0107中英文05设备吊装施工方案.doc

拜 耳 异 氰 酸 酯 和 聚 醚 项 目TDI联合装置-基础设施BAYER ISOCYANATE&PET PROJECT TDI TRAIN INFRANSTRUCTURE起重吊装施工方案Work Method of Hoisting 编 制：Compiled by: 王海峰 Wang Haifeng审 核：Reviewed by:2009年10月22日October 22, 2009目 录Content一. 概况 OVERVIEW31.1 工程概况PROJECT OVEWVIEW31.2 施工范围 SCOPE OF WORK3二 编制依据 COMPILATION BASIS4三工程施工组织CONSTRUCTION ORGANIZATION4四. 施工准备 PREPARATION54.1 技术准备TECHNICAL PREPARATION54.2 设备及材料准备EQUIPMENT AND MATERIAL PREPARATION54.3 作业环境准备OPERATING ENVIRONMENT PREPARATION6五. 吊装主要施工工序和施工方法THE MAJOR LIFTING CONSTRUCTION PROCESSES AND CONSTRUCTION METHODS65.1 施工方法CONSTRUCTION METHODS65.2 吊索计算SLING CALCULATION75.3 施工方法及步骤CONSTRUCTION METHOD AND PROCEDURES85.3.1 10KV/0.7KV 干式变压器的吊装 10KV/0.7KV DRY-TYPE TRANSFORMER HOISTING85.3.2 1300KVA 690VAC柴油发电机的吊装95.3.3 中压柜、低压柜和其它设备的吊装MV CABINET LIFTING95.3.4 控制、信号屏的吊装CONTROL AND SIGNAL SCREEN LIFTING105.4 安全技术措施SAFETY MEASURES10六. 安全生产、文明施工要求和措施 SAFETY PRODUCTION, CIVILIZED CONSTRUCTION REQUIREMENTS AND MEASURES116.1 起重吊装作业安全CRANE LIFTING OPERATION SAFETY116.2 起重司机驾驶安全作业要点CRANE DRIVERS SAFETY OPERATION POINTS116.3 起重机司机的“十不吊”CRANE DRIVERS 10 NO126.4 安全措施、文明施工SECURITY MEASURES AND CIVILIZED CONSTRUCTION12七. 应急预案EMERGENCY PLAN127.1 危险源和不利环境因素RISK SOURCES AND ADVERSE ENVIRONMENTAL CONDITIONS137.2 应急措施EMERGENCY MEASURES13一. 概况 Overview1.1 工程概况Project Overview工程名称：拜耳异氰酸酯和聚醚项目TDI联合装置基础设施变电站安装工程Project name: Bayer Isocyanate and PET Project TDI Train- Transformer Substation Installation建设单位：拜耳（上海）聚氨酯有限公司Construction Unit: Bayer (Shanghai) Polyurethane Co., Ltd.总包单位：美施威尔（上海）有限公司Contractor Unit: M + W Zander (Shanghai) Co., Ltd.设计单位：浙江美阳国际石化医药工程设计有限公司Design Units: Zhejiang Mei Yang International Petrochemical Pharmaceutical Engineering Design Co., Ltd.项目地点：上海市漕泾开发区拜耳一体化基地Project Location: Shanghai Caojing Bayer Integrated Site Development1.2 施工范围 Scope of work拜尔异氰酸和PET项目试验基础设施TSS项目位于上海漕泾的上海化学工业园区内。Bayer Isocyanate and PET Project Train Infrastructure TSS project locate in Shanghai Caojing Chemical Industry Park.本项目工程涉及四个变电站，分别是220KV/35KV A472变电站、 35KV/10KV B301变电站、35KV/10KV C581变电站、 10KV/0.69KV B551变电站及C593发电机站。工作内容为四个变电站和一个发电机站的电气设备吊装、就位，设备包括柴油发电机、变压器、中压柜、低压柜、控制屏、FA/PA/DCS/ESD盘等。其中： The project involves four substations, namely 220KV/35KV A472 substation, 35KV/10KV B301 substation, 35KV/10KV C581 substation, 10KV/0.69KV B551 substation and C593 diesel generator. Work scope is electrical lifting and placement of the equipment in four substations and one generator station, which are two sets of diesel generator, transformers, MV&LV cabinets, control panel, FA/PA/DCS/ESD plate, etc. Of which:1） 220/35KV变电站A472吊装的主要设备有：Main lifting equipment of 220/35KV substation in A472:1台35KV线路纵差屏。