CSPCNANHAIPETROCHEMICALSPROJECT中海殼牌南海石化項目CRANELOADTEST起重機載荷試驗PROJECTPROCEDURE:PR-8710-0000-0010工程程序：PR-8710-0000-0010ProjectManagementContractor(PMC)工程治理承包商〔PMC〕REV版本DATE日期REASONFORISSUE公布緣由BY公布人CHK’D審核人QA質保APPR.批準人0023Jan02IssuedforITB招標用PFAVCFCB0124May02IncorporatedChineseTranslation參與中文翻譯XYMJRDD0221Mar03IncorporatedEPCandCcontractorsresponsibility參與DKTKOBCLKMC總承包商和施工承包商的職責DOCUMENTISSUE/REVISIONINFORMATIONCSPCCSPCNanhaiPetrochemicalsProject/CSPC南海石化工程BechtelSEIFosterWheelerPMC/工程治理承包商PR-8710-0000-0010PR-8710-0000-0010Rev.02CraneLoadTest起重機載荷試驗10of17Document#:PR-8710-0000-0010CraneuseandoperationCurrentRevision#:Rev02ReasonforIssue/Revision:Thisdocumentisrevisedbecause: CurrentProcedurerefersBSFasbeingresponsibleforthedirectroleinperformingtheload-testofcranemobilizedtothesite.ResponsibilityofEPCandCcontractorsareincorporatedinthisrevision.DescriptionofChange: RemoveBSFSeniorConstructionManagerresponsibilityinadministeringtheloadtestofliftequipment. IncludeEPCandCcontractorsasresponsibleintheadministeringandperformanceoftheloadtestofliftequipment.Applicability:Thisdocumentappliesto:EPCandCcontractorsandotherthirdpartycranerental.Nameofcontactperson:DennisKiuContactNumber:+867525565944CRANELOADTEST起重機載荷試驗TABLEOFCONTENTS目錄No.編號頁碼1.0PURPOSE 42.0SCOPE 43.0DEFINITIONS 64.0RESPONSIBILITIES責任75.0REQUIREMENTS 86.0REFERENCES 167.0ATTACHMENTS 161.0 PURPOSE ThepurposeofthisprocedureistoestablishaconsistentapproachfortheloadtestingofhydraulicandconventionalliftcrawlerandwheelmountedcranesonallBSFprojects.本程序的目的是對BSFSCOPE ThisProcedureisapplicabletoallBSFConstructionprojectsthatusecranestoperformliftingactivities.本程序適用于BSFTheScopeofthisprocedurecoverscranesusedforconstructionpurposesthathavepreviouslybeen“qualified“foruse.Itisnotintendedtogivedirectiontoqualifynewequipment.Forthetestingandqualificationofnewequipment,refertothemanufacturersoperationsandmaintenancemanualsaswellasallapplicabletestplans,turnoverpackages,andowner/clientuseagreements.本程序的范圍涵蓋用于施工目的的合格起重機，不對檢驗設備賜予指導。對于設備的試驗和取得合格證，參考制造商操作與修理手冊，以及全部適用的試驗打算、移交文件和全部者/顧客使用協議。ThisprocedureappliestoallBSFconstructionprojectsincludingsubcontractorsand/orthirdpartycranes&liftequipmentrentals.Specifically,itappliestotheloadtestingofthefollowingformsofliftingequipment:本程序適用于BSF/或第三方吊裝設備租賃。特別地，本程序適用于以下形式吊裝設備的載荷試驗：ConventionalLatticeBoomCrawlerCranes.傳統的桁架起重臂履帶式起重機HydraulicDrivenlatticeBoomCrawlerCranes液壓驅動桁架起重臂履帶式起重機ConventionalLatticeBoomTruckCranes,(friction/hydraulicdriven).傳統的桁架起重臂式汽車吊〔摩擦/液壓驅動〕RoughTerrain,CarryDecks,AllTerrain,andHydraulicTruckCranes.適于平坦地形、帶支腿或適于全部地形的汽車起重機BridgeCranesandOverheadCranes.橋架和高架吊車JackingLiftsystemstoincludeGantryType,StrandType,andGinPole.牽引式起升系統，包括門架式、絞線式、把桿TelescopicBoom&BoomTrucks.