大型設備吊裝方案.doc

上海賽科石油化工有限責任公司50萬噸/年乙苯/苯乙烯裝置大型設備吊裝施工方案頁碼： 21 組織管理體系：Organization management system1.1 現(xiàn)場吊裝組織機構(gòu)Suspending organization on site吊裝總指揮技術(shù)供應質(zhì)量安全吊裝顧問組抬尾指揮主吊指揮起重班機械操作員測量人員其他工種設備鉚工班現(xiàn)場吊裝指揮 Suspending advisor team Chief commander of suspending Technology supply facility quality safety Suspending commander on site Main suspending commander lifting trail commander Lifting team machine operator other types workerRivet worker team measure worker1.2 主要人員職責 Duties for important personnel吊裝總指揮對大件設備吊裝工作的總體運行進行協(xié)調(diào)控制，提供資源保證，簽發(fā)吊裝令。 The suspending chief commander correspond and control the whole suspending work of the heavy facilities, also supply the guarantee of materials and sign the command o suspending. 吊裝現(xiàn)場指揮負責組織吊裝方案的實施。 Suspending commander on site take charge of organizing to practice the suspending scheme.技術(shù)負責人負責編制吊裝方案，參加技術(shù)交底，參加技術(shù)攻關工作，參與風險評估和吊裝前的檢查確認。 Technology principal take charge of writing the suspending scheme, telling the technology intentions, attending in tackling key technology problem and risk evaluating and affirming checking before suspending.質(zhì)量負責人負責審查、確認特殊作業(yè)人員上崗資格，參加到貨設備的檢查和驗收，組織設備基礎驗收、檢查確認施工質(zhì)量。 Quality pricipal charge in examination and affirm the special worker mooount guard with certification, he also attend in checking and accept the received facilities, organize to check and accept the facilities basic, check and affirm the construction quality.設備負責人負責對進場施工設備的狀況進行核實確認。負責設備的日常維護管理，參與風險評估工作。 Facility pricipal take charge of vertify and affirm the conditions of construction facilities on site, daily maintaining and management of facilities and attending risk evaluating. 安全負責人負責提出HSE實施計劃，監(jiān)督HSE管理的實施。 Safety pricipal take charge of supplying HSE practice scheme and supervising HSE management implementation.供應負責人根據(jù)工程需要及時保質(zhì)保量供應器材，組織到貨設備驗收。 Supply pricipal purvey equipments with quality and quantity in time according to the project requirement, and organize to check and accept the received facilities. 2運輸路線： （運輸公司編制）Transportation route: (workout by transport company)3運輸車輛的性能特點（運輸公司編制） Functions and features of vehicles (workout by transport company)4卸車位置及方位 Unloading places and orientation 4.1大型設備卸車、吊裝順序（詳見大型設備吊裝運行計劃） Unloading and suspending orders of heavy facilities (see running plan of suspending heavy facilities)4.2 設備擺放所占的道路及時間： Road and time occupied by putting the facilities:1）10#路：擺放T-4001、T-4003安裝平臺、保溫、管線 03年10月15日-11月6日；2月1日-2月9日 NO 10 Road: put T-4001 during October 15 to November 6, 2003; February 1st to 9,20042）8#路：1250t吊車組車 04年2月1日-2月9日。 NO 8 Road: install 1250t crane from February 1st to 9, 2004. 4.3 設備卸車配合及支撐 Cooperating and supporting of unloading facilities 4.3.1 卸車 Unloading 預搭設支撐垛; Build the supporting buttress in advance; 油壓板車進入指定位置； Enter the oil pressure plank machine to the appointed place; 在卸車支撐處擺好卸車用的鋼梁及鞍座； Putting the unloading girder and bicycle saddle in the unload supporting place; 啟動油壓板車升降千斤頂，將設備頂起； Startup the lifting and droping jack of oil pressure to peak up the facilities; 將卸車用鋼梁及鞍座放置到支撐垛上； Put unload on the supporting buttress by the girder and bicycle saddle; 降下油壓板車，將設備落到卸車鞍座上； Down the oil pressure plank and let the facilities on the unloads bicycle saddle; 退出油壓板車。 