起重机载荷试验

CSPC NANHAI PETROCHEMICALS PROJECT中海壳牌南海石化项目CRANE LOAD TEST起重机载荷试验PROJECT PROCEDURE: PR-8710-0000-0010项目程序：PR-8710-0000-0010Project Management Contractor (PMC)项目管理承包商(PMC)REV版本DATE日期REASON FOR ISSUE 发布原因BY发布人CHKD审核人QA 质保APPR.批准人0023 Jan 02Issued for ITB 招标用PFAVCFCB0124 May 02Incorporated ChineseTranslation加入中文翻译XYMJRDD0221 Mar 03Incorporated EPC and C contractors responsibility 加入 总承包商和施工承包商的职责DKTKOBCLKMCDOCUMENT ISSUE/REVISION INFORMATIONDocument #: PR-8710-0000-0010 Crane use and operationCurrent Revision #: Rev02Reason for Issue/Revision:This document is revised because: Current Procedure refers BSF as being responsible for the direct role in performing the load-test of crane mobilized to the site. Responsibility of EPC and C contractors are incorporated in this revision.Description of Change: Remove BSF Senior Construction Manager responsibility in administering the load test of lift equipment. Include EPC and C contractors as responsible in the administering and performance of the load test of lift equipment.Applicability:This document applies to: EPC and C contractors and other third party crane rental.Name of contact person: Dennis KiuContact Number: +86 752 556 5944CRANE LOAD TEST起重机载荷试验TABLE OF CONTENTS目录No.Page编号页码1.0PURPOSE目 的42.0SCOPE范围43.0DEFINITIONS定义64.0RESPONSIBILITIES 责任75.0REQUIREMENTS要求86.0REFERENCES参考167.0ATTACHMENTS附件161.0 PURPOSE 目 的The purpose of this procedure is to establish a consistent approach for the load testing of hydraulic and conventional lift crawler and wheel mounted cranes on all BSF projects.本程序的目的是对 BSF 所有活动应用的各类吊装设备提供统一的载荷试验方法。2.0 SCOPE 范 围2.1 This Procedure is applicable to all BSF Construction projects that use cranes to perform lifting activities.本程序适用于 BSF 所有使用起重机进行吊装作业的施工。2.2 The Scope of this procedure covers cranes used for construction purposes that have previously been qualified for use. It is not intended to give direction to qualify new equipment. For the testing and qualification of new equipment, refer to the manufacturers operations and maintenance manuals as well as all applicable test plans, turnover packages, and owner/client use agreements. 本程序的范围涵盖用于施工目的的合格起重机，不对检验新设备给予指导。 对于新设备的试验和取得合格证，参考制造商操作与维修手册，以及所有适 用的试验计划、移交文件和所有者/顾客使用协议。2.3 This procedure applies to all BSF construction projects including subcontractors and/or third party cranes & lift equipment rentals. Specifically, it applies to the load testing of the following forms of lifting equipment:本程序适用于 BSF 所有施工活动，包括分承包商和/或第三方吊装设备租赁。 特别地，本程序适用于下列形式吊装设备的载荷试验： Conventional Latt ice Boom Crawler Cranes.传统的桁架起重臂履带式起重机 Hydraulic Driven lattice Boom Crawler Cranes 液压驱动桁架起重臂履带式起重机 Conventional Lattice Boom Truck Cranes, (friction/hydraulic driven).传统的桁架起重臂式汽车吊(摩擦/液压驱动) Rough Terrain, Carry Decks, All Terrain, and Hydraulic Truck Cranes.适于平坦地形、带支腿或适于所有地形的汽车起重机 Bridge Cranes and Overhead Cranes.桥架和高架吊车 Jacking Lift systems to include Gantry Type, Strand Type, and Gin Pole. 牵引式起升系统，包括门架式、绞线式、把杆 Telescopic Boom & Boom Trucks.伸缩臂式汽车吊 Duty Cycle Cranes (Clamshell/Dragline)工作(负荷)循环提升设备(蛤壳式/铲斗式) Piling equipment打桩设备 Tower cranes塔吊Note: While this procedure does not specifically address many lifting devices, (Hoists, Tuggers, etc.). This procedure should be used for guidance for those items not specifically covered. Also refer to manufacturer operations and maintenance manuals, applicable jurisdictional codes, standards, and regulations for any requirements. In the absence of local or regional standards utilize applicable PRC REQUIRED/ regulations and standards as guides.注：由于没有特别说明许多吊装设备(升降机、卷扬机等)，本程序应用于 指导未提及的项目。对于任何要求，还要参考制造商操作与维修手册、适用 的法律规范、标准和规程。没有当地或地区性标准时，使用国家规定和标准 作为指导。