伸縮臂式汽車吊DutyCycleCranes(Clamshell/Dragline)工作〔負荷〕循環提升設備〔蛤殼式/鏟斗式〕Pilingequipment打樁設備Towercranes塔吊Note: Whilethisproceduredoesnotspecificallyaddressmanyliftingdevices,(Hoists,Tuggers,etc.).Thisprocedureshouldbeusedforguidanceforthoseitemsnotspecificallycovered.Alsorefertomanufactureroperationsandmaintenancemanuals,applicablejurisdictionalcodes,standards,andregulationsforanyrequirements.IntheabsenceoflocalorregionalstandardsutilizeapplicablePRCREQUIRED/regulationsandstandardsasguides.注：由于沒有特別說明很多吊裝設備〔升降機、卷揚機等〕，本程序應用于指導未提及的工程。對于任何要求，還要參考制造商操作與修理手冊、適用的法律標準、標準和規程。沒有當地或地區性標準時，使用國家規定和標準作為指導。AnydeviationfromthisprocedureshallbedocumentedandsubmittedinadvancetotheBSFProjectFieldEngineer(PFE)whowillobtainapprovalfromtheappropriateauthorities.任何與本程序的分歧均應書面記錄并在事先提交BSF場工程部經理取得相關部門的批準。Changeinthisrevision.本版次修改.Paragraph2.5:Addsummariesoftheallchanges.2.5Paragraph2.3:AddTowerCranes.2.3Paragraph4.1:Change“SeniorConstructionManager”to“EPCandCContractors”.4.1DEFINITIONS TruckMountedCrane 汽車起重機Acraneconsistingofarotatingsuperstructure(Centerpostorturntable),boom,operatingmachinery,andoneormoreoperator’sstationsmountedonaframeattachedtoacommercialtruckchassis.Itsfunctionistolift,lowerandswingloadsatvariousradii.該起重機由安裝在汽車底盤上的構造組成，包括上部回轉構造〔中心柱或轉盤〕、起重臂、運轉機械、一個或幾個駕駛室。其功能是起升、降低或以各種轉彎半徑旋轉載荷物。CrawlerCrane 履帶式起重機Acraneconsistingofarotatingsuperstructurewithapowerplant,operatingmachinery,andboom,mountedonabaseandequippedwithcrawlertreadsfortravel.Itsfunctionistolift,lowerandswingloadsatvariousradii.該起重機由安裝在裝備履帶的基座上的構造組成，包括帶發電裝置的上部回轉構造、運轉機械、起重臂。其功能是起升、降低或以各種轉彎半徑旋轉載荷物。DesignatedPerson(DP) 指定人員Anindividualselectedorassignedbytheemployeroremployer’srepresentativeasbeingcompetenttoperformspecificduties.由雇主或雇主代表選擇或任命的人，勝任執行特別的職責。RESPONSIBILITIESEPCandCcontractorsConstructionManager(CM)包商施工經理〔CM〕

承包商和施工承Constructionmanagerisultimatelyresponsibleforthesafeuseandoperationofthecranesontheproject.Hemaydelegatehisresponsibilitythroughthefollowingpersonnel:Projectsuperintendent,Equipmentsuperintendent,MasterMechanicordesignatedperson(s).施工經理最終負責起重機在工程上的安全使用和運行。他可能通過以下人員代表其職責：工程總監、設備監理、技工工長或指定的人員。ProjectEquipmentMaintenanceandOperationTeam(PEMOT)工程設備修理與操作組〔PEMOT〕TheConstructionmanagershallassembleaprojectequipmentmaintenanceandoperationteamtomanageallcraneoperations(includingsubcontractors)attheproject.Thedesignatedperson(s)thatwillleadtheEquipmentmaintenanceteammustbefullyconversantwiththeimplementationofcraneoperationandmaintenanceprocedures,inspectionsthatarerequiredbythecranemanufacturersandbyPRCREQUIREDregulations,codesandstandards.施工經理將組建一個工程設備修理與操作組來治理工程〔包括分包商〕全部起重機的運行。領導設備修理與操作組的指定人員必需完全生疏并執行起重機修理與操作程序，生疏制造商和中國法律法規要求的檢驗。DuetothevaryingsizesandcomplexitiesofBSFprojects,onequalifiedindividualwithintheProjectEquipmentMaintenanceandOperationTeammayfillseveraldifferentpositions(i.e.RiggingSupervisor,MasterMechanic.&OperatingEngineer)BSF人員可能會安排不同的崗位〔即：索具監管員、機械和運行主管工程師〕REQUIREMENTS 要求Allcraneswhicharriveon-sitewillreceiveaninitialinspectioninaccordancewithConstructionProcedurePR-8710-0000-0009,CraneUseandOperation.Onceasatisfactoryinspectioniscomplete,loadtestingperthisproceduremayproceed.