II. METODO
2.2. VARIABLES, OPERACIONALIZACIÓN
PRPD. BY: CHKD. BY: APPRD. BY: ISSUED ON: MAR ’94
9.0.0 LOOSENING SLIDE END ANCHOR BOLT 10.0.0 INSPECTION RECORD
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of three cable clamps or equivalent at each connection to prevent slippage. The diameter of the usable guy ropes shall not be less than that specified in the installation plan. The safety factor of guy ropes shall comply with ANSI B 30.6.
4. Anchor
Anchoring of winch, guy ropes etc. shall be accomplished by installing deadmen unless otherwise specified. Deadmen shall be placed so as not to interfere with eqpt foun-dations, underground facilities & struc-tures.
5.1.2 Winch
1. The winch shall be located so that it does not obstruct passage of equipment nor prevent the operator from observing the signalman.
2. Anchors to the winch shall be provided to withstand the maximum force working on the winch. Brakes and clutches shall be protected from the weather so that a sudden rain fall, during lifting, shall not cause the load to slip or drop.
5.1.3 Mobile crane
1. All mobile crane operators shall be qualified by governmental or other equivalent authorities.
A set of the manufacturer’s lift tables shall be placed conspicuously in the mobile crane operator’s cab at the job- site. The capacities given shall be adhered to strictly.
Additional boom sections installed on the equipment shall be compensated by addi-tional counterweights in accordance with the instruction manual. Timber mats and/or steel mats shall be provided for treads or tires considering the soil bear ing. Basically, outriggers and jacks shall be provided on the mobile crane to guard it against sudden tire failures and overturning while lifting heavy equipment.
2. All cranes shall be inspected in accordance with ANSI B 30.5 . When a risky condition is found, appropriate measures shall be taken immediately.
Major items of inspection shall be as follows:
a. All control mechanisms as to maladjust-ment.
b. All control mechanisms as to excessive wear of components and contamination by lubricants or other foreign matter.
c. All control mechanisms as to malfunction.
d. Deterioration or leakage in air or hydraulic systems.
e. Electrical apparatus as to malfunctions and signals.
f. Crane hooks with deformations or cracks.
g. Deformed, cracked, or corroded members in the crane structure and boom..
h. Rope reeving as to noncompliance.
i. Ropes.
5.2.0 WIRE ROPE, SLINGS, CHAINS AND FIT-TINGS
1. Wire Rope
Wire ropes shall be of suitable size, grade and construction to withstand the maximum load imposed.
Wire ropes in the main hoisting system shall be of ample length for the entire range of movement specified with at least two full wraps of the rope on the hoist drum at all times.
Wire ropes shall be inspected in accordance with ANSI B 30.6.
When any of the risky conditions listed below is found, the wire rope shall be removed from the sling service and appropriate measures shall be taken to improve the condition.
a. In running ropes, six randomly distributed broken wires in one rope lay, or three broken wires in one strand in one rope lay.
b. Wear of one-third of the original diameter of the outside individual wires.
c. Linking, crushing, bird caging or any other damage resulting in distortion of the rope structure.
d. Evidence of any heat damage from any cause.
e. Reductions from nominal diameter of rope exceeding:
3/64 inch for diameters upto 3/4 inch in-clusive.
1/16 inch for diameters 7/8 inch to 1-1/8 inches inclusive.
3/32 inch for diameters 1-1/4 inches to 1-1/2 inches inclusive.
f. In standing ropes, more than two broken wires in one lay in sections beyond the end connection or more than one broke wire at an end connection.
2. Wire Rope and Sling
Wire rope slings shall comply with ANSI B 30.9.
The safety factor for wire rope slings of all grades shall be not less than five.
3. Chain
All chains shall be forged or electric welded steel link type of the proper size for the loads to be lifted.
Overloaded chains shall be discarded im-mediately.
4. Drum, Pulley and Sheave
The diameter of the drum or pulley shall be not less than 20 times the rope diameter.
The diameter of sheaves shall be not less than 10 times the rope diameter.