One set of 35KV line differential panel.2) 35/10KV变电站B301S吊装的主要设备有：Main lifting equipment of 35/10KV substation in B301S:7台10KV空气绝缘双母线柜； Seven sets of 10KV AIS duplicate busbar switchgears;1台主变差动保护及有载调压控制屏; One set of main transformer differential protection & load tap changing control panel;1台转接屏；One set of marshalling rack;1台主变端子箱；One set of main transformer terminal box; 3) 35/10KV变电站B551和C581吊装的主要设备有：Main lifting equipment of 35/10KV substation in C581 and B551:20台10KV空气绝缘双母线柜；Twenty sets of 10KV AIS duplicate busbar switchgears;8台10千伏/0.7千伏3150KVA干式变压器; Eight sets of 10 KV / 0.7 KV 3150KVA dry-type transformers;4台0.69千伏/0.4千伏800KVA干式变压器的安装；Four sets of 0.69 KV / 0.4 KV 800KVA dry-type transformers;4台0.69千伏/0.4千伏500KVA干式变压器的安装；Four sets of 0.69 KV / 0.4 KV 500KVA dry-type transformer;2台0.69千伏/0.4千伏250KVA干式变压器的安装；One set of 0.69 KV / 0.4 KV 250KVA dry-type transformer;7台110V直流电池屏；Seven sets of 110V DC battery panels;1台主控单元屏；One set of station unit SICAM PAS;1台公共信号屏; One set of common alarm panel;2台主变差动保护及有载调压控制屏；Two sets of main transformer differential protection & load tap changing control panels;2台主变端子箱；Two sets of main transformer terminal boxes;1台转接屏；One set of marshalling rack;1台站用交流屏；One set of subsation auxliary AC power supply panel;239台690V及400V等低压开关柜；239 sets of 690V and 400V low-voltage switchgears;75台FA/PA/DCS/ESD盘；75 sets of FA/PA/DCS/ESD plate;47台VSD屏;47 sets of VSD plate,1套230V直流UPS电池;One set of 230V DC UPS battery;2套230V交流UPS及配电盘;Two set of 230V AC UPS and distribution plate;1套24V直流UPS及配电盘; One set of 24V DC UPS and distribution plate;4）2台1300kVA 690VAC柴油发电机。Two sets of 1300kVA 690VAC diesel generators二 编制依据 Compilation Basis1）根据拜耳（上海）聚氨酯有限公司电气包招标文件及招标图纸编制而成。According to Bayer (Shanghai) Polyurethane Co., Ltd. Electric package the tender and tender drawings.2）在充分研究工程的客观情况和施工特点，结合我公司类似工程施工经验的基础上编制的。Based on full study on construction characteristics and objective situation and combined with similar construction experience.3）在本方案编制过程中，严格执行国家现行有关起重技术规范、标准、规定、规程，按建筑施工起重、吊装安全技术、起重机械与吊装In this compilation process, strictly implement current national hoisting technical specifications, procedures, standards, and design specifications. As construction crane, hoisting safety technology, Lifting Appliances and Lifting4) 施工现场特点、设备特殊情况及起重吊装技术要求。 Construction site characteristics, special circumstances and hoisting equipment and technical requirements三工程施工组织Construction Organization项目经理GM耿文宝 Geng Wenbao公司安全Safety officer程宗强 Cheng Zongqiang班长（总指挥）Commander陈健 Chen Jian质量员Quality Officer吴雪飞 Wu Xuefei班组成员Member熊向东 Xiong Xiangdong班组安全员Safety member钱根强 Qian Genqiang四. 施工准备 Preparation4.1 技术准备Technical preparation1) 组织工程技术人员吊装场地、施工区域及变压器和设备进出线路实地考察，确定吊装作业涉及范围，向甲方提出吊装作业范围清障要求；Organize engineering technical personnel to check hoisting and construction site and transformer and equipment route, determine lifting range and ask the owner to clear up the obstacles in the lifting operation area;2) 编制变压器和设备吊装工艺技术方案和质量保证措施，作业方案实行审批手续，符合工艺要求；Compile transformer and equipment hoisting technology programs