036超限设备运输施工方案englishREV1.docx

1、036超限设备运输施工方案englishREV1 YPC-BASF Company Ltd. IPS ProjectBCC 600,000t/y Ethylene PlantOverride equipment shipmentConstruction Plan(REV 1)BASF-YPC Ethylene Project Management Dept.The Fourth Construction Company of SINOPECCode：FCC-BCC/Procedure-036 ImportantComprehensive GeneralYPC-BASF Company Ltd.

2、 IPS ProjectBCC 600,000t/y Ethylene PlantOverride equipment shipmentConstruction Plan(REV 1)Prepared by:Din JianReviewed by:Xu JianlingApproved by:Gao HongyanBASF-YPC Ethylene Project Management Dept.The Fourth Construction Company of SINOPEC20 Jun 2003Table of Contents1 Preparation basis 12 General

3、 13 Shipment organizing system 24 Construction procedure 25 Shipping plan 26 Quality assurance measure 37 HSE assurance measure 41 Preparation basis 1） Design drawings 2） Petrochemical construction safety technical regulation（SH35051999）3） lifting machine safety regulation （GB606785）2 General 2.1 Pr

4、oject general This project includes many large-scale equipments especially some of them specification and size override. For this condition, we make this plan. 2.2 Equipment parameter, loading cranes and shipping vehicles (see attachment)2.3 Shipping route and barricade（see figure 1）2.3.1 Route 1） T

5、wo route of warehouse equipment shipping: No. route（equipment shipping diameter not more than 3m）、号路线（except equipment shipped in No. ）2） Warehouse No. 3 and No. 4 shipped in route No.3） Equipment in Yard 8 shipped in route No.2.3.2 Barricade and shipped equipment specification on this route1） Total

6、 7 barricades in route No. with lowest height 5m，among of which have two 6000V high voltage wire with height of 7m；width of road is 6m. Another place has a high voltage cable with height 5.5m.2） Equipment 390-V-901（W 31.55t，specification 19750*5360*5400）350-V-520（W45.65t，specification 10620*3150*422

7、0）320-C-230（W22.8t，specification 10900*4500*5070）3 Shipment chief director Shipment organizing system Machinery CompanyEquipment CompanyGuard DeptSupply DeptEngineering Dept.Technical Dept.Safety Inspection station4 Construction procedure 5 Shipping plan 5.1 Loading and packing（key procedure）1） Befo

8、re equipment shipping, engineering department shall organize inspection, repair and maintenance for lifting equipment, slings and hoists to confirm safe shipping. All equipment nozzles and pressure gauges shall be properly protected and not damaged during handling and transportation.2） Before loadin

9、g, clean work site of cranes and shipping vehicles. If over two cranes working together, the operators are required to obey direction and cooperate closely. The speed and rise of every crane shall be equal. Load of every crane shall not exceed its rated load capacity 75%.3） When packing, skid proof

10、objects, such as rubber and sleeper, are required to fill between equipment and vehicle. After packing, use ropes, hoists and shackles for making into whole. If use binging ways for packing, required firm and credible.4） For thinned wall equipment (such as cold box), need to add a steel rack on ship

11、ping vehicles and lay steel plate on the rack for enhancing compressive strength. (Detailed specification of the steel rack see figure 2)5） All lifting equipment shall be such that it is not possible to damage the equipment material and paint work.6） Cold box less than 15m is transported without tra

12、iler plate and steel rack. 7） Cold box Z401 has been transported by LI SHENG company.8） When cold box packing, shall pay special attention to wall protection. 9） After inspection qualified, it shall be confirmed by safety and quality inspectors and then shipped.5.2 Equipment shipment （important proc

13、edure）1） During shipping, driver shall control the speed seriously, keep slow speed and a close eye on changing to make consideration easily. Average speed per hour shall be limited in 20km/h.2） When pass pipe rack, shall “stop, observes and then pass it.3） When pass crossing and turn the corner, sh

14、all keep close eye on surroundings especially have research on over long equipment to make practical plan. 4） During shipping, shall inspect whether equipment is loose. If find problem, shall make action to confirm shipping quality. 5.3 Equipment unloading Use opposite order of loading and packing.5

15、.4 Return When return, pack all shipping appliance and then return on coming ways. 6 Quality assurance measure6.1 Inspection before shipping 1） Shall have complete inspection for shipped component. If find defects, shall get in touch immediately, after make modification and then permit to pack.2） Us