2.4 Any deviation from this procedure shall be documented and submitted in advance to the BSF Project Field Engineer (PFE) who will obtain approval from the appropriate authorities.任何与本程序的分歧均应书面记录并在事先提交BSF现场工程部经理，由现 场工程部经理取得相关部门的批准。2.5 Change in this revision.本版次修改.Paragraph 2.5:Add summaries of the all changes.2.5 节:加入修改汇总Paragraph 2.3:Add Tower Cranes.2.3 节:加入塔吊Paragraph 4.1: Change “Senior Construction Manager” to “EPC and C Contractors”.4.1 节:修改“高级施工经理”为“承包商和施工承包商施工经理”.3.0 DEFINITIONS 定 义3.1 Truck Mounted Crane汽车起重机A crane consisting of a rotating superstructure (Center post or turntable), boom, operating machinery, and one or more operators stations mounted on a frame attached to a commercial truck chassis. Its function is to lift, lower and swing loads at various radii. 该起重机由安装在汽车底盘上的构造组成，包括上部回转结构(中心柱或转 盘)、起重臂、运转机械、一个或几个驾驶室。其功能是起升、降低或以各 种转弯半径旋转载荷物。3.2 Crawler Crane履带式起重机A crane consisting of a rotating superstructure with a power plant, operating machinery, and boom, mounted on a base and equipped with crawler treads for travel. Its function is to lift, lower and swing loads at various radii. 该起重机由安装在装备履带的基座上的构造组成，包括带发电装置的上部回 转结构、运转机械、起重臂。其功能是起升、降低或以各种转弯半径旋转载 荷物。3.3 Designated Person (DP)指定人员An individual selected or assigned by the employer or employers representative as being competent to perform specific duties. 由雇主或雇主代表选择或任命的人，胜任执行特殊的职责。4.0 RESPONSIBILITIES 责 任4.1 EPC and C contractors Construction Manager (CM) 承包商和施工承包商施工经理(CM)Construction manager is ultimately responsible for the safe use and operation of the cranes on the project. He may delegate his responsibility through the following personnel: Project superintendent, Equipment superintendent, Master Mechanic or designated person(s).施工经理最终负责起重机在项目上的安全使用和运行。他可能通过下列人员 代表其职责：项目总监、设备监理、技工工长或指定的人员。4.2 Project Equipment Maintenance and Operation Team (PEMOT)项目设备维修与操作组(PEMOT)The Construction manager shall assemble a project equipment maintenance and operation team to manage all crane operations (including subcontractors) at the project. The designated person(s) that will lead the Equipment maintenance team must be fully conversant with the implementation of crane operation and maintenance procedures, inspections that are required by the crane manufacturers and by PRC REQUIRED regulations, codes and standards.施工经理将组建一个项目设备维修与操作组来管理项目(包括分包商)所有 起重机的运行。领导设备维修与操作组的指定人员必须完全熟悉并执行起重 机维修与操作程序，熟悉制造商和中国法律法规要求的检验。Due to the varying sizes and complexities of BSF projects , one qualified individual within the Project Equipment Maintenance and Operation Team may fill several different positions (i.e. Rigging Supervisor, Master Mechanic. & Operating Engineer) 由于 BSF 项目不断改变的规模和复杂性，在项目设备维修与操作组中的合格 人员可能会安排不同的岗位(即：索具监管员、机械和运行主管工程师)5.0 REQUIREMENTS 要求5.1 All cranes which arrive on-site will receive an initial inspection in accordance with Construction Procedure PR-8710-0000-0009, Crane Use and Operation. Once a satisfactory inspection is complete, load testing per this procedure may proceed.所有到达现场的起重机要根据施工程序PR-8710-0000-0009 （起重机使用与 操作）接受初步的检查。一旦检查合格，即按本程序进行载荷试验。Crane operator shall be qualified per PR-8710-0000-0007, Crane Operator Qualification起重机驾驶员要符合程序PR-8710-0000-0007 （起重机驾驶员资格）的要 求。Note: If the crane has received a satisfactory load test within the past 12 months and is recorded with the equipment file, then an initial load test is not required.注：如果起重机在过去十二个月内接受过满意的载荷试验，并记录在设备档 案中，就不需要初始载荷试验。5.2 Load Test Prerequisites载荷试验必备条件5.2.1 Set up crane according to manufacturers recommendations in a suitable area clear of obstructions.根据制造商的建议在没有障碍物的合适区域安置起重机。5.2.2 Ensure all operation manuals and load charts applicable to the crane, are properly located.确保用于该起重机的所有操作手册和负荷图表放置在适当的地方。5.2.3 Perform a full crane inspection （Refer Periodic Inspection Checklist） to assess the operational and mechanical condition of the crane. 