压缩机装置维护和检修一体化服务模式的探索

1、 压缩机装置维护和检修一体化服务模式的探索摘要：介绍了压缩机装置维护和检修一体化服务模式，这是在压缩机运行维护方面的全新探索，其目的是确保压缩机组的安全平稳运行。关键词：一体化服务；故障处理；巡检；故障诊断中图分类号：TP277 文献标志码：BExploration of the Integrated Service Model for Maintenance and Repair of Compressor InstallationAbstract: This paper has introduced the integration service model for maintenance

2、 and repair of compressor installation, which is the completely new exploration in the aspect of compressors operation and maintenance. Its purpose is to ensure the safe and stable operation of compressor units.Key words: integrated service; fault treatment; inspection; fault diagnosis1 一体化服务概述1 sum

3、mary of integration services 一体化服务是压缩机装置维护和检修的一种专业技术服务模式，也称为保运服务。Integration is one of the compressor equipment maintenance and overhaul services professional technical service mode, also known as a confirmed delivery service. 一体化服务涵盖压缩机组主机、驱动机、辅机、辅助设备多专业的巡检、监测、保养、维护和维修等工作。具体主要包括离心压缩机、往复压缩机、汽轮机、电动机、

4、变速机及其润滑油系统、气路系统、水路系统、联轴器、电气仪表、控制系统等。Integrated services include compressor host, drive machine, auxiliary machinery and auxiliary equipment more professional inspection, monitoring, maintenance, maintenance, and repair, etc. Specific include centrifugal compressor, reciprocating compressor, steam tu

5、rbine, electric motors, variable speed machine and the lubricating oil system, pneumatic system, water system, coupling, electrical instrumentation, control system, etc. 风机生产厂家利用现代化的技术手段、丰富的维修经验和结合现场巡检，确保用户压缩机组的安全平稳运行。Fan manufacturers make use of modern technology, rich experience in maintenance, a

6、nd combined with the on-site inspection, ensure the safety of the user compressor running smoothly. 2 一体化服务模式2 integrated service mode 一体化服务模式采用压缩机行业“4S”服务，即维修服务、备件供应信息反馈（Survey）和整机解决 “四位一体”服务。4 s integrated service model using compressor industry services, namely, maintenance services, spare parts

7、supply, information feedback (Survey) and service the solution four one. 维修服务：一体化范围内的巡检、监测、保养、维护和检修。一切为保运产品让路，提供便利、快捷的服务。Maintenance services: integration within the scope of inspection, monitoring, maintenance, maintenance and overhaul. Everything to make way for the insurance products, to provide

8、convenient and fast service. 备件供应：实行“业主备件零库存”。设立专门的备件储备库，将随机备件、常用易损件的备件放置于该储备库中，并For owner spare parts spare parts supply: zero inventory. To set up dedicated spare parts reserve, will commonly random spare parts, wearing parts of spare parts placed in the pool, and 专人管理，以便于及时取用和检查。Personnel managem

9、ent in order to access and check in time. 信息反馈：全面执行检维修服务流程，在检维修中心、机组远程监测及故障诊断中心、监测平台、机动设备检修部以及各巡检分站之间搭建起一个畅通的信息反馈平台，确保维护和检修工作的顺利进行。Information feedback: full implementation maintenance service process, in the center of the inspection unit, remote monitoring and fault diagnosis center, monitoring pla

10、tform, mobile equipment maintenance department and each inspection stations set up between an open platform for the information feedback, to ensure the smooth implementation of the maintenance and repair work. 整机解决:机组的巡检、故障抢修、大修、转子动平衡、远程监测、故障诊断、增容改造等项目提供整机解决方案。Whole solution: checking, fault repair,

11、 overhaul of the unit, the rotor dynamic balance, remote monitoring and fault diagnosis, such as compatibilizing modified project provide the whole solution. 为保证维护和检修项目的顺利实施，在组织模式上，也就是在机构、制度、人员和设备方面做出相应的保障和安排。In order to ensure the smooth implementation of the maintenance and overhaul project, on th