16、e shipping vehicles, cranes, lifting slings, hoists, shackles and steel wire after inspection qualified. 3） When packing, shall make necessary protection for preventing paint off caused by ropes and wires.6.2 Process control Engineering department shall be responsible for process quality control. Sh

17、ipping principals shall fill record on time to confirm equipment on site without defects.7 HSE assurance measure 1） Lifting plans, equipment lift record cards and job safety analysis shall be compiled in accordance with the procedures. All safety matters shall be in accordance with the BCC site safe

18、ty plan.2） All personnel into site shall wear PPE and safety helmet.3） Sleeper or steel plate shall be filled under outrigger firmly. When working, seriously implement “Ten prohibition”.4） Shall fill pipe sheet or other similar protection on lifting point. 5） Lifter shall choose lifting slings, hois

19、ts and shackles practically to confirm safety parameter; flag and symbol whistle shall be full and direction symbol shall be clear.6） Pack equipment firmly. Have inspection in shipping frequently. 7） Trailer driver shall control speed seriously with average speed in 20kg/h.8） When shipping, shall ge

20、t touch with local relevant units and transportation department for confirming shipping route, directing transportation and insuring safe shipment. 9） During shipment, specialist shall be sent to snag the barricades (such as high wire, road establishment, corner and crossing)10） When pass under high

21、 voltage wire, shall pay attention to insulation protection of vehicles, equipment and personnel. H.V. cables must be powered down and specific personal arranged to monitor.11） For over wide and overlong equipment, set signal lamps and hang caution flag. 12） During shipment, set exploring vehicles a

22、nd install detecting pole 20mm40mm longer than outside size of shipped equipment. Specialist observes it if find problem, notify the back team to stop immediately. 13） During shipment, guard and safety personnel must follow shipment as assistant.14） No lifting shall be carried out in darkness or thu

23、nderstorm.Risk analysisNO.ActivityStepsPossible RiskGeneral ControlL DateD DateSpectral control measureL DateDDateE DateRisk GradeE DateRisk GradeC DateC Date1LiftingRigging SelectionSelect do not refer to lifting actual weight, cause accidentRigging should meet safety factor and lift height require

24、ment0.56453Signal TransmitterWrong signal, device damageFollow lifting regulation14451Hook ReleaseInjury during manual transmittalFollow manual transmittal requirement162532TransportationRunningThe equipment slide down from the trailer because of quick speed or turn or tied looseSlowing down and pay

25、ing attention to everything during transportation318Assure the road unblocked253Throw under H.V. wireElectric shockKeep safety distance13153Overweight Equipment and vehicle damageSelect suitable vehicle36251Attachment ：Override equipment specification NO.Equipment location No.W（T）Geometric size（m）Un

26、loading place Packing crane Shipping trailer Unloading crane Barricade or not and disposal Remark 1340-E-430599.962.443.35Changlu fabrication shop 100Tcrane+50Tcrane60Ttrailer +40Ttrailing plate55Tcrane+50Tcrawler craneN2350-E-530A539.852.442.89Changlu fabrication shop100Tcrane+50Tcrane60Ttrailer +4

27、0Ttrailing plate55Tcrane+50Tcrawler craneN3350-E-530B539.852.442.89Changlu fabrication shop100Tcrane+50Tcrane60Ttrailer +40Ttrailing plate55Tcrane+50Tcrawler craneN4350-E-530C539.852.442.89Changlu fabrication shop100Tcrane+50Tcrane60Ttrailer +40Ttrailing plate55Tcrane+50Tcrawler craneN5350-E-530D539

28、.852.442.89Changlu fabrication shop100Tcrane+50Tcrane60Ttrailer +40Ttrailing plate55Tcrane+50Tcrawler craneN6350-E-540A419.631.982.89Changlu fabrication shop100Tcrane+50Tcrane60Ttrailer +40Ttrailing plate55Tcrane+50Tcrawler craneN7350-E-540B419.631.982.89Changlu fabrication shop100Tcrane+50Tcrane60T

29、trailer +40Ttrailing plate55Tcrane+50Tcrawler craneN8350-E-540C419.631.982.89Changlu fabrication shop100Tcrane+50Tcrane60Ttrailer +40Ttrailing plate55Tcrane+50Tcrawler craneN9350-E-540D419.631.982.89Changlu fabrication shop100Tcrane+50Tcrane60Ttrailer +40Ttrailing plate55Tcrane+50Tcrawler craneN10350-E-5654111.382.132.74Changlu fabrication shop100Tcrane