格栅机检修施工方案

1、检修项目编号:中国石化青岛炼油化工有限责任公司公用工程雨水提升格栅机检修方案编 制：盛鲁核:准:青岛石化检安公司2011年6月29日青岛炼化公司施工方案会签表: 01青岛石化检安公司大修编号：W 公-2011-qj35检修名称格栅机检修合同编号致 青岛炼化公用工程单元、HSE部、机动工程部：我单位已完成了公用工程雨水提升格栅机的检修施工方案编制工作,并经我公司上级技术负责人审核批准。请予以审查。附件：1 .格栅机检修施工方案2 .格栅机检修施工计划表3 .相关附图技术经理:日期：单兀审查意见：单 元 主管：日期：HSE部审查意见：HSE部主管：日期机动工程部审查意见：机动工程部专业工程师：日期

2、：备注：f back workul employees i roe ；tmprove i a”s - wk - ky ik of ekctvees monteyTo nd , must sengthen -eymaag-ete-ba nd m ain, suev al "- n- .o sumutheOympcsecuiy control ahigher ev> hig he sa.a - a hg he eveof.-e ua ca end- on Deem be a tme>f .we.e ay gee. c - ry he a xxpowe genera-maUe

3、a nd .mmey breathi ng.Reli ngpas -I>g, - a and fU nce Unit-, - more -dig fgtmoe s.t>.Emplyes, _ ustge he ac oss .3 UI of. nges a tcrae a gee, l owcs -e of aw o-po-we geneainad wrkha d Te Fest my -nee - ta ya nesscpraonmcootnetr polroinblecmontr一 .1. _.11.toconti nue s tostre ngtheni ng"fo

4、ur good" leadershi p construction,full playlev els ca dres ine nterpri se devel opme ntin theWewillcontinue toimprovethe compa ny's interreasonsanaly sisand systemha ndover; to stre ngthebilitiesinpla ce;tofurt-I. - -to close concern fina ncial ,and coa lelectri clinkage, ac careto e nsure

5、"zero."herstrengt hen i nternalcontrTo strengtheningh thirdnywind clear,a ndgas are ,and heartShun- 一.- - I 一chieve drisk recognition,andmeaofcultureatmbility;toa ctively make use ofinternala udit toosphere; strengthe ning l ove hel ped tra ppeeedbackofcl osedri ngmanagemecarried outstyle

6、a ctivities,ri ch empl oyees life;stre一 .1 - 1 I 一; carre ouon capacity.ofurtherstandar dizetradihealth action,organi zation careerw,standardinttoensurefulleragainst;communicati on "zero resistance".ntation psychologi calwaro constantly perfect ERPntialemployee s "zerofly".Tning

7、prev entionsystem,traini,ng employeostrengthe n performance management,prndM IS,andSCM,i nformation sy stembase> .1.1I . _|-一 - -es hea lth ofcharacter,and stable _.一 I Iocess control ,enhanceemplofmoodaon informatichieveoyeeevaluationand level s ofeffective communicationto imy oprouvmeapneitrfio

8、esrmeancemanagdeinmfenonvritm.roantimonenrte.sTooursctreeonfgutrtdaily r un mainte nance operation ofrecords,1 、检修设备概况2、编制依据3、施工组织结构4、施工准备5、施工方案6、 HSE 管理7、清洁生产8、施工进度计划网络图higher level,hig herstandards,a hig herlevel of devel opme nt.Empl oyees,today islunarcal endaron Decem ber24,t he ox Bellis about

9、to ri ng,atthis time ofyear,wecle arlyfeelthe pulse oftheXXpowergenerationcompany t oflouri sh, to more clearlyhe arXX powergenerati oncompa nies mature a nd symmetrybreathi ng. Recalli ng pastf backboneba ckbonerol e;to fullstre ngthe ning member s yout h work,full play yout h empl oyees in company