Exit from the oil pressure plank.4.3.2 支撐處理 Supporting disposal設備下由2個支撐點4個支撐垛受力，每個支撐垛應滿足受力要求，支撐垛與地接觸面積為9平方米（每個支撐垛下面鋪設3040mm鋼板，支撐垛由鋼結(jié)構(gòu)支架或道木垛組成）。 Two supporting points and four supporting buttress under the facilities to bear the weight, each buttress should meet the requirements of bearing. The contact area between supporting buttress and ground is 5 square meters (lay 3040 mm armor plate under each buttress containing of steel structure plank or crosstie buttress.)支撐示意圖Supporting sketch map4.3.3 卸車原則上采用以下方法： Unloading adopt the following measures in principle:1） 充分考慮設備進入現(xiàn)場與其吊裝時間的邏輯關系，盡量使用CC8800直接從拖車上卸貨及吊裝。 Consider the logical relationship of entering onsite and suspending time for facilities sufficiently, try best to use CC8800 to unload and suspend directly from the trailer.2） 大型設備根據(jù)合同由運輸方直接運輸至現(xiàn)場指定位置。 According to the contract, heavy facilities should be deliveried by transport side directly to the appointed places3） 較小型設備直接運輸至現(xiàn)場后，采用M250型250噸履帶吊直接卸車或吊裝。 Use 250ton pedrail crane Model 250 to delivery or suspend directly after the smaller facilities being deliveried on site.4） 如果設備卸于臨時庫房，則根據(jù)設備重量、規(guī)格尺寸等條件采用KMK5160型160噸汽車吊單車或160噸汽車吊與TG-1300型130噸汽車吊雙車抬吊的方法將設備裝車，封車后運輸至現(xiàn)場，采用160噸汽車吊單車或160噸汽車吊與130噸汽車吊雙車抬吊的方法卸車。 If delivery the facilities in a temporary storeroom, use 160ton auto suspending single vehicle Model KMK5160 or 160 ton auto suspending and 130ton auto suspending twin vehicles lifting to install the vehicle, close the vehicle then delivery on site in accordance with conditions of fcilities weight and specification then adopt the measures of unloading facilities by 160ton auto suspending single vehicle or 160ton auto suspending and 130 ton auto suspending tiwn vehicles lifting.5） 說明: Narration設備支點用4個支撐垛支撐。每個支撐面積9平方米（每個支撐垛下面鋪設3040mm鋼板）。The facilities pivot support by the four supporting buttress. Each can support the area of 5 square meters (lay 3040mm stell plank under each buttress). 支撐鞍座利用設備運輸?shù)陌白?。Use the deliverying bicycle saddle of the facilities to support the saddle.4.4 設備擺放要求 Requirements for putting the facilities4.4.1 T-4001 抬尾吊耳在正上面 Suspending trail hole in the median above place主吊耳在水平位置The main suspending hole in the horizontal place主吊耳位置運到基礎中心位置，方向按現(xiàn)場平面圖位置擺放。 The main suspending hole carried to basic center place and put direction as the ichnography place on site. 主吊及抬尾吊耳位置、方位按提供給上海醫(yī)藥工業(yè)設計院的條件執(zhí)行。 According to the conditions supplied to Shanghai medicament industry academy of design, perform the places and directions of main suspending and trail hole.4.4.2 其它設備Other facilities抬尾吊耳在正上方Suspending trail hole in the median above place按現(xiàn)場平面圖位置擺放Put as the ichnography place on site方向按現(xiàn)場平面圖位置擺放。