进行全面的起重机检查（参照定期检查表）以评估起重机的运行和机 械状况。5.2.4 Barricade the test area and erect no entry signs with appropriate crane test warnings.在试验区域设置路障，竖立“禁止进入”的牌子警示起重机试验。5.2.5 Perform checks of all operational and safety systems.进行操作和安全系统的检查a) Each crane shall be tested by the manufacturer and/or the owner/user to the extent necessary to ensure compliance with the operational requirements. These operational functions include the following:每台起重机要由制造商和 /或使用者进行试验达到必要的程度，保证符 合操作要求。这些操作功能包括： Load lifting and lowering mechanisms.载荷物起升机构 Boom lifting and lowering mechanisms起重臂起升机构 Boom extension and retraction mechanism起重臂伸缩机构 Swinging mechanism回转机构 Travel mechanism迁移机构 Safety devices安全装置b) Where the complete production crane is not supplied by one manufacturer, such tests shall be conducted at final assembly.完整的起重机产品不是由一家制造商提供时，试验在最终组装后进行。5.2.6 Load brakes shall be tested and adjusted to manufacturer specifications prior to any machine load test being performed. The manufacturers specifications generally call for a single part line to be utilized for these brake checks to prevent a multi-part line from masking any potential problems. The Preliminary Brake Check Procedure using Single part line all hoisting drums is as follows:在进行任何机械负荷试验前，负载制动器要按制造厂说明进行试验和 调节。制造厂说明通常要求用单条绳索进行制动器检查，防止多条绳 索掩盖了任何可能的问题。初步的制动器检查程序如下：a) On Hydraulic Cranes with spring applied hydraulically released brakes.对于弹簧应用于制动器的液压起重机1. Check brakes as per manufacturer recommendations found in service manuals or published bulletins. 按照服务手册或说明书中制造商的建议检查制动器；2. Determine the maximum load rating for the brakes. 确定制动器的最大额定负载；3. Determine the maximum safe working load of the wire rope installed on the crane.确定起重机钢缆的最大安全工作负荷；4. Note: The lower of the two capacities above will be the limiting factor in planning the test. 注：两倍能力以上的下降是计划试验时的限制因素；5. Determine the test weight needed taking into account all loading the brakes will be subjected to. 确定需要的试验重量要考虑制动器将承受的所有载荷；6. This test must be carried out at a boom length and radius well within the rated capacity of the crane. 执行本试验起重臂长度和回转半径要在起重机的额定能力之内；7. Lift the load approximately 6 inches off the ground. 起升起吊物离开地面约六英寸；8. Move the hoist control to the neutral position allowing the brake to set.将起升控制放于空挡位置，使制动器能够调整；9. Hold the load with the brakes only. 只用制动器保持起吊物10. The load should remain suspended with the brakes set according to manufacturer specifications. 按照制造厂说明，起吊物用制动器保持悬空；11. If required, replace or repair braking system to comply with manufacturers specifications.如需要，按制造厂说明更换或修理制动器系统；b) On Conventional friction type cranes. 对于传统的摩擦力起重机1. Adjust friction brakes as per manufacturer recommendations found in the service manuals or published bulletins. 按照服务手册或说明书中制造商的建议调节摩擦力制动器；2. Determine the maximum load rating for the brakes. 确定制动器的最大额定负载；3. Determine the maximum safe working load of the wire rope installed on the crane.确定起重机钢缆的最大安全工作负荷；4. Note: The lower of the two capacities above will be the limiting factor in planning the test. 注：两倍能力以上的下降是计划试验时的限制因素；5. Determine the test weight needed taking into account all loading the brakes will be subjected to.确定需要的试验重量要考虑制动器将承受的所有载荷；6. This test must be carried out at a boom length and radius well within the rated capacity of the crane. 执行本试验起重臂长度和回转半径要在起重机的额定能力之内；7. Lift the load approximately 6 inches off the ground. 起升起吊物离开地面约六英寸；8. Apply the brake.使用制动器；9. Hold the load with the brakes only. 只用制动器保持起吊物；10. The load should remain suspended with the brakes set according to manufacturer specifications. 按照制造厂说明，起吊物用制动器保持悬空；11. If required, re-adjust or repair the brake to comply with manufacturers specifications.如需要，按照制造厂说明重新调节或修理制动器。