SY/T 6279-2022 (SY/T6279-2022, SYT 6279-2022, SYT6279-2022) & related versions
SY/T 6279-2022: PDF in English (SYT 6279-2022)
SY 6279-2016
SY
PETROLEUM & NATURAL GAS INDUSTRY STANDARD
OF THE PEOPLE’S REPUBLIC OF CHINA
ICS 13.100
E 09
Filing No.: 53351-2016
Replacing SY 6279-2008
Safety code for lifting large equipment
ISSUED ON: JANUARY 07, 2016
IMPLEMENTED ON: JUNE 01, 2016
Issued by: National Energy Administration
Table of Contents
Foreword ... 3
1 Scope ... 4
2 Normative references ... 4
3 Terms and definitions ... 4
4 Lifting organization and responsibilities ... 5
5 Lifting preparation ... 5
5.1 General requirements ... 5
5.2 Technical measures for lifting ... 6
5.3 Lifting machinery, rigging, supporting facilities ... 8
6 Installation and use of mast crane ... 13
6.1 General requirements ... 13
6.2 Installation (disassembly) of mast crane ... 13
6.3 Movement of mast crane ... 14
6.4 Use of mast crane ... 14
7 Installation and use of hydraulic lifting (jacking) gantry crane ... 15
7.1 General requirements ... 15
7.2 Installation of hydraulic lifting (jacking) gantry crane ... 16
7.3 Use of hydraulic lifting (jacking) gantry crane ... 17
8 Selection and use of mobile cranes ... 17
8.1 Selection of mobile cranes ... 17
8.2 Use of mobile cranes ... 17
9 Control of lifting process ... 18
9.1 Working environment ... 18
9.2 Lifting operations ... 18
10 Emergency management ... 22
Safety code for lifting large equipment
1 Scope
This standard specifies the lifting organization and lifting preparation of large
equipment, the installation and use of mast cranes, the installation and use of hydraulic
lifting (jacking) gantry cranes, the use of mobile cranes (crawler cranes, tire cranes,
truck cranes), the lifting process control, the emergency management and other basic
requirements for safe production.
This standard applies to the lifting of large equipment in newly built, renovated
(expanded), overhauled oil field ground projects, onshore petroleum and chemical
engineering projects.
2 Normative references
The following documents are essential to the application of this document. For the dated
documents, only the versions with the dates indicated are applicable to this document;
for the undated documents, only the latest version (including all the amendments) is
applicable to this standard.
GB 5082 Cranes - Hand signals
GB/T 5972 Cranes - Wire ropes - Care, maintenance, installation, examination and
discard
GB 6067.1 Safety rules for lifting appliances - Part 1: General
GB 50798-2012 Code for large-size equipment hoisting engineering in
petrochemical industry
NB/T 47013.1 ~ 47013.13 Nondestructive testing of pressure equipments
3 Terms and definitions
The terms and definitions established in GB 50798-2012, as well as the following terms
and definitions, apply to this document.
3.1
Lifting large equipment
The lifting process (hereinafter referred to as "lifting") of equipment (generally
referring to towers, reactors, modules, components), which has a mass greater than
or equal to 100 t or a one-time lifting length or height greater than or equal to 60 m.
3.2
Tensile connection plate
A plate component, which is used to connect the hook and the lifting eye of the lifted
equipment. It usually uses a shaft as the connecting member.
3.3
Flange connected lug
A lug type which uses the flange on the lifted equipment as a connecting piece to fix
to the equipment, which is usually a welded piece or a forging.
4 Lifting organization and responsibilities
4.1 A lifting organization structure shall be established for lifting, with a general
commander, the lifting technical person in charge, the responsible engineer for lifting,
a lifting commander, and a safety supervisor.
4.2 The job responsibilities of the lifting organization include:
- General commander: Fully responsible for the lifting work and overall responsible
for the safety and quality of the lifting;
- Lifting technical person in charge: Responsible for organizing the preparation of
large equipment lifting technical plans and responsible for review;
- Responsible engineer for lifting: Responsible for the preparation and
implementation of lifting plans (measures);
- Lifting commander: Responsible for the correct implementation of on-site lifting;
- Safety supervisor: Participate in the review of lifting plans (measures); be
responsible for safety inspection and supervision of on-site lifting.
5 Lifting preparation
5.1 General requirements
5.1.1 Lifting operators shall hold certificates when working.
the original approval procedures shall be re-approved.
