水電工程中孔鋼管安裝施工方案

1、吉布3水電工程gibe hydroelectric project中孔鋼管安裝施工方案method statement of middle outlet penstock審批 approved by:校核 checked by:編寫 compiled by:中國(guó)水利水電第八工程局機(jī)電制造安裝分局埃塞吉布3項(xiàng)目部sinohydro bureau 8 electrical and mechanical fabrication erection division ethiopia gibe iii hydroelectric project department二零一三年一月二十四日2013.01.

2、24目 錄contents1.概述 general32.施工準(zhǔn)備 construction preparation521安裝前檢查 inspecting before erection522 控制樣點(diǎn)放置setting out reference points523技術(shù)要求technical requirements53.中孔鋼管安裝erection for middle outlet steel lining631定位節(jié)、湊合節(jié)的選取selection of locating section and fitting allowance section632鋼管的吊裝及就位 lifting a

3、nd positioning of steel lining733鋼管的轉(zhuǎn)運(yùn)、臨時(shí)堆放 transportation and temporary stacking of steel lining834鋼管的安裝場(chǎng)地基本要求 basic requirements for steel lining erection area935用于鋼管安裝調(diào)整加固的埋板、錨筋 embedded parts, anchor bar used for steel lining erection, adjustment and reinforcement1036鋼管的安裝 erection for steel lin

4、ing11361鋼管安裝的流程圖 steel lining erection procedure flow chart11362鋼管的安裝主要工序general process of steel lining erection1237鋼管的焊接 welding of steel lining1438鋼管的最終驗(yàn)收 final acceptance of steel lining1439鋼管驗(yàn)收后的移交 handing over after acceptance154.下游閘門埋件及鋼襯安裝 embedded parts and steel liner installation for down

5、stream gate155.上游閘門埋件安裝 embedded parts installation for upstream gate196.工期及資源配置 construction duration and resource allocation2061勞動(dòng)力資源 manpower resource2062主要施工設(shè)備投入 allocation of main construction equipment2163 鋼管安裝工期 erection duration of steel lining237.安全注意事項(xiàng) precautions241. 概述 general埃塞俄比亞吉布3水電工

6、程大壩共設(shè)兩套泄洪鋼管，分為右側(cè)泄洪鋼管和左側(cè)泄洪鋼管，左、右孔結(jié)構(gòu)及布置形式相同。 two flood discharge steel linings are designed for the dam of ethiopia gibe iii hydroelectric project, which are divided into right steel lining and left steel lining. the both sides of outlet are in the same structure and layout.中孔鋼管長(zhǎng)度約116.5m，包括為：進(jìn)口過渡段，漸變段

7、（7m6m，彎管段（6m），直管段（6m），收縮段（6m5.4m）,直管段（5.4m），收縮段（5.4m4.6m）,出口漸變段。鋼管結(jié)構(gòu)形式如下： middle outlet steel lining is about 116.5m long, consisting of inlet transition part, transition part (7m6m), curved part (6m), straight part (6m), contraction part (6m5.4m), straight part (5.4m), contraction part (5.4m4.6m) a

8、nd outlet transition part. the structure of steel lining is as follow: 進(jìn)水口幾何尺寸inlet geometry dimension 出水口幾何尺寸outlet geometry dimension進(jìn)口過渡段，20.3minlet transition section, 20.3m12.5m7m（方形）12.5m7m (square)6m（圓形）6m (round)彎管段，56.8mcurve section,56.8m6m6m直管段，9.8mstraight section,9.8m6m6m漸變段，20mtransiti

9、on section,20m6m5.4m出口漸變段，5.09moutlet transition section,5.09m5.4m8.3m圖1：中孔鋼管示意圖1(左右孔結(jié)構(gòu)形式相同) sketch 1: layout sketch of middle outlet steel lining (left and right outlet in the same structure) 參考圖紙：5-hss-7.1-d-chiww-001-d，右側(cè)中孔鋼管整體布置圖；5-hss-7.1-d-chiww-002-c，左側(cè)中孔鋼管整體布置圖；5-hss-7.1-d-chiww-003-c，右側(cè)中孔鋼管

10、詳圖；5-hss-7.1-d-chiww-004-c，左側(cè)中孔鋼管詳圖； 5-hss-3.3-d-chims-011-d，中孔鋼管閘門及啟閉機(jī)布置圖;5-hss-3.3.1-d-chims-003-b，中孔鋼管封堵閘門二期埋件圖；5-hss-3.3.1-d-chims-003-b，中孔鋼管封堵閘門二期埋件圖。 reference drawing: 5-hss-7.1-d-chiww-001-c, right middle outlet general layout;5-hss-7.1-d-chiww-002-b, left middle outlet general layout;5-hss-