5.2.7 Locate suitable test weight. The weight must either be a stamped certified weight or weighed with a certified and/or calibrated dynamometer or scale. If local Jurisdictional codes, standards, or regulations are more stringent, and require a certified weight, then one must be used.确定合适的试验砝码。该砝码或者是批准的经鉴定的砝码，或者是用 经鉴定和/或校准的量具称过的砝码。如果当地法规标准更严格，并要 求经鉴定的砝码，则必须采用。Note: Common sense must prevail when choosing a suitable test weight. It should have readily available pick points and not be of a geometry which would require special rigging fixtures and calculations to determine the center of gravity. If a piece of equipment is used, it should be rigged such that the slings and rigging will not damage the test weight.注：选择一个合适的试验砝码时应使常识可以应用。砝码应有吊 点，且不能是特殊的几何结构以致需要特殊的夹具并且计算来确定重 心。如果使用一个装置，安装索具不能破坏试验砝码。5.2.8 Use certified rigging for all loads (i.e., slings, shackles, spreaders, etc.).对所有起吊物使用合格的索具(即吊索、吊钩等)。5.2.9 While it is not required, documentation of crane load tests using photographs has proven to be an effective medium to communicate what transpired.虽然不要求，但是起重机载荷试验文件使用照片被证明是一种有效的 媒介表示所发生的事。5.3 Rated Load Test额定负荷试验5.3.1 Prior to initial use, annually, and/or when maintenance on cranes in which load sustaining parts have been altered, replaced, or repaired a load test is to be conducted by, or under the direction of, a qualified person. The replacement of the rope is specifically excluded from this requirement. However, a functional test of the crane under a normal operating load should be made prior to putting the crane back in service.最初使用前、每年、或者起重机维修时负荷支撑部件被改变、更换或 修理的情况下，载荷试验要由合格人员进行或在其指导下进行。绳索的更换在本要求之外。但是，起重机正常运行负荷下的功能试验应在 其投用前进行。Caution: The crane shall not be loaded to more than 100% of its rated chart capacity without prior written approval from the crane manufacturer. If a 110% load test is required by the project, then manufacturers approval and test plan shall be obtained.注意：没有制造商的预先书面批准，起重机不能负载超过其额定能力 的100%。如果项目要进行 110%的载荷试验，要获得制造商的批准 和试验计划。5.3.2 A written lift plan must be generated for approval in accordance with PR-8710-0000-0008, Construction Rigging Work Operatio.ns 书面吊装方案必须根据程序 PR-8710-0000-0008 施工索具操作获 得批准。5.3.3 Determine/confirm deductions from the gross capacity chart for the following:确定/确认从净起重能力图表中扣除： Manufacturer approved att achments制造商认可的附件 Load block滑轮 Overhaul ball检查球 Wire rope钢缆 Rigging索具5.3.4 Determine test load required based upon available weights and load charts to achieve 100% capacity.确定需要的试验负荷要基于已有的重量和负荷以达到100%的能力。5.3.5 Refer to in cab load charts and select a radius at which the total test load will be 100% of gross capacity.参考驾驶室内的负荷图，选择一个半径，试验负荷要达到净能力的 100%。For cranes with automatic safe load indicators and alarms, in order to achieve a 100% lift, These load moment indicators may need to be overridden. The systems are generally equipped with override switches to aid in the performance of these load tests.对于有自动安全指示和报警的起重机，为了达到 100%，这些指示 器可能需要过载。通常系统安装了过载开关以辅助载荷试验的进 行。5.3.6 Measure the test radius and place a suitable marker. 测量试验半径并做适当的标记。5.3.7 Position the test load inside the test radius well within the capacity of the crane as configured.在试验半径内确定试验负荷在起重机设定的能力之内。5.3.8 Lift the test load and allow it to stabilize. 起升试验起吊物并使其稳定。5.3.9 Maintain the load no more than one foot from the ground. 保持起吊物离地面不超过一英尺。5.3.10 Boom down to the predetermined test radius with the guidance of a ground signalman.起重臂按地面指挥的指示降至预先设定的试验半径。5.3.11 Measure the distance of the test weight height from the ground. 测量试验砝码距地面的高度。5.3.12 Apply all brakes and shut down the engine.使用所有制动器并关闭发动机。5.3.13 Observe the load for 5 minutes to check for load drift.观察五分钟，检查载荷的漂移距离。5.3.14 Restart the crane and swing the test load 360 degrees if permitted by the load chart work area diagram.重新启动起重机，如果负荷图、工作区域图许可，转动试验起吊物360 度。