5.2.2 When a new process or method is adopted for the first time, it shall be reviewed
and approved by the technical person in charge of the enterprise.
5.2.3 Technical measures for lifting shall include but not be limited to the following:
- Project overview;
- Basis for preparation;
- Main parameters of equipment, components and lifting process methods;
- Calculation of stress in lifting process;
- The composition and job responsibilities of lifting operators;
- Technical, quality and safety requirements;
- Risk analysis and emergency plans;
- Summary table of lifting equipment and rigging;
- List of materials used for construction methods;
- Lifting process flow chart;
- Design drawings and calculations of self-designed slings and facilities, including
lifting lugs, tensile connection plates, connecting shafts, spreader beams,
reinforcements, etc.;
- Lifting floor plan, etc.
5.2.4 The force calculation shall include but not be limited to the following:
- Calculation of loads;
- Calculation of the location of the center of gravity of the equipment;
- Stress calculation in the lifting state (process) of the equipment, selecting
machinery and rigging according to the maximum stress and calculating the safety
factor;
- Verification of crane foundation bearing capacity;
- If necessary, verification of the entire or partial equipment and components.
5.2.5 The lifting floor plan shall include but not be limited to the following:
wire rope. Generally, the diameter of the winding drum shall be 16 to 25 times the
diameter of the steel wire rope.
5.3.4.4 When multiple winches are used to lift equipment, their traction speed and
lifting capacity shall match.
5.3.4.5 When multiple winches are used to lift equipment, each winch shall be equipped
with a separated switch.
5.3.4.6 The insulation resistance of electrical equipment such as motors shall be greater
than or equal to 0.5 MΩ.
5.3.4.7 The braking device of the winch shall be safe and reliable.
5.3.4.8 The resistance value of the winch protective grounding shall be less than 10 Ω.
5.3.5 Pulley (block)
5.3.5.1 The pulley (block) shall be used according to its rated lifting capacity. When the
pulley block is used partially, the load shall be reduced in proportion to the
corresponding number of pulleys.
5.3.5.2 Before use, the pulley grooves, axles, splints, hooks, rings, suspension beams
and other parts shall be inspected for defects such as cracks, damage, deformation.
5.3.5.3 The selection of the pulley (block) and the wire rope shall match. The diameter
of the pulley shall usually not be less than 16 times the diameter of the wire rope; the
inclination angle of the wire rope entering the pulley groove shall be less than 15°.
5.3.5.4 The minimum clear distance of the pulley block shall not be less than 5 times
the wheel diameter.
5.3.5.5 The pulley (block) shall be maintained regularly.
5.3.6 Ground anchor
5.3.6.1 For the setting of ground anchor, it shall be excavated and buried according to
lifting technical measures. A tensile test shall be carried out if necessary.
5.3.6.2 There shall be no trenches, cables, underground pipes, etc. within 2.5 times the
pit depth in front of the ground anchor.
5.3.6.3 During the installation process of ground anchors, supervision and inspection
shall be carried out and concealed engineering records shall be kept. The records shall
include geometric dimensions of the pit, concrete strength grade, embedded parts
materials and welding quality, compaction conditions after burial, geology and
landform of the location of the anchor pit, etc.
5.3.6.4 Ground anchors shall be pre-tensioned when setting them.
5.3.6.5 When backfilling the ground anchor, pure soil shall be used. Compact in layers,
with the filling height of each layer not exceeding 300 mm. The backfill height shall be
more than 400 mm higher than the ground around the foundation pit; water
accumulation shall be prevented.
5.3.6.6 The concrete strength grade of concrete ground anchors shall not be lower than
C20.
5.3.6.7 When using buildings or structures as ground anchors, approval procedures shall
be performed and corresponding calculation shall be carried out.
5.3.6.8 The use of ballast ground anchors shall be calculated and tested before use.
5.3.7 Lifting point location and lifting lugs
5.3.7.1 The position of the lifting point shall meet the following requirements:
- Facilitate equipment placement;
- Easy to observe the stress conditions of lifting equipment and rigging;
- Meet strength and stability requirements;
- There shall be sufficient working space for lifting equipment and rigging.
5.3.7.2 Lifting lugs shall meet the following requirements:
- The structure shall meet its own strength and the local strength requirements of the
equipment;
- Lifting lugs shall have quality certification documents; the materials shall not have
defects such as cracks, overlapped skin, interlayers;
- The location, quantity, orientation, elevation shall meet the requirements of lifting
technical measures.