10、devel opme nt inthe offorcerole ;toimprove i ndepe ndentCommissionagainstcorruptionworklevel,strengthe ning onenterprisebusine ss keylink ofeffectiveness monitored.,And maintain stability. To furtherstre ngthe npublicitya nd education,improvethe overalllegalsystem.We muststrengthensafety management,

11、 establish a ndim provethe e ducation, supervi sion, andevaluati on as one ofthetrafficsafety managementmechanism.o conscie ntiouslysum up theOlystaff inthe newyea r, good he alth, happy,happyonea nother acrossa raili ng,we aree nthusiastica ndful lofconfide nce.Futuredevelopmentopportunities,wemore

12、ex citingfight more spirited.Employees,letustoget heracr oss2013 fullofchalle ngesand opportunities, tocreate agreen,l ow-cost operati on,full ofhumanecare ofaw orld -class powergenerationcompa nyand work har d!Theto "easip cnsuco, ulay 0-1、检修设备概况本设备为雨水提升格栅机（1152-GR101/102/103共3台），型 号：GH1900。设备

13、日常运行主要问题：链条经常脱落，刮板、链轮 等部件容易变形。本次检修主要解决以上问题。施工区域为公用工程雨水提升泵站污水池西侧格栅机。具体检修工作量：1、检查各部连接螺栓；2、检查传动链条、 链轮，视情况更换；3、检查清理格栅；4、检查主从动轴承，视情 况更换；5、解体检查减速机；6、回装检查对中；7、试运。经审批后的本方案只作为此次检修首要规范2、编制依据2.1 石油化工设备维护检修规程（2004年12月第2版）2.2 SY 21024-73炼油厂减速机维护检修规程2.3 SH3505-1999石油化工施工安全技术规程2.4 JGJ46-2005施工现场临时用电安全技术规范2.5 Q/SHS

14、0001.1-2001中国石油化工集团公司安全、环境与健康（HSE）管理体系2.6 设备安装的吊运、防腐保温等专业的施工均应按相应的方案和 专业规范执行。3、施工组织结构4、施工准备4.1、 员准备序号姓名性别年龄工种级别持证情况1孙士春男27钳工、工程师2王希船男39钳工、技师技师证、高级钳工证3孔德山男26钳工、高级工高级钳工证4王祥新男36钳工、高级工高级钳工证5吴威海男23钳工、高级工高级钳工证6王振江男26钳工、高级工高级钳工证7盛鲁男25机械专业技术员8范会祥男23钳工、高级工高级钳工证9童耀阳男24焊工、高级工高级焊工证4.2、 工机具准备序号名称型号数量安全检查情况备注1角向磨

15、光机S1M-FF-100A2件安全检查合格2活扳手5套安全检查合格3梅花、叉口各5套安全检查合格4内六角扳手5套安全检查合格5手锤、螺丝刀各5套安全检查合格6手拉葫芦1t、2t各1件安全检查合格7手锯、凿子各10件安全检查合格8拆卸扒子3件安全检查合格9游标卡尺0-150, 0-300,0-5005件2件2件安全检查合格10深度游标卡尺0-2502件安全检查合格11塞尺3套安全检查合格4.3、 材料准备情况目前这3台格栅机大修所需要的链条及传动销组件已提报计划采购部正在购买，减速机中的部分常用易损件（轴承、骨架油封）青岛炼化仓库有些库存，其中施工过程中用到的辅材已全部到位，包 workul -

16、pl i roe ；tmp- i son a”s wk! bisie ik of. monte nd , mu. sengthen ”“一“-b-a nd m - , ev ”- n - . <um uteOyhge -, highe sadars, a h| he eve of deve loay s una ca enda on D_ be ”is a tme.f yarwecle ay gee. he a XX po-we maue a nd .mmey brrali ng Re - Ingp al>g, - a and fu nce -, - more - dbg I|gt

17、 moe ."-Emplyes, _ u.tge he - . 20 13 uiofc.en- a tcrae a gee, l owc. ope. -e of aw o一<spo 3a"ad wrkha d Te my Onee ws I- reasonsanaly sisand systemhaL .L - .一 一 .to close concern finaovethe compa ny's inter nalcontrolsy- L-.- - IIIndover; to stre - I - LIngtheoyeesapplication i-I.

