履帶吊安裝方案

拜耳材料科技（中國）有限公司擴建5萬噸/年HDI和3萬噸/年IPDI項目履帶吊安裝方案 Contents目錄一、 References編制依據(jù) 1二、 PreparationStatement編制說明 1三、 GeneralInformation吊機概況 13.1 BasicDimensions基本外形尺寸 13.2 DimensionandWeightofMainTranspotationComponents主要運輸部件外形尺寸及重量 23.3 MainPerformanceParametersofQUY200QUY200主要性能參數(shù)表 63.4 BoomCompositionTable吊臂組成組合表 7四、 ProjectFeaturesAnalysis工程特點分析 7五、 ConstructionArrangements施工安排 7六、 ConstructionProcedures施工流程 7七、 SiteLayout現(xiàn)場布置圖 7八、 ConstructionMethods施工方法 88.1 RelevantPreparationsinAdvance前期相關準備 88.2 HostUnloading主機卸車 98.3 TrackedUnloadingandAssembly履帶卸車及組裝 108.4 Counterweight,BottomUnloadingandAssembly配重及底板卸車及組裝 118.5 BoomUnloadingandAssembly臂架卸車及組裝 128.6 MainBoomandJibInstallation主副臂安裝 138.7 TieRopeandHookInstallation拉桿鋼絲繩及吊鉤安裝 138.8 BoomElevation臂架提升 148.9 CommissioningandTesting調(diào)試及檢測 14九、 ProductionSafetyMeasures安全生產(chǎn)措施 159.1 PrinciplesandGoalsofSafetyProduction安全生產(chǎn)的原則和目標 159.2 SiteSafetyRequirementsforMandatory施工現(xiàn)場強制性安全要求 15References編制依據(jù)Documentsprovidedwithcranebymanufacturer履帶式起重機隨機資料；OperationInstructionfor200TCrawlerCrane《200T履帶吊使用說明書》；

JGJ/T189-2009TechnicalSpecificationonSafetyAssessmentofBuildingCraneonConstructionSite《建筑起重機械安全評估技術規(guī)程》；GB/T5972-2009Cranes-Wireropes-Care,Maintenance,Installation,ExaminationandDiscard《起重機鋼絲繩保養(yǎng)、維護、安裝、檢驗和報廢》；GB50278-2010CodeforConstructionandAcceptanceofCranesInstallationEngineering《起重設備安裝工程施工及驗收規(guī)范》；JGJ33-2012TechnicalSpecificationforSafetyOperationofConstructionMachinery《建筑機械使用安全技術規(guī)程》；BayerShanghaiSiteRoadLayoutPlanandrelatedspecifications拜耳上?；噩F(xiàn)場道路布置圖及相關規(guī)范。PreparationStatement編制說明ThisplanispreparedforthepurposetoinstructtheinstallationofQUY200crawlercrane,andavoidimpactsonconstructionprogresscausedbyunfamiliaritywithworkprocesses.為了指導QUY200履帶式吊機安裝工作，預防出現(xiàn)各種因不了解各工序施工方法而影響施工進程，特制定本方案。GeneralInformation吊機概況ThecrawlercraneQUY200mainlyconsistsofhost,counterweight,boom,hooketc..Specificationsofeachpartarelistedasfollows.QUY200履帶式吊機主要分為主機、配重、吊臂、吊鉤等部分組成，各部分規(guī)格參數(shù)如下圖所示。