（中英）大件设备吊装施工方案.doc

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1、目 录Contents第1章 工程情况 protect introduction31.1工程概况及编制说明 General Situation and Information31.2本装置工程范围内设备概况 Condition of Facilities3第2章 编制依据 basis of compilation6第3章 吊装方案确定及吊车选型、来源confirming of hoisting scheme and the type and source of crane73.1方案的确定 Confirming of Hoisting Scheme73.2吊车选型、来源Type and Sou

2、rce of Crane73.3吊装条件 Condition of Hositing8第4章 大型设备的吊装工艺及吊装准备hoisting craft and equipmeng of large-scale equipments104.1吊装工艺流程图Process Flow Diagram of Hoisting104.2 吊装方案前期确定的原则Principle of Hoisting Scheme Confirmed on the Early Stage104.3吊装准备 Preparation of Hoisting114.4主吊吊车的站位设计 Design of the Posit

3、ion of the Main Crane124.5大型设备吊装主要参数及主要设备的吊装工艺方法 Main Parameter of Large-scale Equipment Hoisting and Hoisting Craft of Main Equipments134.6 吊装机具的运输 Transportaion of Hoisting Equipments164.7设备的卸车及二次倒运Unloading and Secondary Transportation of Equipments164.8吊装工具及附件 Hoisting Tools and Accessories17第5章

4、 大型设备吊装计算及校核calculationg and checking of large-scale hoisting equipments195.1尿素塔（R06101）的吊装 Hoisting of urea tower R06101195.2氨合成塔（R04501）的吊装 Hoisting of ammonia synthesis tower (R04501)235.3真空预浓缩分离器(S06104)的吊装Hoisting of vacuum pre-concentration separator (S06104)285.4其他设备吊装 Other equipments hoisti

5、ng315.5吊装用工装及校核 Lifting with the tooling and checking32第6章 起重吊装的指挥和吊装工艺岗位的分工direction of hoisting and division work of hoisting craft366.1起重吊装的指挥协调工作Direction and Coordination Work of Hoisting366.2吊装工艺岗位的分工 Division Work of Hoisting Craft37第7章 吊装安全保证体系及措施SYSTEM AND MEASURES OF HOISTIN SAFETY397.1安全目

6、标Safety Target397.2 建立吊装安全保证体系 Establishing System of Hoisting Safety397.3吊装安全措施和要求 Measures and Requirements of Hoisting Safety40第8章 文明施工、环境保护措施MESSURES OF CIVIL CONSTRUCTION AND ENVIRONMENTAL PROTECTION40第9章 主要机具设备与工装MAIN EQUIPMENTS AND TOOLING44第10章 施工进度计划及劳动力计划安排SCHEDULED PLAN OF CONSTRUCTION AN

7、D ARRANGEMENT OF LABOR46第11章 附件：大型设备吊装总平面图ATTACHMENT: GENERAL LAYOUT OF LARGE-SCALE EQUIPMENTS HOISTING46第1章 工程情况 protect introduction1.1工程概况及编制说明 General Situation and Information越南金瓯化肥项目是越南当地单套年产量最大的化肥项目。EPC总承包商为中国五环工程有限公司，工程地点在越南金瓯省金瓯市幽明县。The Chemical Fertilizer Project in Ca Mau Vietnam is the V

8、ietnams largest single set of annual fertilizer project. The EPC general contractor is the China Wuhuan Engineering Co., Ltd. The site of project is in Ca Mau City Ca Mau Province Vitenam.本项目中最大的生产单位工程为合成氨、尿素、造粒和尿素储运等工序，大型设备主要集中在合成氨、尿素，共有30台，其中氨合成塔、尿素塔、尿素装置内的其他高压容器为吊装工程的重点。吊装前地基的处理尤为重要。The largest p

9、roduction units in this project are ammonia synthesis, urea, granulation and urea storage and transportation, etc. Large-scale equipments are focused on ammonia synthesis and urea, a total of 30 sets. And ammonia synthesis tower, tower of urea and other high-pressure vessels in urea devices are the

10、focuses of hoisting work. Lifting pre-treatment of the foundation is particularly important.由于本次招标文件所提供的技术资料不尽详细，因此我公司将根据同类的施工经验、技术参数的基础上进行了方案的编制，如有不妥之处，待施工图纸和相关技术资料完备后，再进行补充和完善。吊装方案的编制从整个项目安装整体考虑。Because of the provided technical information in this tender document is not in detail exactly, our com

11、pany wrote the scheme based on similar construction experience and technical parameters. Any wrong with that, we will complete and improve it further after supplementing the construction drawings and related technical information. The hoisting scheme is from the overall consideration of the entire p