5. Fitting
All hooks, swivel hooks, anchor shackles, swivel sockets, safety hooks, cable clamps, turnbuckles, and other attach ments shall be made of drop forged steel.
6. Safety Factor
TABLE - 1
ITEM MIN.
SAFETY FACTOR Hoist Rope
Hoist Rope for Raising and 3.5 Falling Boom
Wire Rope for Supporting Boom
Wire Rope for Turning 3 Wire Rope or Guy Rope for Tension
Wire Rope for Sling 5
6.0.0 INSTALLATION
6.1.0 ERECTION OF GIN POLE/BOOM DERRICK 6.1.1 Inspection of gin pole components
Prior to erecting the gin pole/boom derrick all winches, hooks, shackles, thimbles, wires, chains, etc., shall be inspected thoroughly as to material, capacity, wear and tear.
6.1.2 Grounding
The gin pole/boom derrick shall be equipped with grounding. Resistance of grounding shall be under 10 ohms.
6.1.3 Assembly and disassembly
The following precautions shall be taken in the assembly and disassembly of the gin pole.
1. During the assembly and disassembly operation of the gin pole/boom derrick only persons to be engaged directly in the work shall be admitted into the work area.
2. Only qualified operators for hoisting and slinging shall be assigned and a list of such operators shall be prepared and filled.
6.1.4 Inspection after assembling
Immediately after assembly and prior to starting the lifting of any equipment, the following parts of the gin pole/boom derrick shall be inspected carefully:
1. Gin pole/boom derrick members and con-nections thereof.
2. Anchor of winch.
3. Guy ropes as to number, tension and con-dition.
4. Wire ropes as to condition of wear and damage.
5. Hook, shackle, thimble and other hanging implements as to conditions of wear and damage.
6. All control mechanisms and other safety devices.
7. Electrical apparatus and controls of winch.
6.1.5 Preventing accidents by guy rope
For preventing accidents, all guy ropes shall be attached with red flags so that they will be recognizable from a distance.
6.2.0 PREPARATION OF SHIMS AND WEDGE 6.2.1 Shims & wedges shall be made of carbon steel.
6.2.2 In general shims & wedges shall be prepared by machining or grinding as indicated in Table 2.
TABLE - 2
ITEM LENGTH
mm WIDTH
mm THICK
mm SLOPE
Shim 100-450 50-200 3.2,4.5,9,12,
19,25 —
Wedge 100-450 50-200 6,9,12,16,19, 25 (max.) 4o-5o 6.3.0 INSTALLATION OF EQUIPMENT
6.3.1 Inspection before installation
1. Prior to commencing the installation work, any damage during the transportation, the orientation of the equipment, the center of gravity, base level from the datum line of the foundation, the condition of the slings and lifting lugs, and the condition of the anchor bolts etc., shall be inspected thoroughly.
2. The function of brakes, clutches, other safety devices and controls of the winch shall be inspected.
3. To prevent overloading, any test water or other temporary materials remaining or left in the equipment shall be drained or removed.
4. The bottom face of the equipment base plate shall be cleaned.
5. The concrete surface of the foundation shall be thoroughly chipped and then be cleaned completely with compressed air, etc.
6. The required number of shims and wedges with the necessary tools shall be prepared to ready use.
6.3.2 Precautions against storm
1. When the wind velocity exceeds 15m/sec.
all installa tion work shall be stopped.
2. No equipment shall be installed under stor-my winds, heavy rain or heavy snow.
6.3.3 Special crew
1. During heavy equipment installation, espe-cially installation by the gin pole/boom der-rick a special crew shall be organized.
2. The crew shall comprises a general super-visor, signal/flag man, hoist operator, crane operator, rigger, safety supervisor, etc.
3. The function of each individual of the crew shall be clearly defined.
6.3.4 Installation
1. Heavy equipment shall tentatively be lifted, slightly, to examine all parts of the gin pole/boom derrick, crane, wire ropes, tools, etc. If any defect is found, the equipment to be installed, shall be lowered on the ground.
After the defect is corrected, the equipment shall be lifted slowly.
2. Crane work shall not be suspended at dangerous and incomplete positions during the lifting operation.
3. The protective cover on equipment for noz-zles and flanges shall not be removed without the approval of the Engineer-in-charge.