BasicDimensions基本外形尺寸DimensionsandWeightofMainTransportationComponents主要運輸部件外形尺寸及重量Host48t主機—48噸TrackFrameAssembly23t×2履帶架總成—23t×2CounterweightBottom15t×1配重底板—15t×1Counterweight4.45t×10配重—4.45t×10Counterweight2.94t×2配重—2.94t×230THook1.1t×130T吊鉤—1.1t×1BottomPartofMainBoom2.2t×1主臂底節(jié)臂—2.2t×1TopPartofMainBoom2.9t×1主臂頂節(jié)臂—2.9t×13mPartofMainBoom0.5t×1主臂3m節(jié)臂—0.5t×16mPartofMainBoom0.9t×1主臂6m節(jié)臂—0.9t×19mPartofMainBoom1.3t×1主臂9m節(jié)臂—1.3t×1BottomPartofLuffingJib0.8t×1變幅副臂底節(jié)臂—0.8t×1TopPartofLuffingJib0.9t×1變幅副臂頂節(jié)臂—0.9t×13mPartofLuffingJib0.2t×1變幅副臂3m節(jié)臂—0.2t×16mPartofLuffingJib0.4t×1變幅副臂6m節(jié)臂—0.4t×19mPartofLuffingJib0.6t×1變幅副臂9m節(jié)臂—0.6t×1FrontStrutofLuffingJib1t×1變幅副臂前撐桿—1t×1BackStrutofLuffingJib1.2t×1變幅副臂后撐桿—1.2t×1MainPerformanceParametersofQUY200QUY200主要性能參數(shù)表項目Items數(shù)值Value備注NoteMaxWeight×Range最大起重量×幅度t×m200×5BasicElbowWeight基本臂時自重t196MainBoomLength主臂長度m20~83FixedJibLength固定副臂長度m12~30MaxWeightofFixedJib固定副臂最大起重量t32InstallationAngleofFixedJib固定副臂安裝角度°10,30MainBoom＋MaxLengthofFixedJib主臂＋固定副臂最大長度m71＋30JibTowerLength塔式副臂長度m21~51MaxWeightofJibTower塔式副臂最大起重量t55BoomWorkingAngleunderTowerConditions塔式工況主臂工作角度°65、75、85MainBoom＋MaxLengthofJibTower主臂＋塔式副臂最大長度m59＋51Rollingspeedofsinglerope卷筒單繩速度MainLifting主起升m/min102Thefourthlayerofroll卷筒第四層ViceLifting副起升m/min102Thefourthlayerofroll卷筒第四層RangeofChange變幅m/min45Thefourthlayerofroll卷筒第四層SwingSpeed回轉速度rpm0~1.39WalkingSpeed行走速度km/h0~0.98CrawlingCapability爬坡能力％30GroundPressure接地比壓MPa0.1Dimensionslength×width×height總外形尺寸長×寬×高m10.6×7.2×3.9MastBoomnotIncluded不含桅桿臂架Engine發(fā)動機Ratedpower/speed額定功率/轉速kW/rpm256/2100228/2100Maxoutputtorque/speed最大輸出扭矩/轉速Nm/rpm1750/12001505/1400Emissionstandards排放標準EUStageIITierⅢTrackgauge×groundinglength×creeperwidth履帶軌距×接地長度×履帶板寬度mm6000×7935×1400BoomCompositionTable吊臂組成組合表number序號Condition工況Numberofmainbooms主臂節(jié)數(shù)NumberofJibs副臂節(jié)數(shù)Note備注135mmainboom+27mjib35m主臂+27m副臂3m*1+6m*23m*1+6m*12輛247mmainboom+36mjib47m主臂+36m副臂3m*1+6m*1+9m*23m*1+6m*1+9m*12輛ProjectFeaturesAnalysis工程特點分析Becauseofthesmallsiteanddifficultperformance,coordinationsforroadsclearingandclosingareneeded;現(xiàn)場場地狹小，操作難度大，需要協(xié)調(diào)場內(nèi)道路疏通及道路封閉；Theheavycrawlercraneneedshighfoundationbearingcapacity,soroadsshouldbehardenedandlayedfoundationboardsandboxes;履帶吊自重較大，需要地基承載力較高，因此需要對路面進行硬化處理及鋪設路基板及路基箱；Becauseofthegreatweightofcomponents,truckcranesareneededforcooperationduringinstallation,sotheoperationisverydifficult.各部件自重大，安裝需要汽車吊進行配合，操作難度大。ConstructionArrangements施工安排Accordingtothesiteconstructionschedule,HDI5unitisexpectedtotransfertostructuralsteelconstructionattheendofJune.Weintendtostartcrawlercraneinstallationworkon20thJune.Crawlercranedismantlingworkwillbecarriedoutafterfinishingstructuralsteelbodylifting.Thedismantlewillbephrasedandthedatewilldependonsiteinstallationschedule.