12、roject to install.1.2本装置工程范围内设备概况 Condition of Facilities 本项目各种容器、塔器、换热器、分离器及储罐达数百台。其中超限设备达30台之多,主要有以下关键设备（其他部分散装设备重量待定）： The various containers, towers, heat exchangers, separators and tanks of the project are up to hundreds. Transfinite equipments are as many as 30 sets. The following are the key

13、equipments (Other parts of the weight of loose equipment to be determined):(1) 氨合成塔（R04501）是本装置单体最重的设备,设备直径2800mm，立式，上下切线之间高度22400mm，重量407.7吨,安装标高为6.00m。吊装作业区域较小。The Ammonia Synthesis Converter（R04501）is the heaviest single unit of equipment. Its diameter is 2800mm, vertical. The height between the

14、upper and lower tangent is 22400mm, and the weight is 407.7 tons. The absolute elevation of installation is 6.00m. The region of lifting operations is small.(2) 尿素塔（R06101）是尿素装置单体高度最高的设备,设备直径为2250mm,高度达43000mm,重量为230吨(不包括内件及外部平台), 安装标高为3.7m。The Urea Synthesis Converter（R06101）is the highest single u

15、rea plant equipment. Its diameter is 2250mm, height of up to 43000mm, weight 230 tons (not including the inner parts and the external platform), and the absolute elevation of installation is 3.7m.(3) 二氧化碳吸收塔（C04302）是本装置最大超限设备之一,设备直径为4360* mm,高度达39530mm,重量为252.1吨(不包括内件及外部平台), 安装标高为0.30m。The Carbon Di

16、oxide Absorption tower（C04302）is one of the largest transfinite Equipment units. Its diameter is 4360 * mm, height of up to 39530mm, weight 252.1 tons (not including the inner parts and external platforms), and he absolute elevation of installation is 0.30m.(4) 汽轮机冷凝器(E04401) 为本装置最大的卧式设备之一, 外形尺寸为130

17、0032004350,重量为85吨(包括内件) , 安装于压缩机主机下部，吊装就位难度较大。The Steam Turbine Condenser (E04401) is one of the largest horizontal devices. The overall dimensions is 13000 3200 4350, weighs 85 tons (including the inner parts), installed in the lower part of the host compressors. It is more difficult to be installa

18、ted.(5) 二段转化炉（R04302）,为本装置最关键设备之一,外形尺寸为3500*10200重量为173吨。转化炉配套的冷凝器及过热器较多，重量都在40吨以上，最重达180吨，设备布置较集中，吊装难度较高。The Sec-Reformer (R04302) is one of the most critical equipments. The overall dimensions is 350010200, weighs of 173 tons. The quantity of the condenser and superheater of the conversion furnace

19、 supporting is more. The weight is more than 40 tons and the max-weight is up to 180 tons. The equipment layout is more focused and the lifting is more difficult.(6) 尿素工序的高压设备：此处设备布置的较密集，多数设备支撑楼层之间，且大部分为联体设备，设备总长度较大，多数需从楼层顶部，从吊装孔吊入，作业难度大。The high-pressure urea process equipment: Equipment layout her

20、e is more intensive. Many of the equipments are between the floor supports, and most of them are conjoined equipments. The total length of them is much longer. Many of the equipments need to be lifted from the top of the floors, from the lifting crane into the hole, operation difficult.(7) 1#废热锅炉，外形

21、尺寸为2324*20600 mm，重量为130吨。The external dimensions of 1 # waste heat boiler is 2324 * 20600 mm, weight 130 tons.第2章 编制依据 basis of compilation2.1大型设备吊装工程工艺标准 SHJ515-90 Large Equipment Hoisting Engineering Process Standards2.2化工工程建设起重规范 HGJ20183Chemical Engineering Construction Crane Specification2.3石油化

22、工施工安全技术规程 SH3505-1999Petrochemical Construction Safety Technical Regulation2.4现场施工平面布置图General Layout for Construction Site2.5装置设备布置图 Equipment Arrangement Drawing of the Plant2.6公司吊装技术装备及人员技术状况 The State of Companys Technical Equipment and Personnel Lifting Technology2.7起重工操作规程 （SYB411280）Crane Wor

23、kers Operating Procedures2.8 LR1750型750/400吨及SCC1500型150吨级履带式起重机性能表LR1750-type 750/400 tons and SCC1500-type 150-ton crawler cranes Performance Table2.9中国化学工程第十四建设有限公司的有关标准和制度Relevant Standards and Systems of CNCEC No.14 Co., Ltd.第3章 吊装方案确定及吊车选型、来源 confirming of hoisting scheme and the type and sour