全部到達現場的起重機要依據施工程序PR-8710-0000-0009〔起重機使用與操作〕承受初步的檢查。一旦檢查合格，即按本程序進展載荷試驗。CraneoperatorshallbequalifiedperPR-8710-0000-0007,CraneOperatorQualification起重機駕駛員要符合程序PR-8710-0000-0007〔起重機駕駛員資格〕的要求。Note:Ifthecranehasreceivedasatisfactoryloadtestwithinthepast12monthsandisrecordedwiththeequipmentfile,thenaninitialloadtestisnotrequired.注：假設起重機在過去十二個月內承受過滿足的載荷試驗，并記錄在設備檔案中，就不需要初始載荷試驗。LoadTestPrerequisites 載荷試驗必備條件Setupcraneaccordingtomanufacturersrecommendationsinasuitableareaclearofobstructions.依據制造商的建議在沒有障礙物的適宜區域安置起重機。Ensurealloperationmanualsandloadchartsapplicabletothecrane,areproperlylocated.確保用于該起重機的全部操作手冊和負荷圖表放置在適當的地方。Performafullcraneinspection(ReferPeriodicInspectionChecklist)toassesstheoperationalandmechanicalconditionofthecrane.進展全面的起重機檢查〔參照定期檢查表〕以評估起重機的運行和機械狀況。Barricadethetestareaanderectnoentrysignswithappropriatecranetestwarnings.在試驗區域設置路障，直立“制止進入”的牌子警示起重機試驗。Performchecksofalloperationalandsafetysystems.進展操作和安全系統的檢查Eachcraneshallbetestedbythemanufacturerand/ortheowner/usertotheextentnecessarytoensurecompliancewiththeoperationalrequirements.Theseoperationalfunctionsincludethefollowing:每臺起重機要由制造商和/或使用者進展試驗到達必要的程度，保證符合操作要求。這些操作功能包括：Loadliftingandloweringmechanisms.載荷物起升機構Boomliftingandloweringmechanisms起重臂起升機構Boomextensionandretractionmechanism起重臂伸縮機構Swingingmechanism回轉機構Travelmechanism遷移機構Safetydevices安全裝置Wherethecompleteproductioncraneisnotsuppliedbyonemanufacturer,suchtestsshallbeconductedatfinalassembly.完整的起重機產品不是由一家制造商供給時，試驗在最終組裝后進展。Loadbrakesshallbetestedandadjustedtomanufacturerspecificationspriortoanymachineloadtestbeingperformed.Themanufacturersspecificationsgenerallycallforasinglepartlinetobeutilizedforthesebrakecheckstopreventamulti-partlinefrommaskinganypotentialproblems.ThePreliminaryBrakeCheckProcedureusingSinglepartlineallhoistingdrumsisasfollows:在進展任何機械負荷試驗前，負載制動器要按制造廠說明進展試驗和調整。制造廠說明通常要求用單條繩索進展制動器檢查，防止多條繩索掩蓋了任何可能的問題。初步的制動器檢查程序如下：OnHydraulicCraneswithspringappliedhydraulicallyreleasedbrakes.對于彈簧應用于制動器的液壓起重機Checkbrakesaspermanufacturerrecommendationsfoundinservicemanualsorpublishedbulletins.依據效勞手冊或說明書中制造商的建議檢查制動器；Determinethemaximumloadratingforthebrakes.確定制動器的最大額定負載；Determinethemaximumsafeworkingloadofthewireropeinstalledonthecrane.確定起重機鋼纜的最大安全工作負荷；Note:Thelowerofthetwocapacitiesabovewillbethelimitingfactorinplanningthetest.注：兩倍力氣以上的下降是打算試驗時的限制因素；Determinethetestweightneededtakingintoaccountallloadingthebrakeswillbesubjectedto.確定需要的試驗重量要考慮制動器將承受的全部載荷；Thistestmustbecarriedoutataboomlengthandradiuswellwithintheratedcapacityofthecrane.執行本試驗起重臂長度和回轉半徑要在起重機的額定力氣之內；Lifttheloadapproximately6inchesofftheground.起升起吊物離開地面約六英寸；Movethehoistcontroltotheneutralpositionallowingthebraketoset.將起升把握放于空擋位置，使制動器能夠調整；Holdtheloadwiththebrakesonly.只用制動器保持起吊物Theloadshouldremainsuspendedwiththebrakessetaccordingtomanufacturerspecifications.依據制造廠說明，起吊物用制動器保持懸空；Ifrequired,replaceorrepairbrakingsystemtocomplywithmanufacturer’sspecifications.