5.3.7.3 The connection welds between the lifting lugs and the equipment and the
connection welds between reinforcements shall be welded according to the welding
process; the non-destructive testing shall be carried out according to the design
requirements. The testing shall comply with the provisions of NB/T 47013.1 ~ 47013.13.
5.3.8 Spreader beam
5.3.8.1 Spreader beams shall be manufactured and used according to their design
requirements.
5.3.10.3 The hydraulic lifting (jacking) jack and its component holder shall have firm
and reliable support. After loading, the holder or the pressure plate bolts fixing the
anchor block shall be tightened twice.
5.3.10.4 When lifting, the slide-out path of the steel strand wire harness shall adopt a
rolling friction track. If blockage occurs, it shall be eliminated in time.
5.3.10.5 During the lifting process, if the steel strands are loose, it shall stop lifting,
analyze the reasons, take adjustment measures.
6 Installation and use of mast crane
6.1 General requirements
6.1.1 The organization that installs and uses mast cranes shall have corresponding
qualifications issued by the competent government departments.
6.1.2 The mast shall have the following exit-factory technical documents:
- Design and manufacturing organization's qualification certificate;
- Mast manufacturing drawings, mast operating instructions, mast design
calculations;
- Material certificate (including main materials, welding materials, accessories, etc.);
- Manufacturing process and quality inspection records;
- Load test records and load test certificate.
6.1.3 The foundation of the mast crane shall meet the foundation bearing capacity
requirements in the lifting technical measures.
6.1.4 The mast crane shall be inspected and maintained before use.
6.1.5 After the mast is installed, a safety warning sign shall be installed on its top.
6.1.6 After the mast is installed, there shall be a reliable grounding device.
6.2 Installation (disassembly) of mast crane
6.2.1 A technical plan shall be prepared for the installation (disassembly) of the mast
and implemented according to the technical plan.
6.2.2 A uniform wrench shall be used to tighten the mast connecting bolts. If necessary,
a torque wrench shall be used; the mast connecting bolts shall be tightened
symmetrically and in a certain order, to ensure a tight fit between the joint surfaces.
6.3 Movement of mast crane
6.3.1 The inclination in the direction of mast movement shall be less than 5°; the
inclination amplitude should not exceed 5 m; the lateral inclination angle of the mast
shall not be greater than 3°.
6.3.2 When the mast moves, at least four wind ropes shall be evenly distributed for
controlling.
6.3.3 The road for mast movement shall be smooth and solid; foundation treatment shall
be carried out if necessary.
6.3.4 When the mast movement route has a downhill slope or a turn, a tail slide device
shall be installed and the movement shall be done intermittently.
6.3.5 Portal masts should be moved using the intermittent method and comply with the
following requirements:
- A rigid connection is provided between the two lower legs of the portal mast;
- The forward inclination of the portal mast shall be less than 5°; the inclination
amplitude should not exceed 5 m;
- The two bottom rows at the bottom shall move synchronously, with a relative
deviation of not more than 100 mm.
6.4 Use of mast crane
6.4.1 The setting of wind ropes shall meet the following requirements:
- The number of wind ropes shall be determined according to the usage conditions.
Generally speaking, when a single mast is used, the number of wind ropes shall not
be less than six; when there are double masts or multiple masts, the number of wind
ropes on each mast should not be less than six; when a portal mast is used, the
number of wind ropes for each portal mast shall be less than six;
- The angle between the wind rope and the ground is preferably 30°, which shall not
be greater than 45° under special circumstances;
- When the mast's wind rope is clamped, the clear distance between the first rope
clamp and the ground anchor pulley shall not be less than 4 times its pully diameter;
- The wind rope and its adjustment device shall have a safety margin and meet the
7.2 Installation of hydraulic lifting (jacking) gantry crane
7.2.1 Foundation treatment
7.2.1.1 Foundation treatment shall be carried out according to the lifting foundation
treatment plan; the bearing capacity shall meet the lifting requirements.
7.2.1.2 The levelness of the mast foundation and the height difference between two
adjacent mast foundations shall be implemented according to the design documents.
7.2.1.3 During the foundation treatment process, there shall be a dedicated person
responsible for quality monitoring and testing; construction records shall be kept.
7.2.2 Track installation
7.2.2.1 The installation of the track shall comply with the technical requirements for the
installation of hydraulic lifting (jacking) gantry cranes.