根據(jù)現(xiàn)場施工進度安排，預計HDI5單元6月底移交鋼構施工，我司擬在6月20日開始進行履帶吊的安裝工作。鋼結構主體吊裝完成則進行履帶吊拆除工作，預計后期會分階段拆除，具體拆除日期根據(jù)現(xiàn)場安裝進度確定。ConstructionProcedures施工流程Craneapproaching→craneinspection→transportationroutechecking→installationsitechecking→craneunloading→crawlertrackcounterweightself-installation→truckcranecooperatingwithboominstallation→cranecommissioningandtesting→craneacceptance→layingmeasuresforfoundationboards→liftingoperations.吊機進場→吊機檢驗→運輸路線查看→安裝場地查看→吊機進場卸車→履帶吊自行安裝履帶配重→汽車吊配合安裝吊臂→調(diào)式檢測吊車→吊車驗收→路面鋪設路基板措施→吊裝作業(yè)。SiteLayout現(xiàn)場布置圖CranecomponentsshouldbetransportedoutsideBayersiteandtoliftingareaafteracceptance.Routesfortrucksinsiteareasfollows:吊車部件運輸至拜耳基地場外，在場外驗收完成后運至吊裝區(qū)域，場內(nèi)貨車行走路線如下所示：Structuralsteelyard1#2#1#2#4#3#Seeattachments1and2forsitecraneassemblylayouts.吊機現(xiàn)場拼裝布置圖見附件1、2。Assemblyorderforthe4cranesis:first1#crane,then3#crane,next2#crane,andatlast4#crane.4輛吊機的拼裝順序為：先拼裝1#吊車，再拼裝3#吊車，爾后拼裝2#吊車，最后拼裝4#吊車。Constructionmethods施工方法Relevantpreparationsinadvance前期相關準備Transportroadsshouldbecheckedbeforecrawlertracktransportation.Theroadsmustbesolid,smoothandwithnolargepotholes.Eachroadcurvemustbeabletoensurethesmoothcornering.Thereshouldbenoobstaclesovertheroads.Clearanceshouldmeettherequirementsofaccessandsoon.Ensuresafeandsmoothtrafficduringtransport.履帶吊運輸前需先查看運輸沿線道路情況，道路必須堅實平整無大型坑洼。道路各彎道必須保證車輛能夠順利進行轉彎行駛。道路上空無障礙物，凈空是否滿足通行等。確保運輸過程中安全順利通行。Installationsitechecking.Sincetheweightofcrawlertrackafterassemblyisabout210t,thefoundationbearingcapacityshouldbehighandthereshouldbenounstablesoilorlaminatedsiltetc.underground.Thefoundationbearingcapacitymustnotbelessthan10T/㎡.Inviewofthese,theroadsshouldbelayedwithfoundationboardsandthewestlawnbackfillareashouldbecompactedandleveledwithhardconstructionmaterials.Thebestmethodistopourconcretefirstandthenlaysteelboardsonit.查看安裝場地，由于履帶吊組裝完成后自重約210T，要求地基承載力高，安裝場地不得有不穩(wěn)定土質(zhì)，下層不得有淤泥夾層等，地基承載力必須≥10T/㎡。因此需要在原路面上鋪設路基板，且西側草地回填區(qū)域要用硬質(zhì)施工材料夯實整平，最好是澆筑砼，爾后在面上鋪設鋼板。Thediagramisasfollows:示意圖如下：Diagramforroadteethprotectionnodes:路牙保護節(jié)點示意圖：HostUnloading主機卸車Whencrawlertrackarrivesinsite,legswillliftfromthetopofthehost.Thenthetrackdriveoutthesitealongtheroad,withthespeednotmorethan25km/h.履帶吊運輸至現(xiàn)場后，主機頂升支腿，貨車沿道路前行駛出現(xiàn)場，時速不超過25km/h。