如需要，按制造廠說明更換或修理制動器系統；OnConventionalfrictiontypecranes.對于傳統的摩擦力起重機Adjustfrictionbrakesaspermanufacturerrecommendationsfoundintheservicemanualsorpublishedbulletins.依據效勞手冊或說明書中制造商的建議調整摩擦力制動器；Determinethemaximumloadratingforthebrakes.確定制動器的最大額定負載；Determinethemaximumsafeworkingloadofthewireropeinstalledonthecrane.確定起重機鋼纜的最大安全工作負荷；Note:Thelowerofthetwocapacitiesabovewillbethelimitingfactorinplanningthetest.注：兩倍力氣以上的下降是打算試驗時的限制因素；Determinethetestweightneededtakingintoaccountallloadingthebrakeswillbesubjectedto.確定需要的試驗重量要考慮制動器將承受的全部載荷；Thistestmustbecarriedoutataboomlengthandradiuswellwithintheratedcapacityofthecrane.執行本試驗起重臂長度和回轉半徑要在起重機的額定力氣之內；Lifttheloadapproximately6inchesofftheground.起升起吊物離開地面約六英寸；Applythebrake.使用制動器；Holdtheloadwiththebrakesonly.只用制動器保持起吊物；Theloadshouldremainsuspendedwiththebrakessetaccordingtomanufacturerspecifications.依據制造廠說明，起吊物用制動器保持懸空；Ifrequired,re-adjustorrepairthebraketocomplywithmanufacturer’sspecifications.如需要，依據制造廠說明重調整或修理制動器。Locatesuitabletestweight.Theweightmusteitherbeastampedcertifiedweightorweighedwithacertifiedand/orcalibrateddynamometerorscale.IflocalJurisdictionalcodes,standards,orregulationsaremorestringent,andrequirea“certifiedweight“,thenonemustbeused.確定適宜的試驗砝碼。該砝碼或者是批準的經鑒定的砝碼，或者是用求‘經鑒定的砝碼’，則必需承受。Note: Commonsensemustprevailwhenchoosinga“suitabletestweight“.Itshouldhavereadilyavailablepickpointsandnotbeofageometrywhichwouldrequirespecialriggingfixturesandcalculationstodeterminethecenterofgravity.Ifapieceofequipmentisused,itshouldberiggedsuchthattheslingsandriggingwillnotdamagethe“testweight“.注：選擇一個‘適宜的試驗砝碼’時應使常識可以應用。砝碼應有吊點，且不能是特別的幾何構造以致需要特別的夾具并且計算來確定重心。假設使用一個裝置，安裝索具不能破壞‘試驗砝碼’。Usecertifiedriggingforallloads(i.e.,slings,shackles,spreaders,etc.).對全部起吊物使用合格的索具〔即吊索、吊鉤等〕。Whileitisnotrequired,documentationofcraneloadtestsusingphotographshasproventobeaneffectivemediumtocommunicatewhattranspired.雖然不要求，但是起重機載荷試驗文件使用照片被證明是一種有效的媒介表示所發生的事。RatedLoadTest 額定負荷試驗Priortoinitialuse,annually,and/orwhenmaintenanceoncranesinwhichloadsustainingpartshavebeenaltered,replaced,orrepairedaloadtestistobeconductedby,orunderthedirectionof,aqualifiedperson.Thereplacementoftheropeisspecificallyexcludedfromthisrequirement.However,afunctionaltestofthecraneunderanormaloperatingloadshouldbemadepriortoputtingthecranebackinservice.最初使用前、每年、或者起重機修理時負荷支撐部件被轉變、更換或修理的狀況下，載荷試驗要由合格人員進展或在其指導下進展。繩索的更換在本要求之外。但是，起重機正常運行負荷下的功能試驗應在其投用前進展。Caution:Thecraneshallnotbeloadedtomorethan100%ofitsratedchartcapacitywithoutpriorwrittenapprovalfromthecranemanufacturer.Ifa110%loadtestisrequiredbytheproject,thenmanufacturersapprovalandtestplanshallbeobtained.100%110%的載荷試驗，要獲得制造商的批準和試驗打算。AwrittenliftplanmustbegeneratedforapprovalinaccordancewithPR-8710-0000-0008,ConstructionRiggingWorkOperatio.sPR-8710-0000-0008施工索具操作’獲得批準。