11、7.1-d-chiww-003-b，right middle outlet detail drawing;5-hss-7.1-d-chiww-004-b，left middle outlet detail drawing; 5-hss-3.3-d-chims-011-d，layout of middle outlet bulkhead gate and hoist general layout;5-hss-3.3.1-d-chims-003-b, middle outlets bulkhead gate -2nd stage embedded parts;5-hss-3.3.1-d-chims

12、-004-b middle outlets bulkhead gate -2nd stage embedded parts。 2. 施工準(zhǔn)備 construction preparation21安裝前檢查 inspecting before erection 雙方應(yīng)保證安裝場(chǎng)地具備交接條件，我部也會(huì)對(duì)施工材料及設(shè)備等進(jìn)行仔細(xì)檢查并確保符合圖紙及相關(guān)規(guī)范要求。before erection, both salini and dec shall ensure the installation area is ready for handing over. dec shall carefully c

13、heck material and equipment, and guarantee they are in compliance with the drawings and the technical specifications.22 控制樣點(diǎn)放置setting out reference points使用gps定位系統(tǒng)放置基準(zhǔn)點(diǎn)（benchmarks）。gps參數(shù)由貴部提供。要求對(duì)這些基準(zhǔn)點(diǎn)進(jìn)行一次由雙方測(cè)量人員參與的聯(lián)合檢查。benchmarks from gps system on site will be used, and salini shall provide the gps

14、 data. it is necessary to give a joint inspection towards the benchmarks attended by surveyors from both parties。23技術(shù)要求technical requirements安裝的程序、方法、標(biāo)準(zhǔn)要求都會(huì)按照相關(guān)圖紙及相應(yīng)標(biāo)準(zhǔn)（包括設(shè)計(jì)藍(lán)圖、技術(shù)合同要求、通過現(xiàn)場(chǎng)協(xié)調(diào)上報(bào)的圖紙和qcr和itp等）進(jìn)行施工。同時(shí)，在施工前，我部會(huì)對(duì)每一個(gè)參與此項(xiàng)工作的工人進(jìn)行技術(shù)交底，確保其了解每一步工作、每一項(xiàng)要求。erection procedure, method, and standard req

15、uirement shall all in compliance with relevant drawings and standard (including design blue print, contractual technical requirement, drawings, qcr and itp submitted after coordinate at site). furthermore, before construction, a technical explanation will be given towards the construction staffs in

16、order to make them understand each step and each requirement involved in their work. 3. 中孔鋼管安裝erection for middle outlet steel lining由于所有鋼管均以瓦塊形式到貨，鋼管需在車間進(jìn)行拼裝，拼裝工作先于安裝工作開始，并能滿足鋼管安裝工作的連續(xù)進(jìn)行。since all steel lining will be transported to site in segments, it needs to be assembled at workshop before erec

17、tion, and the assembly shall be carried out in a way that is capable to make the penstock erection continually. 31定位節(jié)、湊合節(jié)的選取selection of locating section and fitting allowance section為滿足工期要求，結(jié)合現(xiàn)場(chǎng)實(shí)際情況，每條鋼管選取2個(gè)定位節(jié)（藍(lán)色區(qū)域），1個(gè)湊活節(jié)（中間斜線陰影部分）。鋼管安裝將由上游及下游兩個(gè)定位節(jié)同時(shí)進(jìn)行，向中間湊合節(jié)合攏。如下圖示：in order to meet the erection s

18、chedule, two locating sections (the blue area) and one fitting allowance section (the middle oblique line shadowed part) shall be selected from each steel lining with the consideration of site actual situation. the steel lining erection will be conducted simultaneously at upstream and downstream. re

19、fer to the following drawings: 圖2：定位節(jié)、湊合節(jié)示意圖32鋼管的吊裝及就位 lifting and positioning of steel lining關(guān)于鋼管的吊裝方案，在纜機(jī)工作區(qū)域（空白區(qū)域），我部堅(jiān)持使用纜機(jī)直接進(jìn)行吊裝就位。根據(jù)salini提供的纜機(jī)覆蓋范圍可以看出，左岸鋼管約2/3可以直接由纜機(jī)吊裝到位，右岸鋼管約3/5是可以直接由纜機(jī)吊裝就位的。with respect to the lifting scheme of steel lining, we insist to use cable crane to lifting the steel

