s 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。

五、Labor Organization 劳动力组织
S.N.
Trade 工种
Number 人数
１
Riveter 铆工
2
２
Rigger 起重
1
３
Labor 力工
2

welding焊工
1
4
Safety personnel 安全员
1
5
Technician 技术员
1

六、List of Riggings and Materials 吊装机索具及材料一览表
S.N.
Description
名称
Size and Quality
规格及材质
Unit
单位
Quantity
数量
Remark
备注
1
Liftiing strap吊带
3t
Pc.
2
单根3m长
2
Clamp 卸扣
3t
Pc.
2

3
Pull rope牵引绳
Hemp roap麻绳 Ф20
Pc.
1

4
Crane吊车
50t
Set
1

5
Steel tube钢管
Φ48
m
24

七、Calculation of cable wire 吊索具计算
吊带选用3t，破断拉力≥180000N，安全系数取6。
钢丝绳的实际拉力F1、F2、因为F1、F2、都是长度和角度一致的吊带，
所以F1=F2。
2F×sina =G+g（F为吊带实际拉力，G为钢结构重量，g为吊具重量，sina =600）
则F=(G+g)/(2sina)
=(4000+500)/(2×0.866)
=25982N
P=SP/K=180000/6=30000N
（P—吊带的许用拉力,N； SP—吊带的破断拉力,N；K —吊带的安全系数。）
F<P,故吊带安全。

八、Risk Evaluation风险评估
1.0 Preparation method编制方法
JHA (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.
JHA（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=L×S
风险值R(Risk)： 风险值=可能性值×严重性值，即：R=L×S
Risk 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 JHA 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JHA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
JHA返回后下发所在施工班组执行。
After issuance, JHE shall be executed by the construction team concerned.
⑴Before 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 JHA to ensure execution of JHA 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JHA背面签字，以保证按JHA安全措施执行。
⑵During construction, JHA shall be hanged near construction site to facilitate readings for construction workers.
施工期间，JHA应挂在施工位置附近，以方便施工人员翻阅。
⑶JHA shall be content to be studied in safety activities on every Monday and toolbox meeting every day.
将JHA作为每周周一安全活动和每天班前会的学习内容。
⑷Safety department shall inspect execution condition of JHA.
安全部门将对JHA执行情况进行检查。

It can be said that by execution of JHA 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JHA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 or
Risk
L/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
Remaining
Danger
一、起吊设备存在缺陷 Defects of Lifting Equipment
1
性能达不到要求
Function not meeting requirement
2
3
6
按施工技术方案要求选择起重吊车。
Crane shall be selected according to construction method.

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.
2
3
6
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.

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
2
3
6
1、 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%

4
Surface abrasion of rope slot of pulley and reel滑轮与卷筒的绳槽表面磨损
2
3
6
1、 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.

5
Out of effect of limiting device and switch 限位及开关失效
2
3
6
1、 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.
1
No driver’s permit 司机无证上岗
2
3
6
1、 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.

2
No rigger’s permit 起重工无证上岗
2
3
6
1、 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 Requiremen