-
设备吊装施工方案
一
.
概况
Overview
1.1
工程概况
Project Overview
工程名称：
XXXX
基础设施变电站安装工程
Project name: -Transformer
Substation Installation
建设单位：
XXXX
Construction Unit: XXXX Co., Ltd.
总包单位：
XXXX
公司
Contractor Unit: XXXX Co., Ltd.
设计单位：
XXXX
公司
Design Units: XXXX Co., Ltd.
项目地点：
XXXX
Project
Location: XXXXt
1.2
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。<
/p>
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
B
551
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<
/p>
：
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。
On
e 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
< br>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)
3
5/10KV
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
< br>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
3150KV
A
干
式变压器
;
Eight
sets
of
10
KV
/
0.7
KV
3150KVA
dry-type
transformers;
1
设备吊装施工方案
4
台
0.69
千伏
/0.4
千伏
800KV
A
干式变压器的安装；
Four
sets
of
0.69
KV
/
0.4
KV
800KV
A
dry-type
transformers;
4
台
0
.69
千伏
/0.4
千伏
500KV
A
干式变压器的安装；
< br>Four
sets
of
0.69
KV
/
0.4
KV
500KV
A
dry-type
transformer;
2
台
0.
69
千伏
/0.4
千伏
250KV
A
干式变压器的安装；
One set of 0.69 KV / 0.4 KV 250KV
A
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
< br>台
VSD
屏
;47 sets
of VSD plate,
1
套
2
30V
直流
UPS
电池
;One set of 230V DC UPS battery;
2<
/p>
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
1300kV
A
690V
AC
柴油发电机。
Two
sets of 1300kV
A 690V
AC
diesel generators
二．
编制依据
Compilation
Basis
1
）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、
< br>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.
construction crane, hoisting
safety technology
4)
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
2
设备吊装施工方案
项目经理
GM
耿文宝
Geng Wenbao
公司安全
Safety
officer
程宗强
Cheng
Zongqiang
班组安全员
Safety
member
钱根强
Qian Genqiang
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
四
.
施工准备
Preparation
4.1
技术准备
Technical preparation
1)
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；
Co
mpile 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
< br>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)
<
/p>
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，<
/p>
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 preparation
1
）
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,
3
设备吊装施工方案
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，
< br>800*800*8000mm
钢架
3
< br>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
< br>只；
One hammer;
地锚
3
只，吊锁
10
副，大小头木塞<
/p>
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 preparation
1
）
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 methods
5.1
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 690V
AC
柴油发电机根据提供的资料表明长
12
< br>米，宽
2.4~2.5
米，高
2
.2~2.3
米，
4
设备吊装施工方案
单台重
23.5~24
吨。
As the
provided information shows, 1300kV
A
690V
AC diesel generator in C593 is
12 m long, 2.4~2.5 m wide and 2.2~2.3
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
< br>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
company's
experience
on
hoisting
and
the
conditions
construction
site
required,
under the premise of the safety of
lifting operations, decide:
本工程中
10KV
3150KV
A
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 3150KV
A
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
irons
’
cetification
has
not
gotten
already,
we
can
use
the
following
formula
to
calculate and check.
1
）
100
T
（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：
Q
≈
54
d2
Q
≈
54
< br>×
46
×
46
≈
114264
㎏
钢丝绳的安全系数<
/p>
K
取
8
P
≈
114264
÷
8
≈
14283
㎏
每根吊索的受力
(
分支与水平线夹角取
60°
)
S =24000
㎏×
(1
÷
sin60°
< br>)
÷
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
< br>变压器）吊装采用
4
根
?25m
m
钢丝绳千斤，
5