20、 lining into position for working area (blank area) within his service. infer from the covered region of cable crane provided by salini, about 2/3 of the left side steel lining, and 3/5 of the right side steel lining can be lifted into position directly by cable crane. 對(duì)于纜機(jī)工作區(qū)域之外的部分（陰影區(qū)域），我部將使用移動(dòng)臺(tái)車進(jìn)

21、行轉(zhuǎn)運(yùn)。a transporting trailer shall be adopted to transport the steel lining for the area (shadowed area) beyond cable cranes working region.鋼管的重量每節(jié)均不超過25噸，在纜機(jī)的起吊范圍之內(nèi)。the weight of each section is no more than 25 ton, which is within cable cranes capacity.33鋼管的轉(zhuǎn)運(yùn)、臨時(shí)堆放 transportation and temporary stack

22、ing of steel lining 對(duì)于已拼裝完成鋼管，按照salini的提議，將被運(yùn)抵左岸896m平臺(tái)，纜機(jī)主鉤下方進(jìn)行卸車?？紤]到交通、運(yùn)輸及能及時(shí)滿足前方施工進(jìn)度的需求，經(jīng)過我部人員到現(xiàn)場(chǎng)實(shí)地勘察后，我部認(rèn)為在896m平臺(tái)處臨時(shí)堆放部分鋼管是必要且可行的。in compliance with salinis suggestion, the steel lining already been assembled shall be transported to the elev. 896m platform on the left bank, and unloading under th

23、e hook of cable crane. in order to satisfy the construction schedule, it is necessary and viable to put part of the steel lining temporarily on the elev. 896 m platforms after our site inspection with the consideration of traffic, and transportation. 34鋼管的安裝場(chǎng)地基本要求 basic requirements for steel lining

24、 erection area參照salini提供圖紙：1、left m.o. current section formworks，no. 535-con-d-sp-006-b2、left m.o. drains layout，no. 535-con-d-sp-007-b3、right m.o. current section formworks，no. 535-con-d-sp-008-b4、right m.o. drains layout，no. 535-con-d-sp-009-breference drawings provided by salini:1、left m.o. curre

25、nt section formworks，no. 535conndsp006b2、left m.o. drains layout，no. 535conndsp007b3、right m.o. current section formworks，no. 535conndsp008b4、right m.o. drains layout，no. 535-con-d-sp-009-b我部要求salini首先完成第二階段的混凝土澆筑工作（1.2m高）?；蛘邔⒌诙A段混凝土的澆筑高度調(diào)整為1m，以便排水管的安裝，并完成澆筑。總之，保證混凝土面至鋼管底部的高度在0.8m-1.0m之間，以便鋼管的安裝調(diào)整及加

26、固。鋼管進(jìn)口端及出口端同樣應(yīng)保證如此。therefore, we kindly requested salini to complete the second stage concrete pouring (1.2m high) first, or modify the height of second stage concreting to 1m for an easy installation of drainage pipe, and complete the concrete casting. in conclusion, it shall ensure the height betw

27、een concrete face to bottom of the steel lining is within 0.8m-1.0m in order to achieve an easy erection, adjustment and reinforcement of steel lining. it is also the same for the outlet side and inlet side.35用于鋼管安裝調(diào)整加固的埋板、錨筋 embedded parts, anchor bar used for steel lining erection, adjustment and

28、reinforcement我部將提前提供鋼管支撐埋板（即軌道埋板）于salini進(jìn)行安裝。同時(shí)要求salini提供用于鋼管加固插筋并進(jìn)行安裝。dec shall provide sole plates for salini to install in advance. in the meantime, salini is kindly requested to offer and install the anchor bar for penstock reinforcement. 注：埋板及錨筋詳細(xì)布置圖待方案最終確定后將正式上報(bào)。note: the detail arrangement of

29、 sole plates and anchor bars shall be submitted after finalized the method statement.36鋼管的安裝 erection for steel lining 361鋼管安裝的流程圖 steel lining erection procedure flow chart最終驗(yàn)收施工準(zhǔn)備 construction preparation定位節(jié)安裝、驗(yàn)收其它管節(jié)吊裝、調(diào)整及驗(yàn)收移交土建進(jìn)行混凝土回填錨鉤等附件安裝鋼管焊接探傷construction preparationerection and acceptance of

30、 locating section erection and acceptance of other sectionswelding of steel lininganchorage and other accessories installationndt inspectionfinal acceptancehanding over for back-fill concreting3-1中孔鋼管安裝工藝流程圖3-1 flow chart of middle outlet steel lining erection362鋼管的安裝主要工序general process of steel lin