24、ce of crane3.1方案的确定 Confirming of Hoisting Scheme综合此项目吊装工程特点和施工现场的场地条件，在确保吊装工程安全可靠、工艺合理及工程进度的前提下，经过认真分析、研究，我公司决定采用以下方法完成本装置特大设备的吊装就位工作：Integrated the characteristics of hoisting project and the c conditions of construction site of this project, in order to ensure lifting safe and reliable and to ens

25、ure reasonable technology and construction schedule, after careful analysis, and research, our company decided to use the following methods to complete the installation of hoisting large equipment in place work:一台750吨履带吊，一台400吨履带吊车实施：A 750-ton crawler crane, a 400-ton crawler crane:大型履带吊车以“单机提升、辅助吊车

26、抬尾递送”的吊装方法来完成各大型塔类设备的吊装工作，对进场设备均采取整体吊装方法完成其就位安装工作（分段到场设备在地面组焊成整体）：采用一台750吨履带吊做主吊，400吨履带吊车做辅吊来完成二氧化碳吸收塔（C04302），尿素塔（R06101），氨合成塔（R04501）的吊装;对尿素区高压设备、转化炉区等其他的大件设备，则采用400吨吊车一次性吊装就位。The large crawler crane with the lifting method of stand-alone upgrade, auxiliary crane lift the end of delivery to comple

27、te the major work of hoisting tower equipment and use integral lifting method for approach equipment to complete the work of putting into place and installation (Sub-scene equipments will be welded as a whole on the ground.): Using a 750-ton crawler crane as the main crane and a 400-ton crawler cran

28、e as the auxiliary crane to complete the hoisting of carbon dioxide absorption tower (CO4320), urea tower (RO6101), ammonia synthesis tower (RO4501). Using 400-ton crane to complete hoisting at one-time for high-pressure equipment in urea area and other equipments in reformer area.3.2吊车选型、来源Type and

29、 Source of Crane3.2.1 吊车选型 Type of Crane本装置吊装工程所用的主吊车，我公司经过考察,拟选用750吨级履带式起重机（LR1750型）一台；在吊装过程中，另需要一台起重量为400吨级履带式起重机（LR4000-2型）用做特大型设备吊装的抬尾递送工作。400吨履带吊也可作为大中型设备的主吊工作，并投入一台150吨履带（SCC1500型）吊作为400吨的辅吊。After inspection, our company intend to use a 750-ton crawler cranes LR1750) for as main crane. In the

30、process of lifting, a 400-ton crawler crane (LR4000 - 2) should be needed to complete the work of lifting the end of large-scale equipments. The 400-ton crawler crane can also be used as the main crane for large and medium size equipments and a 150-ton crawler crane (SCC1500) can be as the auxiliary

31、.3.2.2 吊车来源 Source of Crane750吨吊车、400吨吊车为与本公司有联营协作关系的单位自有设备，吊车由国外引进，其技术先进，性能可靠，车况良好，可充分保障本工程吊装安全。上述吊车资源已与联营单位落实，一旦中标，即可签定使用合同。750-ton crane and 400-ton crane belong to the unit that has the collaborative relationship with our company. Crane imported from abroad, it has advanced technology, reliable

32、performance, good condition, and can fully protect the safety of this project hoisting. The crane resources have been implemented with the joint venture unit, once the successful bidder, you can sign the contract.本公司自有150吨履带吊一台,可满足50吨以下超限设备的安装就位工作。Our company owned a 150-ton crawler cranes that can

33、meet the equipment under 50-ton to installated the transfinite equipments.3.3吊装条件 Condition of Hositing3.3.1 本吊装工程还需要配备一件500吨级的无弯距、可调节长度的专用平衡吊梁，计划采用钢管结构形式，并由专业厂家制造，以满足大件设备吊装条件。A 500-ton level balance girder with non-bending moment and adjustable length should be used for lifting, planning to use ste

34、el pipe structure and through professional factory manufacturing, to meet the conditions for lifting large equipment.3.3.2 对两台吊车的吊装站车位置处的承压地面和吊车的移动道路应进行平整和夯实处理，地耐力应大于30吨每米平方。关于施工现场吊装场地的具体处理措施，特别是针对越南施工当地的土质条件，建议根据现场的具体地面情况而定,可采用混凝土基础或换填土铺设坚实道木与30mm钢板,但地耐力必须满足规定要求。To Formate and compact the ground wh

35、ere the two cranes located and the road where the crane moving on. The bearing capacity of soil should be more than 30 tons per Meter Square. With regard to the construction site lifting site-specific treatment measures, especially with regard to the construction of local soil conditions in Vietnam,

36、 it is recommended according to the site-specific conditions of the ground. Concrete can be used to lay a solid foundation or for filling Woods and 30mm steel plate, but must meet the requirements to endurance requirements3.3.3 关于29台大型设备的现场卸车工作，大部分可以由在场的150吨吊车和400吨吊车在其吊装位置来完成。其中200T以上的设备需用750T吊车配合卸车