7.2.2.2 The levelness and height difference of the track shall be implemented in
accordance with the design documents.
7.2.3 Ground anchor setting
7.2.3.1 The ground anchor setting of hydraulic lifting (jacking) gantry crane shall
comply with the provisions of 5.3.6.
7.2.3.2 The position, type, load-bearing capacity of the ground anchor of the hydraulic
lifting (jacking) gantry crane shall meet the requirements of the design documents.
7.2.4 Wind rope setting
7.2.4.1 The installation and use of wind ropes for hydraulic lifting (jacking) gantry
cranes shall comply with the requirements of the design documents.
7.2.4.2 The pretightening force of the wind rope shall meet the maximum design value
requirements of the operating conditions.
7.2.5 Installation and debugging of hydraulic lifting (jacking) and automatic
control system
7.2.5.1 The number of steel strands inserted into each hydraulic jack shall be determined
according to the load.
7.2.5.2 The angle between the load-bearing steel strand and the plumb line shall not be
greater than 2°.
7.2.5.3 Before using the automatic control system, the parameters shall be set according
to the product technical documents, the objects to be controlled, the control accuracy.
7.2.5.4 The control system shall be equipped with uninterruptible power supply
facilities.
7.3 Use of hydraulic lifting (jacking) gantry crane
7.3.1 The use of hydraulic lifting (jacking) gantry cranes shall meet the requirements of
the usage (operation and maintenance) instructions.
7.3.2 The use of hydraulic lifting (jacking) gantry cranes shall comply with the
corresponding provisions of Chapter 9.
8 Selection and use of mobile cranes
8.1 Selection of mobile cranes
8.1.1 The calculated load hoisted by a single crane shall be less than its rated load.
8.1.2 The crane shall select reasonable working conditions based on its performance.
8.1.3 When two cranes are used as main hoists, the lifting weight shall be reasonably
distributed. The load of a single crane should not exceed 80% of its rated load. Balance
measures shall be taken when necessary.
8.1.4 The safe distance between the boom and the external accessories of the equipment
shall not be less than 500 mm.
8.1.5 The safe distance between cranes, equipment and surrounding facilities shall not
be less than 500 mm.
8.1.6 When two or more cranes are used for lifting, the crane's boom length, working
radius, lifting speed of the lifting pulley block, sling length should match.
8.1.7 The minimum height lifted by the crane shall maintain a safe distance of at least
200 mm between the bottom of the equipment and the top of the foundation or anchor
bolts.
8.2 Use of mobile cranes
8.2.1 The outriggers of the truck crane shall be fully extended.
8.2.2 The foundation bearing capacity of the lifting standing position of the crane shall
meet the usage requirements.
9.2.2 Before lifting, the lifting machinery shall be idling checked or tested; the braking
device, guard device, safety protection device shall be confirmed to be normal before
work can begin.
9.2.3 Before using the winch, the mechanical transmission and electrical control parts
shall be checked to ensure their normal performance. During the lifting process,
electricians and fitters shall be on duty for maintenance; the power supply shall be cut
off in time after the lifting is completed.
9.2.4 Rainproof measures shall be taken where the winch and power supply are placed.
9.2.5 A joint inspection shall be carried out before lifting. The items of the joint
inspection mainly include:
- Technical briefing has been conducted;
- Worker personnel are familiar with their work content;
- The selection and arrangement of lifting machinery and lifting equipment are
consistent with the plan;
- Technical disclosure records, machinery and rigging setup records, self-inspection
records, mutual inspection records, concealed engineering records, other quality
certification documents;
- The total weight of equipment lifting, installation of equipment accessories,
settings of machinery and rigging;
- Equipment placement;
- Arrangement of spare tools and materials;
- Obstacles that hinder lifting work;
- The construction roads and sites determined in the lifting technical measures;
- Power supply capability;
- Participate in lifting personnel command signal drills;
- Weather forecast;
- Emergency plan;
- Other necessary inspections.
9.2.6 After the joint inspection of large lifting is completed, the inspectors shall sign the
joint inspection record.
......
| Standard ID | SY/T 6279-2022 (SY/T6279-2022) | | Description (Translated English) | (Safety regulations for hoisting large equipment) | | Sector / Industry | Oil & Gas Industry Standard (Recommended) | | Word Count Estimation | 17,124 | | Date of Issue | 2022-11-04 | | Date of Implementation | 2023-05-04 |
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