Determine/confirmdeductionsfromthegrosscapacitychartforthefollowing:確定/確認從凈起重力氣圖表中扣除：Manufacturerapprovedattachments制造商認可的附件Loadblock滑輪Overhaulball檢查球Wirerope鋼纜Rigging索具Determinetestloadrequiredbaseduponavailableweightsandloadchartstoachieve100%capacity.確定需要的試驗負荷要基于已有的重量和負荷以到達100%的力氣。Refertoincabloadchartsandselectaradiusatwhichthetotaltestloadwillbe100%ofgrosscapacity.參考駕駛室內的負荷圖，選擇一個半徑，試驗負荷要到達凈力氣的100%。Forcraneswithautomaticsafeloadindicatorsandalarms,inordertoachievea100%lift,Theseloadmomentindicatorsmayneedtobeoverridden.Thesystemsaregenerallyequippedwithoverrideswitchestoaidintheperformanceoftheseloadtests.對于有自動安全指示和報警的起重機，為了到達100%，這些指示器可能需要過載。通常系統安裝了過載開關以關心載荷試驗的進展。Measurethetestradiusandplaceasuitablemarker.測量試驗半徑并做適當的標記。Positionthetestloadinsidethetestradiuswellwithinthecapacityofthecraneasconfigured.在試驗半徑內確定試驗負荷在起重機設定的力氣之內。Liftthetestloadandallowittostabilize.起升試驗起吊物并使其穩定。Maintaintheloadnomorethanonefootfromtheground.保持起吊物離地面不超過一英尺。Boomdowntothepredeterminedtestradiuswiththeguidanceofagroundsignalman.起重臂按地面指揮的指示降至預先設定的試驗半徑。Measurethedistanceofthetestweightheightfromtheground.測量試驗砝碼距地面的高度。Applyallbrakesandshutdowntheengine.使用全部制動器并關閉發動機。Observetheloadfor5minutestocheckforloaddrift.觀看五分鐘，檢查載荷的漂移距離。Restartthecraneandswingthetestload360degreesifpermittedbytheloadchartworkareadiagram.重啟動起重機，假設負荷圖、工作區域圖許可，轉動試驗起吊物360Ifduringtheexecutionoftheloadtesting,correctivemaintenanceorrepairsarerequired,theProjectEquipmentMaintenanceandOperationsTeam(PEMOT)isresponsibletoassurecorrectiveactionsareperformed.假設在進展載荷試驗期間需要保養或修理，工程設備修理與操作組負責保證保養的進展。Duringtheexecutionofanycorrectionactions(maintenanceorrepairs)ifanyloadsustainingpartsarealtered,replaced,orrepaired,thenaloadtestwillberequired.在保養〔維護或修理〕時，假設有載荷支撐部件被轉變、更換或修理，要進展載荷試驗。Allrepairsandmaintenancearetoberecordedandplacedintheequipmentfile.全部修理和維護要記錄并放入設備檔案中。AtthecompletionofasuccessfulloadtestallresultsaretoberecordedandplacedintheEquipmentfile.RefertoattachmentAforasampleLoadTestform.A載荷試驗表例如。Writtenreportsshallbereviewedandfiledbyanappointedorauthorizedperson,showingtestproceduresandconfirmingtheadequacyofrepairsoralterations.書面報告要由指定或授權的人審核并歸檔，說明試驗程序并確認修理或轉變適當。ProjectSpecificLoadTesting 工程特別載荷試驗ShouldtheProjectorClienthaveaspecificloadtestrequirement,thisloadtestshallnotexceed100%oftheCraneorLiftingDeviceloadchartcapacity.ThesetestneedsareusuallyaresultofaHeavyorCriticalliftwherea“pre-lift“verificationofthecraneismandatedbytheproject.TheseTypesofprojectspecificloadtestsareinadditiontotherequired“ratedloadtests“previouslydiscussed.假設工程或業主有特別的載荷試驗要求，該載荷試驗不能超過起重機或提升裝100%。這些試驗需要通常是起因于大重量或關鍵吊裝，工程指令進展起重機預吊裝驗證。這些工程特別載荷試驗是前面爭論的“額定載荷試驗”以外的。REFERENCES ApplicableJurisdictionalCodesandStandards適用的法規標準ConstructionProcedurePR-8710-0000-0009,CraneuseandOperation施工程序PR-8710-0000-0009，起重機使用與操作ConstructionProcedurePR-8710-0000-0007,CraneOperatorQualification施工程序PR-8710-0000-0007，起重機駕駛員資格ConstructionProcedurePR-8710-0000-0007,ConstructionRiggingWorkOperations施工程序PR-8710-0000-0007，施工索具操作ATTACHMENTS AttachmentA-“Example“LoadTestFo