5.4 If during the execution of the load testing, corrective maintenance or repairs are required, the Project Equipment Maintenance and Operations Team (PEMOT) is responsible to assure corrective actions are performed. 如果在进行载荷试验期间需要保养或修理，项目设备维修与操作组负责保证 保养的进行。5.4.1 During the execution of any correction actions (maintenance or repairs) if any load sustaining parts are altered, replaced, or repaired, then a load test will be required. 在保养(维护或修理)时，如果有载荷支撑部件被改变、更换或修 理，要进行载荷试验。5.4.2 All repairs and maintenance are to be recorded and placed in the equipment file.所有修理和维护要记录并放入设备档案中。5.5 At the completion of a successful load test all results are to be recorded and placed in the Equipment file. Refer to attachment A for a sample Load Test form.在成功的载荷试验完成时，所有结果要记录并放于设备档案。参考附件 A 载 荷试验表示例。5.5.1 Written reports shall be reviewed and filed by an appointed or authorized person, showing test procedures and confirming the adequacy of repairs or alterations.书面报告要由指定或授权的人审核并归档，说明试验程序并确认修理 或改变适当。5.6 Project Specific Load Testing 项目特殊载荷试验Should the Project or Client have a specific load test requirement, this load test shall not exceed 100% of the Crane or Lifting Device load chart capacity. These test needs are usually a result of a Heavy or Critical lift where a pre-lift verification of the crane is mandated by the project.These Types of project specific load tests are in addition to the required rated load tests previously discussed. 若项目或业主有特殊的载荷试验要求，该载荷试验不能超过起重机或提升装 置负荷这些试验图能力的 100%。这些试验需要通常是起因于大重量或关键吊 装，项目指令进行起重机预吊装验证。这些项目特殊载荷试验是前面讨论的 “额定载荷试验”以外的。6.0 REFERENCES 参 考6.1 Applicable Jurisdictional Codes and Standards 适用的法规标准6.2 Construction Procedure PR-8710-0000-0009, Crane use and Operation施工程序PR-8710-0000-0009，起重机使用与操作6.3 Construction Procedure PR-8710-0000-0007, Crane Operator Qualification 施工程序PR-8710-0000-0007，起重机驾驶员资格6.4 Construction Procedure PR-8710-0000-0007, Construction Rigging Work Operations施工程序PR-8710-0000-0007，施工索具操作7.0 ATTACHMENTS 附 件7.1 Attachment A - Example Load Test Form附件A -载荷试验表示例ATTACHMENT A (Form 8710-0000-0010-A-Rev 02)附件A(表格8710-0000-0010-A-Rev02)WiDes&SigDair见证人签字Crane Configuration & Operation Description起重机构造及操作描述190 Feet of # 22 Boom, 4 1/2Degree offset installed30 Feet of #123 jib at 20 Degree off-set.200 Ton Load Block15 Ton Capacity Ball“EXAMPLE” LOAD TEST FORM载荷试验表-示例WyatWiiDessDateTest Notes试验记录7/17/2000净负荷额定40,400 95Ft. RadiusGross Rating from Crane试半负荷Percentage Over Chart Rating 相对于额 定值的百分比40,400 95Ft. Radius100.040,400 lbs 95 ft Radius represents 100% crane chart capacityNotes on Lift起吊记录：Lifting of the test load on main load line Whip line wps tested to BS of the line.Des cribe the Tes t for example on main load block or whip liiBrake Test result Notes制动器试验记录：Brake function meets requirements, ye held the test load on the brakes with no evidence of drift down of the load Description ui Deductions扣减说明“网口51513 from Gross CapacityDeductions from Gross CapacityT-1US Pounds5 500Kilograms2 495Deductions that are part of the actual load the crane will have during the testfLoad Block weight Deductions1 000454Headache Ball Weight Deductions1 100499Load Lines Weight Deductions2 5001 134Jib Weight Deductions0-0Jib stowed - Jib e rected (nya Cranes)00Rooster sheave Assemblycalculate iotai Deducti ons“cm C“ccc Icc八IDc + ；rc300136Rigging Weight DeuucuonsI00Other Weight Deductions0AWLIIGI_VVCItjlll. WGUUkrllMliaTotal aeductiuns10 4004 717Total Test Load Lbs 30 000Total Test Load Kgs 13 608Deductions plus Test Weight represents total test loadWeight of Test Block Deductions From Gross Load Chart Rating4 717Total Test Load40,4001325Describe if load line brakes hmep down for a given period say 5 minutes.Signature Operator DateSignature Inspector DateSignature witness Date