4. During installation work, special care shall be taken so as not to damage the anchor bolts or their threads.
5. While seating and leveling, use shims and pairs of wedges.
6. As a rule, shims and wedges shall be placed on liner plates fixed on the concrete founda-tion at both sides of the anchor bolts, and leveling shall be done temporarily. Where the distance between anchor bolts is larger than 800mm, extra shims and wedges shall be located between the anchor bolts to prevent the base plate from bending.
Wedges or shims shall not be substituted with wooden strips, bricks concrete blocks, etc.
7. After leveling is finished and all anchor bolts are firmly tightened, all shims and wedges to remain in place shall be tack-welded to prevent them from becoming loose.
8. As a rule, welded lifting lugs used in the installation shall be left in place.
7.0.0 ALIGNMENT 7.1.0 GENERAL
7.1.1 All installed equipment shall be aligned plumb-ness or level.
7.1.2 Towers/vertical vessels shall be aligned plumb-ness and satisfy the requirements of Par. 7.2.0 7.1.3 Horizontal vessels & heat exchangers shall be aligned level and satisfy the requirements of Par.7.3.0
7.2.0 PLUMBNESS
1. Plumbness shall be checked by viewing from two directions 90o apart with a transit.
Check of plumbness of very tall equipment shall be done early in the morning.
2. Out-of-plumb of the equipment installed shall not exceed 1.0mm per lm of height or a total of 25mm for the entire height, whichever is smaller, unless otherwise specified in the job Specification.
3. After alignment is finished and the lock nuts of the anchor bolts are tightened firmly, the shims and wedges shall be tack-welded to each other and any excess in the shims and wedges shall be cut off with gas cutter.
7.3.0 LEVELING
1. The alignment level shall be made using a spirit level instrument or a transit at four points based on the center line marked on the equipment in the shop. The level shall be aligned in the direction of AB or CD and AC or BD at the center line on the equip-ment. ( Refer to Fig. on Page 5 of 5 ) 2. The maximum tolerance shall be as shown
in Table 3, unless otherwise specified.
TABLE - 3
POINT TOLERANCE
A and B or C and D l mm per Meter of Length A and C or B and D 2 mm Max.
3. Considering the drain-out during main-tenance, the channel end of the heat ex-changer shall be lowered 1 to 2mm/m than the shell cover end.
4. After leveling is finished and the lock nuts of the anchor bolts are tightened firmly, the shims and wedges shall be tack-welded to each other and any excess in the shims and wedges shall be cut off with a gas cutter.
8.0.0 GROUTING
Grouting shall be accomplished in accordance with the fol lowing requirements, unless other-wise specified.
8.1.0 PREPARATION FOR GROUTING
1. The foundation surface shall be cleaned thoroughly and be removed of any dirt or oily spots.
2. The top surface of the foundation shall be wetted thoroughly with fresh water prior to grouting.
8.2.0 MATERIAL
1. Portland cement mortar may be used in grouting under the base plates, unless otherwise specified.
2. The mixing ratio of portland cement and clean fine sand shall be approx. 1:2 in volume, and the ratio of water to cement shall be less than 40 percent in volume unless other wise specified.
8.3.0 GROUTING PROCEDURE
1. The base plate shall be grouted as follows:
a. The space under the base plate shall be packed full with grout.
b. The grout shall cover all shims and wedges.
2. After the grouting mortar has been poured fully, the excess grout shall be trimmed away. The surface of the mortar outside of the base plate shall be finished smoothly.
3. The shims and wedges shall not be removed, unless otherwise specified.
9.0.0 LOOSENING SLIDE END ANCHOR BOLT 1. After grouting has set and hardened, the
nuts of the sliding end anchor bolts shall be loosened to allow for thermal expansion.
2. The above requirement shall be applied to horizontal vessels, shell and tube heat ex-changers, and when requested by the En-gineer- in - charge
10.0.0 INSPECTION RECORD
The results of the following inspections shall be recorded and submitted.
1. Alignment a. Plumbness b. Leveling