and quality assurance measures. Operating program should have approval procedures and be in line with process requirements;3) 按变压器和设备自重、吊装方法，确定选用卸车汽车吊吨位及变压器盘路、吊装、就位、调整施工机具规格；As per the wight of the transformer and equipment and lifting method, determine the tonnage of the unloading crane, transformer plate, placement, and adjusting construction equipment size.4) 工种专业、熟悉工艺，持证上岗；配备工种齐全的施工人员，组织精干的施工班组，对施工人员进场进行三级安全教育Workers are professional and familiar with the process, and have certificates; Provide types of construction workers and teams, and conduct three class safety training;5) 组织参与施工的全体人员进行施工及技术交底，熟悉技术方案，掌握吊装作业要点；坚持方案作业，环节无遗漏；严格执行交接手续；Organize all personnel to make technical clafication, be familiar with the technical plan, and main lifting points, adhere to the program without omissions and strict implement hand-over procedures;6) 按吊装作业的特点，制定针对性安全技术措施；As per hoisting operation and characteristics, formulate specific measures for safety and technology;4.2 设备及材料准备Equipment and material preparation1） 配齐施工机具，做好进场前检查、保养，落实到位并有备案，严禁带病作业。Fully service construction machinery, inspect the delivery, carry out maintenance, and make records. Prohibit work work in spite of illness.2） 吊装施工的主要设备有：The main hoisting equipment:100T起重机1台，25T起重机1台，12T起重机1台； One set of 100T crane, one set of 25T crane, one set of 12T crane;25T配重运输车若干辆，5T工具运输车1辆，3T液压车2部； Some 25T heavy transport vehicles, one 5T tool transporter, two 3T hydraulic vehicle; 滑轮组1副，滑轮10只；One set of pulley block 1, 10 pulleys;5T手拉葫芦3只；Three 5T hand chain hoists;滚筒20根，6米20#工字钢4根，16工字钢双拼拖板1副，800*800*8000mm钢架3副；20 rollers, four 20 # I-beam which is 6 m long, one 16 # double I-beam extension unit, 3 sets of 800*800*8000mm steel frame;100T吊车垫脚钢板4块，25T吊车垫脚钢板4块，12T吊车垫脚钢板4块，道木40根；4 pcs of 100T crane pad plate, 4 pcs of 25T crane foot pad plate, 4 pcs of 12T crane foot pad plate, 40 pcs of road wood;起道机4只，撬棒、钢丝绳若干；Four track lifting jack, some pry bar, wire ropes;电锤1只；One hammer;地锚3只，吊锁10副，大小头木塞10只。Three ground anchors, ten lifting slings, ten stoppers.3） 施工用料准备充分，并有应急措施；Construction materials are fully prepared and have contingency measures;4.3 作业环境准备Operating environment preparation1） 施工现场的绿化带处必须采用吊车专用垫脚钢板铺垫。道路旁边的排水沟应进行保护处理，确保吊机进入后的安全。所有变电站门口能停放大型汽车吊，且地面已按要求夯实、平整，能承受大型汽车吊作业。The site green belt must pad with stepping steel plate of the specialized crane. Drains adjacent to roads should be carried out conservation treatment to ensure the crane entering security. All substation entrances can park large truck crane, and the ground has been compacted and leveled can bear large truck crane operation.2） 拆除进入施工现场的所有障碍物。主要是进入施工现场的门、基础近旁的小桩、基础外边沿等。确保地面作业通道无任何车辆及障碍物。Remove all obstacles to enter the site: Mainly the gate, piles and edges nearby foundation etc. To ensure ground handling channel has no obstacles for vehicles.3） 通道保持6米宽度，转弯处保持10米以上宽度，能满足设备运载车及大型汽车吊倒车、转弯不受障碍物影响。