Put as the direction as the ichnography place on site中國石化集團第四建設公司 上海賽科石油化工有限責任公司50萬噸/年乙苯/苯乙烯裝置 大型設備吊裝施工方案頁碼：8 頁碼：94.4.3 大型設備擺放位置詳見附圖大型設備吊裝平面圖 See the closed form about the putting places of the heavy faciilities 序號Ref NO設備位號NO of Facilities擺 放 要 求備注Remarks塔頭朝向Direction of Tower Head塔頭坐標Cooperate of Tower Head兩主吊耳方位Orientations of the two main Suspending Holes塔尾部吊耳方位Orientation of Suspending Hole in Tower Trail1E-2001A塔頭朝東EastE 3624 N 3442水平放置Horizent抬尾吊耳向上up2E-2001B塔頭朝東EastE 3624 N 3423水平放置Horizent抬尾吊耳向上up3E-3004/3006/3007塔頭朝北NorthE 3650 N 3350水平放置Horizent4R-3001塔頭朝西WestE 3716 N 3314水平放置Horizent抬尾吊耳向上up5R-3002塔頭朝西WestE 3710 N 3332水平放置Horizent抬尾吊耳向上up6T-2001塔頭朝東EastE 3614 N 3423水平放置Horizent抬尾吊耳向上up塔體墊高1.4米1.4m higher for tower7T-2003塔頭朝東EastE 3631 N 3448水平放置Horizent抬尾吊耳向上up塔體墊高1.4米1.4m higher for tower8T-4001塔頭朝西WestE 3651 N 3448水平放置Horizent抬尾吊耳向上up塔體墊高1.4米1.4m higher for tower9T-4003塔頭朝東EastE 3642 N 3451水平放置Horizent抬尾吊耳向上up塔體墊高1.4米1.4m higher for tower10E-4003A設備頭朝西NorthE 3725 N3342水平放置Horizent抬尾吊耳向上up11E-4003B設備頭朝西NorthE 3725 N3348水平放置Horizent抬尾吊耳向上up12E-4003C設備頭朝西NorthA 3725 B3354水平放置Horizent抬尾吊耳向上up13E-3009AA 3725 B 3360水平放置Horizent14E-3009BA 3725 B 3366水平放置Horizent中國石化集團第四建設公司上海賽科石油化工有限責任公司50萬噸/年乙苯/苯乙烯裝置大型設備卸車及運輸?shù)缆诽幚硎┕し桨疙摯a：435. 吊車性能特點： Functions and features of crane5.1 吊車分SSL、SVFL等6種工況，最大起重能力為1250t； Six conditions for crane of SSL, SVFL and so on, the most lifting capacility is 1250t5.2 吊車長15米，寬12.5米，車高7.1米； Crane is 15m(L), 12.5m(W) and 7.1m(H); 5.3 吊車的機動性能好，可載重行走； Good flexibility of crane, which can walk with loading as well;5.4 吊裝能力優(yōu)越，超起配重600t，超起半徑最大25米。 Excellent lifting of super lifting 600t and the most semidiameter is 25meter.6 吊車組裝位置和移動位置以及各吊裝作業(yè)位置： Coordinate of the CC8800 pedrail suspending station車位序號Crane Station No.E坐標Cooperate EN坐標Cooperate N所吊設備位號Lifted equipment No.1#3694.53433T-4003 T-4001 2#36443432T-2001 T-2003 E-2001A/B3#36703351R-3001 R-3002 E-3004/3006/3007E-4003A/B/C E-3009A/B7. 吊車站位及移動對場地的要求： Requirements for lifting site by crane standing position and moving:7.1 影響吊車占車及行走的設備基礎及施工時間要求: Requirements for facilities basic and construction time of influencing crane by being occupied and moved: 1） 吊車站位1: 裝置北界區(qū)外管廊、P-4013A/B/C、P-4016；基礎03年11月24日后施工。 Crane station 1: outer pipe porch of installation North boundary P-4013A/B/C. P-4016;Construct the basic from November 24, 2003. 2） 吊車行走： D-6005、P-6011、P-6004 and P-6006；基礎03年11月24日后施工。 Crane moving: D-6005, P-6011, P-6004 and P-6006; Construct the basic from November 24, 2003. 3） 吊車站位3： Z-6008、X-6010、P-6015、P-6016A/B；基礎04年2月20日后施工。 Crane station 3: Z-6008, X-6010, P-6015 and P-6-16A/B; Construct the basic from February 20, 2004.4） 吊車站位影響的地下管道在吊車退場后開始施工。 北區(qū)：03年11月24日開始，南區(qū)：04年2月20日開始。 The underground pipeline influenced by the crane station will construct after exit of crane, the North: November 24, 2003; the South: February 20,2004.7.2 吊車承載地基處理設計計算：（3公司負責） Design calculation of loading basic treatment: (No. 3 company in duty) 7.2.1 地基處理（由3公司提出）Groudwork disposal8 吊裝計算及依據(jù)： Calculation basic for lifting8.1 編制說明 Explanation for compiling8.1.1 適用范圍 Applicable scope 本方案適用于上海賽科石油化工有限責任公司50萬噸/年乙苯/苯乙烯裝置大型設備的吊裝，涉及到重量在100t以上的設備共計17臺。This scheme is applicable to suspending heavy facilities, which involved 17sets over 100 ton each, with installation of 500,000t/y for Ethylbeneze & Styrene of Shanghai SECCO-petro Company Limited. 