Thediagramisasfollows:示意圖如下所示：TrackedUnloadingandAssembly履帶卸車及組裝Crawlercraneapproachingisafterthehostcomestoitsplace.Crawlersareunloadedbyhostandassembledontheirownbythebalancearmofthehost.Mainboominstallationiscarriedoutaftercrawlersandcounterweight,andthelegscanbebackonlyafterpassingtheinspectionsofprofessionals.主機就位后則開始進場吊機履帶，履帶用主機卸車，且自行組裝履帶，自行組裝采用主機平衡臂，履帶及配重完成后進行主臂安裝，經(jīng)專業(yè)人員檢測合格后方可收支腿。Thediagramisasfollows:示意圖如下所示：Counterweight,BottomUnloadingandAssembly配重及底板卸車及組裝Counterweightboardsandblocksinstallationiscarriedoutaftercrawlerinstallation.Thetracktransportsthebottomboardstothehostattachment.Thenthehostunloadsthemtotheelevationplacebehind.Next,placethecounterweightblocksonebyoneonthebottomboards.Afterthat,rotatethehosttoinstallthecounterweightbypowerpin.履帶安裝完畢后則開始進行配重底板及配重塊的安裝，貨車運輸?shù)装逯林鳈C附件，由主機卸車至主機后側提升處，爾后把配重塊依次放置在底板上，待配重放置完成后回轉主機，用動力銷軸把配重重安裝完成。Thediagramisasfollows:示意圖如下所示：BoomUnloadingandAssembly臂架卸車及組裝Theinstallationofbottompartofmainboomiscarriedoutafterfinishingcounterweightsysteminstallation.Thisisdonebyhostitselfafterunloading.配重系統(tǒng)安裝完成后則開始安裝底節(jié)主臂，底節(jié)主臂由主機自行卸車安裝。Thediagramisasfollows:安裝示意圖如下：MainBoomandJibInstallation主副臂安裝Mainboomandjibneed25ttruckcraneforunloadinginstallation.Unloadrelevantcomponentstothebottomforconnection,andmakeslightadjustmentbyworkers.Alignthepinholesofthetwobooms,paintthelubricant,insertthepinfromoutsideandfixit,then,installothercomponentsinorder.主副臂節(jié)需要用25T汽車吊進行卸車安裝，將相關部件卸車至底節(jié)位置進行對接，且采用人工進行微調(diào)，兩節(jié)臂的銷孔對齊，涂抹潤滑油，由外向內(nèi)插入銷軸，并固定，爾后依次安裝其他部件。Thediagramisasfollows:安裝示意圖如下：TieRopeandHookInstallation拉桿鋼絲繩及吊鉤安裝Theinstallationoftrolleywireropeandhookiscarriedoutafterthatofmainboomandjib.Thehookshouldbea30tonewith2*2pulleyblocks.Putthehookattheendofthemainboom,flameoutthecrawlerhostfromoperation,releasethehoistandthenorderworkerstoconnectthehookwithhostbywireropesaccordingtotherequirements,andfixtheendsofwireropeswithsnaprings.主臂及副臂安裝完成后則開始安裝拉桿鋼絲繩以及吊鉤，吊鉤采用30T吊鉤，選用2*2滑輪組，將吊鉤放置在主臂端頭，履帶吊主機熄火，停止運轉，將卷揚機制動放開，用人工將鋼絲繩按照要求將吊鉤與主機連接起來，并有卡環(huán)將鋼絲繩端頭固定。Thediagramisasfollows:安裝示意圖如下：BoomElevation臂架提升Afterassemblingbooms,checkthepintomakesureitisfixedandthewireropesqualified.臂架組裝完成后，檢查銷軸是否緊固完成，穿繞鋼絲繩是否合格。Crawlerhostcanonlybestartedafterhookinstallation.Liftthepole,elevatethemainboomandjibasawholeandthehoistwilltensilethewireropesslowly.Stopfor5minuteswhentheangleofmainboomandtrolleyjibgetsstable.Thencheckthewireropesandboomagain.Elevatethemtotheworkingangleiftheyarequalified.