作业面拆出宽11米以上的通道，满足施工单位提出的要求，能使吊装作业顺利进行。Keep the channel 6m wide and the turn above 10m wide, so that the equipment transportation vehicles and large auto crane can reverse and turn freely. Demolite a channel with 11 meters wide on work surface meet the request of construction unit and enable lifting operations go smoothly.4） 变电站进设备的门有足够的高度。The substation door for entering equipment is high enough. 五. 吊装主要施工工序和施工方法The major lifting construction processes and construction methods5.1 施工方法Construction Methods本期工程五个站分布在工业园区内，全部为地面建筑物。Five substations in current project are located in the industrial park, all of which are the ground-level structures.根据吊装区域对面积的要求，结合我公司工程技术人员对吊装现场的实地考察，确定吊装区须有10M宽道路停车作业，卸车作业距离约10m。大型汽车吊能靠近变电站门口进行吊装作业。According to the requirements of the region for lifting area, combined with the field of hoisting site inspection of the company engineering and technical personnel, the loading area must have 10M wide-street for parking operations, a distance of about 10m for unloading operations. Large vehicle crane could be able to carry out lifting operations near the door of the substation.C593 1300kVA 690VAC柴油发电机根据提供的资料表明长12米，宽2.42.5米，高2.22.3米，单台重23.524吨。As the provided information shows, 1300kVA 690VAC diesel generator in C593 is 12 m long, 2.42.5 m wide and 2.22.3 high with the single weight 23.5 24 T.C581 10KV中压柜室离地面约2500，门口有一装卸平台。但此平台太小进电气设备需重新搭设一个能满足承放中压柜的工作平台。吊装2、3F的设备将搭设一个脚手架吊装平台。10KV MV cabinet room should be about 2,500mm from the ground, a loading platform nearby the entrance. However, this platform is too small to get into the electrical equipment, which should be rebuilt a new working platform, which can support the MV cabinets. Put up a scadford platform for lifting the equipment in 2F and 3F.B301 10KV中压柜室离地约2m，门口重新搭设一个能满足承放中压柜的工作平台。室内中压柜基础重新做加固措施。The 10KV MV cabinets are 2m above the ground in B301. Put up a platform which can support the MV cabinets. Reinforce the base of the cabinets.中压柜宽800、深3560、高2050，单台背靠背柜重1.4-2T。MV cabinet is 800 mm width, 3560 mm depth, 2050 mm high, with a single back to back cabinet weight 1.4-2T.低压柜最大宽1000mm，长1600mm，高2200mm，单台重1.4-2T。The maximum widen 1000mm, length 1600mm, height 2200mm. The weight is 1.4-2T.其他设备单台重。Other equipment weighs 0.5-2T per each.依照我公司设备吊装的经验及施工现场所具备的条件，在确保吊装作业安全的前提下，确定：According to my companys experience on hoisting and the conditions construction site required, under the premise of the safety of lifting operations, decide:本工程中10KV 3150KVA变压器采用25T汽车吊；中压柜采用12T汽车吊吊装卸车。落差处搭设平台，手拉葫芦牵引盘路，用走杆、拖板拖运的施工方法。低压柜等设备采用12T汽车吊吊装卸车，有吊装平台。In the project10KV 3150KVA transformer use 25T crane; MVcabinet uses 12T to unload and hoist. The platform should be set up with the gap using wood and steel frame and hand chain hoist for pulling plate, using construction method of walking pole, extension units haulage. LV cabinets and other equipment uses 12T crane with platform put up.