8.1.2 編制依據(jù) Compiling references1） 國家（行業(yè)）有關標準、規(guī)范； The relative standards and regulations of nation (trade);大型設備吊裝工程施工工藝標準SHJ 515-90；- Technics Standards for Construction of Suspending and installing heavy facilities, SHJ515-90 石油化工施工安全技術(shù)規(guī)程SH 3505-1999； -Safety technology regulations for construction of Petro-chemichal, SH3505-1999；建筑地基基礎規(guī)范選編中國建筑工業(yè)出版社1993年版；- Chapters from architecture groundwork basic regulations, China architecture industry publishing company, 1993 edition起重工操作規(guī)程SYB4112-80；-Operation regulations for craneman, SYB4112-80；2） SECCO IPMT提供的設備規(guī)格表（4月23日）及相關圖紙，詳見設備表； Specification form and related drawings of facilities supplied by SECCO IPMT (April,23), see equipments table for details；3） 上海項目工程部提供的50萬噸/年乙苯/苯乙烯裝置安裝工程施工投標文件； Tender documents, construction of 500,000t/y installation for Ethylbeneze & Styrene Plant, supply by Shanghai Project Engineering Department; 4） 上海項目工程部提供的圖號為A1 10870-00010-J的裝置平面布置圖； Ichnography A1 10870-00010-J of installation supplied by Shanghai Project Engineering Department; 5） DEMAG CC8800型1250噸履帶式吊車性能表。 Capability form of 1250ton pedrail crane Model DEMAG CC8800.8.2 總體吊裝方案 Wholel suspending scheme8.2.1 工程概況Project general1） 場地條件Site conditions上海賽科50萬噸/年乙苯/苯乙烯裝置屬于新建項目，整個裝置作業(yè)面開闊。裝置界區(qū)達180米120米，因此場地環(huán)境較好，有利于進行大型設備的吊裝作業(yè)。另外裝置內(nèi)道路按照設備進廠、DEMAG CC8800型1250噸履帶式吊車行走及吊裝對地面承載力的要求進行施工。Shanghai SECCO 500,000t/y Ethylbeneze &Styrene Plant is a part of new projects, the whole installation site is wide and its boundary is 180 m*120 m, so the environment is better for suspending heavy facilities. Otherwise, roads inside installation site construction is in accordance with facilities entering factory, 1250ton pedrail Model DEMAG CC8800 moving route and requirements of ground bearing for suspending.2） 工程特點 Project characteristics上海賽科50萬噸/年乙苯/苯乙烯裝置吊裝工程大型設備較多，分布面廣。其中100噸以上的設備17臺：最大吊裝重量的設備為乙苯蒸汽過熱器/中間壓力沸熱換熱器/低壓沸熱換熱器（35E3004/3006/3007），重量達679噸吊裝總負荷740噸；最高設備為EB/SM分離器（35- T-4001）高度為80.8米，為本次設備吊裝的重中之重。Suspending project of Shanghai SECCO 500,000t/y Ethylbeneze& Styrene Plant has many heavy facilities distributed in a wild area. 17 sets of these are more than 100ton: the weighest suspending facility is Ethylbeneze steam heat filter/ middle pressure boiling exchanger/ lower pressure boiling exchanger (35-E-3004/3006/3007), which is about 679ton and suspending bearing of 740ton; The highest facility, also the heaviest in all facilities, is EB/SM separator. (35-T-4001) about 80.8meter3） 大型設備一覽表 Form of heavy facilities 序號Ref NO設備位號Facility number設備名稱Name 設備規(guī)格 (mm)Standard 設備重量（Kg）Weight備注Remark1D-3001乙苯/蒸汽分離罐Steam separate tank for Ethylbeneze f70001260010800024/4/2003 SSEC設備表SSEC faxility form of April,24, 20032E-2001A/B苯塔再沸器Benzene tower reboiler8800024/4/2003 SSEC設備表SSEC facility form of April,24,2003 3E-3004/3006/3007乙苯蒸汽過熱器/中間壓力沸熱換熱器/低壓沸熱換熱器Ethylbeneze steam heat filter for /middle pressure boiling exchanger/lower pressure boiling exchangerf550035000679000Drawing No:20389734E-4009苯乙烯塔冷凝器Styrene tower condensator10724024/4/2003 SSEC設備表SSEC facility form of April,24, 20035R-1001烴化反應器Alkylation reactorf2600256357590002329-00-907-11A6R-3001第一脫氫反應器The first dehydrogen reatorf520029973268000Drawing No:571A-22-017R-3002第二脫氫反應器The second dehydrongen