37、。在设备到货前应根据设备到货状况、卸车位置及地面条件及时编制每台设备的卸车技术措施，以保证工程安全。对每台大件设备的吊装，必需制定详细的吊装技术方案。由于目前缺乏详细的设计资料，特别是对各台大件设备的吊点位置、吊耳形式、内附件重量有待进一步核实。The unloading work of 29 sets of transfinite equipments shall be completed approximately by 150-ton cranes and the 400-ton crane on site. The equipment overload 200T shall be li

38、fted by several cranes combined with the capability of 750Ton. The unloading technical measures should be arranged according to the states, unloading position and ground condition before equipments arrival on the site, in order to ensure the project safety. Hoisting scheme should be made in detai fo

39、r every large-scale equipmet. Since there is no detailed design information, especially the various pieces of equipment hanging NTU point position, lug form and the weight of inner accessories should be further verified. 3.3.4 在各台大型设备吊装之前，在满足吊车提升能力的前提下（不抗杆），尽量在地面安装其附带平台结构、工艺配管及保温绝热等项施工，最大限度的减少高处作业和加

40、速工程进度。Before the hoisting of large equipments and to meet the lifting capacity (not anti-stroke), plant construction, process piping and thermal should be installated as far as possible, in order to reduce height operation and speed up projects progress.第4章 大型设备的吊装工艺及吊装准备hoisting craft and equipmeng

41、 of large-scale equipments4.1吊装工艺流程图Process Flow Diagram of Hoisting吊车就位前需对吊车行走道路及就位的地基承载按要求进行处理，并对站位位置测量划线The crane access line, the foundation workload and the location of the crane shall be measured shall be arranged and measured prior to the crane positioning. 主吊车就位 吊 车 组 装吊 臂 组 装 吊 臂 竖 立 主吊车回转

42、半径核实 系挂吊装索具 试吊与正式 吊 装 设 备 就 位 拆除吊装索具 主吊吊车 拆除 撤离 辅助吊车 拆除撤离 设备吊点 设置检查 待吊设备 进 场 辅助吊车 就 位 辅助吊车 吊臂组装 吊臂竖立 系挂吊装 索 具 对于卧置设备吊装不用此工序 4.2 吊装方案前期确定的原则Principle of Hoisting Scheme Confirmed on the Early Stage4.2.1技术先进、经济合理的原则The Principle of Advanced technology and Reasonable Economics4.2.2安全可靠、稳妥可行的原则：确保设备吊装一次

43、成功。The Principle of Safe, Reliable, Sound and Viable: to ensure the equipment hoisting a successful in one-time.4.2.3对现场平面和设备安装工作影响最小的原则：施工场地十分狭窄，工期紧张,在保证设备顺利吊装的前提下，尽量不影响其他设备基础的浇注和设备的安装。The Principle of minimum affects for On-site ground and equipment installation: The construction site is ery narro

44、w. With the tight schedule and in order to ensure lifting smoothly, the concreting of other equipment foundation and installation of equipments should not be affected.4.2.4兼顾到技术先进性的原则：利用750吨大型起重机进行设备吊装，可以缩短设备的吊装工期。The Principle of Advanced Technology: Using 750-ton large-scale crane to lifting can r

45、educe the work schedule.4.2.5本工程设备吊装主要采用单机吊装或双机抬吊法进行吊装，对于直径大、本体高、重量大的立式设备采取双机吊装方法;吊装时设备上部采用单吊车提升，设备下部采用单吊车抬送。对于卧式设备，采用单机吊装就位。This project mainly use single or dual-lifting machine lifting crane. Two-crane lifting method is used for large diameter, high-bulk and heavy equipment vertical equipments. D

46、uring hoisting process, the single crane is used for the lifting of upper part of the equipment and for the carrying of the lower part it. Using single crane to hoisting equipmenta in place for the horizontal device, 4.2.6现场吊装方案的确定，必须结合土建及结构的施工，确定施工的前后顺序，避免土建及结构施工完后，设备吊装时需拆除大部分的结构。The confirmation o

47、f the hoisting scheme on-site should be on the basis of the construction of civil and structure. In order to remove more structure after the civil work, the sequence of construction should be confirmed.4.3吊装准备 Preparation of Hoisting4.3.1施工机具的规格和布置与已批准的施工方案是否一致并便利操作。Whether the specifications and layout of construction equipments are consisten with the construction plan and were facilitated for operation4.3.2机具的合格证以及各项记录是否完整。Whether there are integrated certificate and various records of machinery4.3.3设备的检查、试验以及吊装前应进行的工作是否已完成。Whether the work before che