该吊装工艺具有施工进度快、安全可靠、经济合理的优点。The hoisting process has fast, safe, reliable, economical advantages.5.2 吊索计算Sling calculation在施工过程中，我们所使用的钢丝绳必须是有合格证的钢丝绳，此类钢丝绳的安全工作荷载已经被注明，但有些钢丝绳的合格证没有随钢丝绳到达工地，这样可以用以下的公式进行计算，或对有合格证的钢丝绳进行校核。The steel rope must be qualified ones and the load has been noted. When some of the steel ironscetification has not gotten already, we can use the following formula to calculate and check.1） 100T（柴油发电机）吊装采用4根46钢丝绳千斤单根钢丝绳破断拉力计算：Q54d2Q 544646 114264钢丝绳的安全系数K取8P 1142648 14283每根吊索的受力(分支与水平线夹角取60)S =24000(1sin60)4 = 6960单根受力6960满足14283要求。100T (Diesel generators) using 4 46 mm hoisting rope, A single rope breaking tension calculation: Q 54d2 Q 54 46 46 114264 kg Steel wire rope safety factor K to take 8 P 114264 8 14283 kg Each sling force (the angle between branch and horizontal line can take 60 ) S = 24000 kg (1 sin60 ) 4 = 6960 kg A single force 6960 kg to meet the requirements 14283 kg. 2）25T（10KV/3150变压器）吊装采用4根25mm钢丝绳千斤，单根钢丝绳破断拉力计算：Q 542525=33750kg钢丝绳安全系数取8P337508=4218kg每根吊索受力（分支与水平线夹角取60）S =8900(变压器重量)(1sin60)4 = 2581单根钢丝绳拉力S =2581kg,满足4218kg25T (10KV/3150 Transformer) hoisting rope use four 25mm steel ropes, A single rope breaking tension calculation as follows: Q 54 25 25 = 33750kg Wire rope safety factor can take 8 P 33750 8 = 4218kg Each sling force (the angle between branch and horizontal line can take 60 ) S = 8900 kg (transformer weight) (1 sin60 ) 4 = 2581 kg A single rope tension S = 2581kg, to meet the 4218kg 3）12T (10kv高压柜、低压柜及其它设备)采用4根14千斤吊装，单根钢丝绳破断拉力计算：Q 54d2Q 541414 10584钢丝绳的安全系数K取8P 105848 1323每根吊索的受力(分支与水平线夹角取60)S=2000(1sin60)4=580单根受力580满足1323要求。12T (10kvHV&LV cabinets and other equipment) use 4 14 mm hoisting steel rope, A A single rope breaking tension calculation: Q 54d2 Q 54 14 14 10584 kg Steel wire rope safety factor K to take 8 P 10584 8 1323 kg Each sling force (the angle between branch and horizontal line can take 60 ) S = 2000 kg (1 sin60 ) 4 = 580 kg A single force 580kg meets the requirements of 1323kg.在实际工作中，我们再把各配套钢丝绳放大一号，确保安全系数。In actural work, enlarge one size of the steel rope to secure the safety factor.5.3 施工方法及步骤Construction method and procedures5.3.1 10KV/0.7KV 干式变压器的吊装 10KV/0.7KV dry-type transformer hoisting1） 临时运输平台的搭设 set-up temporary transport platform变压器基础离地面约40，在落差处用道木、工字钢铺搭设与基础齐平的临时平台至门外。临时运输平台可保持一个小坡度。Transformer is away about 40 cm from the ground-based, put up a temporary platform flushed with the base with the gap using woods and I-beam steel to outside. Keep slope on the transportation platform.在平台上放置滚筒和专用拖板。Place rollers and special extension units on the platform.2） 吊车就位crane in place3150KVA/10干式变压器吊装选用25T汽车吊，汽车吊进入现场最理想处展开吊装作业。Use 20T car crane 3150KVA/10 use dry-type transformer hoisting, crane conducts lifting operations when crane get into the perfect site.吊车站位时应尽量靠近路边，支腿处的绿化地上，必须先铺垫吊车专用钢板。The crane should be cl