12、e organization mode, which is in the aspect of organization, system, personnel, and equipment security and arrange accordingly. 3 一体化服务流程3 integration service process 一体化服务流程中需要多专业协调配合，共同完成工作。一体化服务流程见图1。Integration service process need to be more professional in coordination and finish the work toge

13、ther. Integration service process as shown in figure 1. 4 维护和检修内容4 content of maintenance and overhaul 4.1 巡检4.1 inspection 在保运期间严格按照压缩机的技术条件和技术规范及压缩机的操作规程，检查、巡视压缩机的运行和使用情况，第一时间掌握和了解压缩机的工况和实际动态，及时向用户通报发现的不良隐患。巡检工作是重要的基础性工作。During warranty shipment strictly according to the compressor technical condi

14、tions and technical specifications and compressor operating procedures, inspection, inspect the operation of the compressor and usage, the first time to master and understand the operation condition of the compressor and the actual dynamic, timely reported to the user found bad hidden danger. Inspec

15、tion work is an important basic work. 巡检内容：检查运行压缩机组的声音、压力，轴承温度、振动、轴位移、胀差，润滑油液位、压力、油质等情况是否正常；检查压缩机组机械密封冲洗系统冲洗液液位、温度、压力是否正常；检查凝汽器热井液位、真空度；检查冷却水系统、调速系统是否工作正常；检查备用压缩机组是否处于完好状态并按规定进行盘车(具有自启动和远程启动功能，压缩机组除外)；检查压缩机组的跑、冒、滴、漏情况；检查机组主辅油泵、油冷却器、注油器、盘车器是否正常，往复式机气阀温度是否过高、附属管线振动情况；检查各种特阀的各油泵是否正常，各阀是否泄漏，各阀电液系统是否正常。C

16、ontent of the inspection: check the voice of the running compressor, pressure, bearing temperature, vibration and axial displacement and differential expansion, lubricating oil liquid level, pressure, oil, and so on and so forth is normal; Check the compressor mechanical seal flush system flushing f

17、luid level, temperature, pressure is normal; Check the condenser hot well liquid level, the vacuum degree; Check the cooling water system, speed control system is working correctly; Check whether standby compressor unit is in good condition and in accordance with the provisions for turning (have fro

18、m the start and the remote start function, except for compressor unit); Check the compressor run, run, drip, leak; Check unit advocate complementary oil pump, oil cooler, oiler, set up is normal, reciprocating machine valve temperature is too high, the subsidiary pipeline vibration situation; Check

19、all kinds of valve of the oil pump is normal, the leaky valve, the valve electro-hydraulic system is normal. 4.2 故障处理4.2 troubleshooting 维修期不定，将按照巡检等情况，由专业技术维修人员进行修复。Maintenance period, will be in accordance with the inspection, etc., by the professional and technical maintenance personnel to repair

20、. 4.3 大修与故障抢修4.3 repair and fault repair 计划大修的维修期一般为：往复压缩机两年1次，离心压缩机三年1次。选派专家和专业维修人员对其进行大修。Plans to overhaul maintenance period is commonly: reciprocating compressor once for two years, three years in a centrifugal compressor for 1 time. Selected experts and professional maintenance personnel to rep

21、air. 4.3.1 离心压缩机组4.3.1 the centrifugal compressor 整套压缩机组进行解体、检测、调校、备件更换、重新组装、找正对中、运转试验及交付运转等工作。具体包括离心压缩机本体、齿轮、汽轮机、气路系统、联轴器、仪表、电气、控制系统等的检修。Compressor unit to collapse, of a complete set of testing and calibration, spare parts replacement, reassemble, alignment, running test and delivery test of the o

22、peration, etc. Specific include centrifugal compressor body, gears, steam turbine, gas path system, coupling, repair of instrumentation, electrical, control systems etc. 4.3.2 往复压缩机组4.3.2 reciprocating compressor 整套压缩机组进行解体、检测、调校、备件更换、重新组装、找正对中、运转试验及交付运转等工作。具体包括机身、曲轴、连杆、十字头部件、压力体、填料部件、刮油环、缸套、气阀、活塞杆、