reactorf590035315500000Drawing No:571B-22-018T-2001苯塔Benzene towerf45004146514000002329-00-907-01A9T-2003乙苯塔Ethybeneze towerf30004480071530施工圖EQ30-0093M10T-4001EB/SM分離器EB/SM separatorf760080780560100施工圖EQ30-009811T-4003苯乙烯塔Styrene towerf480038480104410施工圖EQ30-0100M12E-4003A/B/CEB/SM冷凝器EB/SM splitter condenser f360011641146700Drawing No:203896913E-3009A/B冷卻器TRIM COOLERf270014194123800Drawing No:20389958.2.2 總體方案概述 General of whole scheme 1） 對于苯乙烯裝置的設備吊裝特點來說，采用機動性好的吊裝機具能適用于重型設備多而分布較廣的特點。同時為使吊裝工期盡量縮短，國內(nèi)最大起重能力的1250噸履帶式起重機的引進，給我們用于上海賽科苯乙烯裝置大型設備吊裝的機具注入了新的內(nèi)容。 For chatacteristics of Styrene facility suspending, using good flexibility suspending machinery can apply to facilities characteristics of quantity and distributeing wildly. Meanwhile, to shorten the working time, 1250ton pedrail crane of the biggest lifting ability introduced in China inject new content to heavy facilities suspending machinery of Shanghai SECCO Styrene Plant.2） 經(jīng)現(xiàn)場勘察和反復論證，兼顧了技術(shù)上的先進性，安全上的可靠性和經(jīng)濟上的合理性，在賽科苯乙烯裝置大型設備的吊裝工程中，我們決定采用大型移動式起重機作為主吊機具的總體方案，即DEMAG CC8800型1250噸履帶式起重機主吊，M250型250噸履帶起重機抬尾配合。 According to the reconnaissance on site and demonstration repeatedly, we paid attention to advanced technology, dependable safety and rational economy, and decided to adopt the whole shceme of heavy jenny as the main suspending machinery, in which 1250ton pedrail crane DEMAG CC8800 is the main suspending machinery and 250 ton pedrail crane Model 250 cooperate with lifting the trail.3） 根據(jù)合同，所有大型設備應運抵FCC指定的吊裝位置、方向、角度及高度卸車，并且直接利用設備出廠裝車原支撐鞍座位置進行支墊。 According to the contract, all heavy facilities should be deliveried and unloaded to appointed suspending place, direction, angle and height by FCC, and underlay directly facilities in the original supporting saddle points as the facility leaving factory.4） 所有塔類設備盡量在地面完成附件安裝（包括附塔管道、梯子、平臺、絕熱防腐）然后吊裝，吊耳以上部分妨礙吊裝繩索及設備擺放支撐處的附件在塔吊裝后施工。 All the tower facilities try the best to install accessories on the ground（including attached tower pipeline,ladder,platform, adiabat and antisepsis）before suspending. The parts higher than suspending hole, where accessories obstruct suspending lines and places to put suppoting facilities, should construct after suspending tower. 5） T-4001塔頂部大口徑管道因吊車的有效吊裝高度所限，不能隨塔吊裝，在其吊裝后，再用CC8800吊裝此管線。 T-4001 big caliber pipeline is limited in height because of its available suspending height and could not suspend with the tower freely. After suspending it, use CC8800 to install this pipe cable.8.3 大型設備吊裝施工工藝 Construction techncis of suspending and installation of heavy facilities8.3.1 設備參數(shù)表 Parameter form of facilities序號Ref No.位號No.名稱Name規(guī)格（m m）Stardard設備吊裝重量明細（t）Details of suspending weight本體Noumenon平臺Platform絕熱Heat insulation配管Attached pipe吊裝重量Weight1D-3001乙苯/蒸汽分離罐Ethylbeneze/steam separate tankf7000126001080005521202E-2001A/B苯塔再沸器Reboiler of Beneze tower880001410101223E-3004/3006/3007乙苯蒸汽過熱器/中間壓力沸熱換熱器/低壓沸熱換熱器Ethylbenezesteam separater/middle pressure boilingchanger/lower boiling changerf5500350006790006794E-4009苯乙烯塔冷凝器Styrene tower condesator1072401075R-1001烴化反應器Alkylation reactorf2600256357590010971026R-3001第一脫氫反應器The first dehydrogen reatorf5200299732680002687R-3002第