31、ing erection1、吊裝前的準(zhǔn)備preparation before liftingl 在896.m平臺(tái)焊接鋼支撐，以便于就位；weld steel supports at the platform of el. 896m for positioning. l 檢查所有吊具及鋼管在臺(tái)車上固定用的綁帶等完好無損，以確保吊裝的安全性（吊裝示意圖如下）；check if all lifting tools and bandages for fix penstock on trolley are complete and in a proper state to guarantee lifti

32、ng safety (refer to the sketches of lifting below):直接通過纜機(jī)吊裝lifted by cable crane 通過臺(tái)車轉(zhuǎn)運(yùn)transfer by transporting trailer2、就位后的調(diào)整l 根據(jù)已放置好安裝樣點(diǎn)，利用千斤頂、拉緊器、線錘等在水準(zhǔn)儀、全站儀的控制下對(duì)鋼管（里程、中心、高程等）進(jìn)行調(diào)整，至各項(xiàng)控制尺寸達(dá)到設(shè)計(jì)要求；under the control of level and total station, make an accuracy adjustment with jacks, turnbuckle, plum

33、b and other adjusting tools on the locating section (including mileage, center, elevation, etc) in accordance with the reference points already located, until each control dimension reach the design requirements. l 加固，并在加固完成后再次對(duì)各項(xiàng)控制尺寸進(jìn)行檢查，以防止其產(chǎn)生位移；reinforce the locating section and have a dimension

34、re-checking after the reinforcing to prevent displacement.3、附件的安裝 accessories installation l 根據(jù)圖紙要求，進(jìn)行錨筋等附件的安裝；install anchorages and other accessories following the drawings;37鋼管的焊接 welding of steel lining中孔鋼管的焊接工藝及評(píng)定以圖紙及相關(guān)規(guī)范（asme，現(xiàn)場(chǎng)itp等）要求進(jìn)行。根據(jù)三方協(xié)議，npt檢查作為內(nèi)部檢測(cè)項(xiàng)目，將由我部自行檢查，并提交檢查記錄。 middle outlet ste

35、el lining welding procedure and evaluation shall be done in accordance with drawings and relevant specifications (site itp and others). according to minutes of meetings gibe hep site 10th-14th december 2012, npt test belongs to the internal inspection, we shall carry it out by ourselves and submit t

36、he inspection record to you. 38鋼管的最終驗(yàn)收 final acceptance of steel lining 中孔鋼管的最終驗(yàn)收工作按圖紙?jiān)O(shè)計(jì)及相關(guān)規(guī)范要求，在相關(guān)各方的共同參與下以現(xiàn)場(chǎng)報(bào)批的itp為準(zhǔn)，采取分段分步（完成20m安裝時(shí)移交salini,6節(jié)左右）的方式聯(lián)合進(jìn)行，并現(xiàn)場(chǎng)簽字認(rèn)可，以確保后續(xù)工作的順利進(jìn)行。 in accordance with the drawings and relevant specifications, the final acceptance of middle outlet steel lining shall be d

37、one by steps (about 6 sections shall be handed over to salini after finished 20m steel lining erection), following the itp to be submitted at site with the participation of the relating parties, and approved by joint signature, so as to ensure the next step of work be carried out smoothly.39鋼管驗(yàn)收后的移交

38、 handing over after acceptance中孔鋼管的最終驗(yàn)收工作完成后，即可移交土建單位進(jìn)行混凝土的回填準(zhǔn)備工作，在各方監(jiān)測(cè)且進(jìn)行，以確?；靥钸^程中鋼管不發(fā)生偏移。我部將提交一份混凝土澆筑計(jì)劃，以供貴部參考。 the middle outlet steel lining shall be handed over to civil work for the preparation of back-fill concreting after final acceptance. for the back-fill concreting shall be done in the pa

39、rallel with steel lining erection, frequency communication is necessary for all the parties to be avoiding of interference. it is also ensure to prevent steel lining from displacement while concreting. we shall provide a concrete methodology for your reference.4.5.6. .下游閘門埋件及鋼襯安裝 embedded parts for

40、downstream gate and steel lining installation關(guān)于下游閘門埋件及鋼襯安裝，我部提議如下： regarding to the embedded parts and steel liner installation for downstream gate, we offer the following suggestion:首先，由土建單位完成第二階段混凝土的澆筑工作，移交我部進(jìn)行定位節(jié)及其上游側(cè)鋼管安裝。 firstly, civil work finish the second stage concrete pouring, and then han