23、活塞环和支撑环、润滑油系统、气路系统、联轴器、电机等。Compressor unit to collapse, of a complete set of testing and calibration, spare parts replacement, reassemble, alignment, running test and delivery test of the operation, etc. Including fuselage, crankshaft, connecting rod, crosshead parts, pressure, packing parts, oil sc

24、raper ring, cylinder liner, valve, piston, piston ring, and the support ring, lubricating oil system, pneumatic system, coupling, motor, etc. 4.3.3 机组故障抢修4.3.3 fault repair unit 在遇到突发故障时，安排有经验的专家成立应急小组，对突发性事故进行现场勘查，给出具体抢修方案，确保机组尽快投产运行。In case of sudden failure, arrangement of experienced experts and

25、 set up emergency response teams, on-site exploration of sudden accidents, specific emergency plan, to ensure that the unit production run as soon as possible. 除以上内容外，压缩机装置维护与检修一体化服务还包括远程监测与故障诊断技术、转子动平衡及修复、压缩机辅助设备采购与供货、增容改造等服务内容。In addition to the above content, the integration of compressor equipme

26、nt maintenance and overhaul services may also include remote monitoring and fault diagnosis technology, rotor dynamic balance and repair, auxiliary compressor equipment procurement and supply, such as compatibilizing modified service content. 5 一体化服务中远程监测及故障诊断技术的应用Five integration services in the ap

27、plication of remote monitoring and fault diagnosis technology 一体化服务中，采用状态监测及故障诊断系统所采集的数据应具有良好的准确性、实时性和良好的网络条件，确保各压缩机组监测数据及时、准确到达远程监测及故障诊断中心。每天定期将巡检记录发至机组远程监测及故障诊断中心，以便进行各压缩机组的状态评估与故障分析工作，及时提交压缩机组故障征兆、故障类型和解决方案。Integration services, condition monitoring and fault diagnosis system of data should be co

28、llected with good accuracy and real-time performance and good network conditions, make sure that the compressor monitoring data timely, accurately reach the remote monitoring and fault diagnosis center. Daily inspection records on a regular basis to set the remote monitoring and fault diagnosis cent

29、er, for the state assessment and fault analysis of compressor unit work, timely submit compressor fault symptoms and fault types and solutions. 6 备品备件6 spare parts 6.1 备品备件制备6.1 spare parts preparation 考虑到保运期间需要更换备件数量和种类，具有一定的不可预见性，预先储备关键件毛坯料；根据大修周期调研数据，提前对用户提出采购计划建议，确定备品备件预制的数量和种类。在车间，将利用“绿色通道”优先为用

30、户安排生产加工。Considering the insurance need to replace spare parts during the shipment number and variety, has a certain amount of unpredictability, reserve in advance key-module blank; Overhaul cycle according to the survey data, purchasing plan Suggestions to users in advance, determine the number and

31、variety of spare parts prefabrication. In the workshop, will use the green channel priority to arrange production and processing for the user. 6.2 备品备件保存的技术要求6.2 save the technical requirements of spare parts 备品备件仓库必须是清洁、干燥、无腐蚀性气体的场所，派专人精心照管，以便于及时取用和检查。轴瓦、密封等应用适当的防锈物质予以保护；转子立式或卧式存放和保管按照压缩机使用要求操作。Spa

32、re parts must be clean, dry, non-corrosive gases warehouse, chosen carefully take care of, in order to access and check in time. Bearing, sealing etc. Applying the appropriate anticorrosive material protected; Rotor vertical or horizontal storage and preservation in accordance with the requirements

33、for compressor used in operation. 7 维护和检修标准7 maintenance and inspection standard 维护和检修标准SHS 01001-2004 石油化工设备完好标准。根据具体压缩机所在装置，按照石油化工设备维护检修规程（SHS）1和API2等行业标准进行检修和维护，但检修和维护中的具体参数应以设备供应商的设计数据和相关技术资料为准。Maintenance and overhaul standard SHS petrochemical equipment in good standard, 01001-2004. Depending on the compressor unit, in accordance with the regulations of petrochemical equipment maintenance (SHS) 1 and 2 apis such as industry standard for repair and maintenance, repair and maintenance of the concr