吊鉤安裝完成后，方可啟動履帶吊主機，指揮起桿，主臂跟副臂整體提升，卷揚機緩慢拉伸鋼絲繩，主臂與拉桿副臂形成穩(wěn)定夾角后停止5分鐘，再次檢查鋼絲繩及臂架后完全符合要求后再次提升至工作角度。Thediagramisasfollows:安裝示意圖如下：CommissioningandTesting調(diào)試及檢測Docheckafterinstallation.Forexample,whethereverypininstallationisqualifiedornot,whetherthepinsarefixedornot,whetherjibluffing,hookliftinganddropping,hookinsurancecards,anti-overturningdevices,slewingmechanism,U-ropesettingandothermechanicalactionsarecorrectandstableornot,whetherthesafetydevicesareflexibleandreliableornot,whetherthetorquedisplayingisflexibleornot.Makeadjustmentstimelyifthereareanyproblems.Checkthebrokenwireinwireropesling,hookwearing,U-shapedringwearing.Aftertheself-testisrunningnormally,inviterelevantinspectionstaffforthewholedetectionandissuingtheliftingoperationlicense.完成安裝后檢查每個銷軸安裝是否到位，別針是否牢固，檢查吊臂變幅、升降吊鉤、吊鉤保險卡、防后傾覆裝置、回轉機構、U型繩卡設置等機構動作是否正確平穩(wěn)，安全裝置是否靈敏可靠。力矩顯示是否靈敏。如若發(fā)現(xiàn)問題及時進行調(diào)整。吊具鋼絲繩的斷絲、吊鉤磨損、U型吊環(huán)磨損的檢查。經(jīng)各項自檢運行正常后，申請相關檢測人員前來進行整機檢測并出具吊裝作業(yè)許可證。Thediagramofworkingconditionisasfollows:工作狀態(tài)示意圖如下：ProductionSafetyMeasures安全生產(chǎn)措施PrinciplesandGoalsofSafetyProduction安全生產(chǎn)的原則和目標Principles原則ResolutelyobeytherelevantrequirementsofBayerIntegratedSiteShanghai;堅決服從拜耳上海一體化基地相關要求；Adheretotheprincipleofsimultaneousimplementationofproductionandsafety;堅持生產(chǎn)與安全同步實施的原則；Adheretotheprincipleofsafetyfirst.堅持安全第一原則。Goals目標ShanghaiConstructionandstrictlyinaccordancewiththeorganizationofcivilizationonbuildingconstructionsiteconstructionsitestandardizeregulationstoeliminateallon-sitesafetyhazards.嚴格按照上海市有關建筑工程施工現(xiàn)場標準化管理規(guī)定組織施工和現(xiàn)場文明施工，消除一切現(xiàn)場安全隱患。SiteSafetyRequirementsforMandatory施工現(xiàn)場強制性安全要求Projectsafetyplansandproceduresshouldbereportedtotheownerssupervisingengineertoreviewandaccepttheproposedadditionalrequirementsunplanned.Constructionsitemustperformthefollowingmandatoryrequirements:項目安全計劃及程序應報業(yè)主監(jiān)理工程師審查，接受計劃外提出的附加要求?，F(xiàn)場施工必須執(zhí)行下述強制性要求：Notwearingprotectiveequipment(helmets,workshoes,etc.)ofemployees(includingvisitor,supplierrepresentatives,materialtransportmember)shallnotentertheconstructionsite;沒有穿防護用品(安全帽、工作鞋等)的職工(包括來訪者、供方代表、材料運送員)不得進入施工現(xiàn)場；Aerialseatbeltwhenever2maboveshouldbeprotectedwithinthescopeoflanding;高空作業(yè)系安全帶，無論何時在2m以上的降落范圍內(nèi)應有保護；Participatedinoperationspersonnelmustundergosafetytraining,examination;參加作業(yè)人員必須經(jīng)過安全培訓，考試合格；Liftingcommandtocommandbyap