41、d over to us for the erection of locating section and upstream steel lining.然后，在我部完成4-6節(jié)（15m-18m）鋼管安裝，通過驗(yàn)收之后移交至salini進(jìn)行第三階段的混凝土澆筑工作，至765m高程。此時(shí)，至765m平臺(tái)的通道（大壩段）形成。 then, we complete the steel lining erection of sections no.4-no.6 (15m-18m), and hand over to salini for third stage concrete pouring to e

42、l. 765 after acceptance. meanwhile, the access road (dam part) to platform at el.765m is ready.待第三階段凝固并具備通車條件后，由我部在借助吊車的幫助下完成下游側(cè)鋼襯的安裝工作，并移交salini完成第四階段的混凝土澆筑工作。 after the third stage concrete setting and is capable for transportation, we shall complete the installation of downstream steel lining wit

43、h the application of mobile crane, and hand over to salini for fourth stage concrete pouring.鋼襯吊裝lifting and erection of steel lining完成第四階段混凝土澆筑finish the fourth stage concrete pouring最后，由我部進(jìn)行閘門二期埋件的安裝工作，閘門埋件、門葉及油缸吊裝通過汽車在765m平臺(tái)實(shí)現(xiàn)。eventually, we shall carry out the second stage embedded parts install

44、ation for gate, and the lifting of gate embedded parts, gate leaf and oil cylinder shall be done by automobile at elev. 765m platform.7. 上游閘門埋件安裝 embedded parts installation for upstream gate上游閘門埋件我部要求分段分步進(jìn)行安裝，基本要求如下： the embedded parts installation for upstream gate shall be done by steps; the basi

45、c requirements are as follows:首先，由我部完成鋼管定位節(jié)及其下游側(cè)約20m長(zhǎng)鋼管安裝工作，移交salini完成該部分混凝土澆筑工作，混凝土澆筑高程至765m。 firstly, we shall complete the erection of locating section and about 20 meters long downstream steel lining, and then hand over to salini for concreting of this part. the concrete casting shall reach el.

46、765m. 然后，由我部進(jìn)行765m高程以下的門槽二期埋件安裝。對(duì)于左岸鋼管封堵閘門埋件可由纜機(jī)直接吊裝就位，右岸鋼管封堵閘門埋件需借助汽車吊吊裝就位。 then, it shall start the second stage embedded parts installation for gate slot below el. 765m. as for the embedded parts for left bank steel lining block gate, it can be lifted into position directly by cable crane, and th

47、e embedded parts for right bank block gate can take use of mobile crane. 對(duì)于765m高程以上的埋件我部要求每15m進(jìn)行一次安裝，直至頂部。由于右側(cè)不是纜機(jī)的覆蓋范圍，埋件安裝將采用salini汽車吊進(jìn)行吊裝。 for the embedded parts beyond el. 765m, we require to install them every 15m until the top. since the right side is out of service of cable crane, salini mobi

48、le crane shall be used for embedded parts installation. 門葉下放通過壩頂門機(jī)完成。 the lowering of gate leaf shall be done by dam gantry crane.8. 工期及資源配置 construction duration and resource allocation61勞動(dòng)力資源 manpower resource勞動(dòng)力資源見分析表6-1。manpower resource refers to form 6-1勞動(dòng)力分析表6-1：analysis of manpower 6-1序號(hào)no.工

49、種position中方人員chinese staff當(dāng)?shù)貏诠ocal labor1金結(jié)安裝工hss erector12482起重lifting man4163電焊welder 24154電氣維護(hù)electrical maintenance485打磨工grinder 206技術(shù)質(zhì)檢technical and quality inspector27專職安全員full-time safetyman18架子工scaffolder4169探傷人員ndt inspector44總計(jì)total5512762主要施工設(shè)備投入 allocation of main construction equipment

50、主要施工設(shè)備投入計(jì)劃見表6.2。allocation of main construction equipment refers to form 6-2施工設(shè)備投入計(jì)劃表6-2allocation of main construction equipment 6-2序號(hào)no.設(shè)備名稱description型號(hào)、規(guī)格type, specification數(shù)量quantity 備注remarks 1平板拖車flat-bed trailer40t1臺(tái)/setsalini2汽車吊mobile crane50t 1臺(tái)/setdec3汽車吊mobile crane200t1臺(tái)/setsalini4皮卡車pick-up1臺(tái)/set5鏈條葫蘆chain block3t, 5t, 10teach 6 pcs6全站儀 total stationtotal 1臺(tái)/set7水準(zhǔn)儀level 2臺(tái)/set8千斤頂jack 16