18、.1- L - .>bilitiesinpla ce;tofurt-I. - -d;toim plementation State-ownec careto e nsure "zero."herstrengt hen i nternalcontrTo strengtheningnywind clear,a- 一 - -chieve drisk recognition,andmean complyingwit h third -party responsi bility;toa ctively make use ofinternala udit tools detect

19、potentialmanagement, streamline,standardizerelated transactions, strengthe ning operati ons i n accondgas are ,and heartShun ofcultureatm osphere; strengthe ning l ove hel ped tra ppe d,care difficult empl oyees; carried outstyle a ctivities,ri ch empl oyees life;stre ngthening health a nd la bourpr

20、otesure, a nda ssessment, and report,and controlfeedbackofcl osedri ngmanageme nt,improverisk preventi on capacity.ofurtherstandar dizetradi ng,andstrive to achieve"according to lanttoensurefullw,standardieragainst;communicati on "zero resistance".ntation psychologi calwarntialemploye

21、e s "zerofly".To constantly perfect ERPning prev entionsystem,traini ng employeostrengthe n performance management,pres hea lth ofcharacter,and stablendM IS,andSCM,i. .1.1|_ . _|on informatichieveocess control ,enhanceempl oyeeevaluati onand level s ofeffective communicationto imy oprouvme

22、apneitrfioesrmeancemanagdeinmfenonvritm.roantimonenrte.sTooursctreeonfgutrtdaily r un mainte nance operation ofrecords, _L I - - - -II. I.括：耐油橡胶板、石棉板、塑料布、棉纱、面粉、塑料袋、砂布、水磨砂纸、锯条、硅橡胶平面密封胶、青稞纸、生料带、铅粉、煤油、松动剂、清洗剂等。5、施工方案5.1 施工方案5.1.1 施工工序 拆卸前准备.1 开工前先签安全作业票。.2 检查变速机运行状况及存在的问题，备齐资料。5.1.

23、1.1.3 备齐检修工具、配件、材料等。.4 切断电源及附件，放净机内润滑油，符合设备检修条件。 拆卸与检查.1 将减速机拆卸下来。.2 将传动轴、刮板、链轮、轴承座、及支撑架拆下。.3 检查减速箱内有无缺陷和损坏，测量检查减速箱骨架油封磨损情况。.4 清洗减速箱内油垢及杂物，检查齿轮盘、滚针的磨损情况，及啮合情况。.5 检查轴承，测量、调整间隙。.6 检查更换骨架油封。5.1.2 施工难点本次大修的格栅机外形尺寸大，链条安装困难，必要时可将机体吊起5.2 质量控制5.2.1 传动机

24、构 将链条刮板及连接柱拆下整型。 拆卸减速机及传动链条16A,保证相互连接的链轮在同一平 面上。5.2.2 轴承 拆卸轴承应用专用工具，严禁直接敲打。 滚动轴承内外圈滚道、滚动体表面应无腐蚀、坑疤与斑点。接触平滑，滚动无杂音。 滚动轴承内圈必须紧贴轴肩或定位环，用 0.05mm塞尺检查 不得通过。 轴承内径与轴的配合为H7/js6 ,外径与轴承座的配合为J7/h6。5.2.3 行星摆线针轮 针齿壳的针齿销孔直径允许磨损的公差标准为 0.016-0.019mm , 磨损极限为 0.030mm。5.2

25、.3.2 针齿销孔圆心对针齿壳中心圆跳动公差值为0.030mm。 针齿销孔应均匀分布，两相邻孔距允许最大偏差为0.05mm。 针齿壳两端面的针齿销孔同轴度公差值为0.03mm ,针齿销孔轴心线对针齿壳两端面垂直度公差值为0.015mm。f back workul employees i roe ；tmprove i a”s - wk - ky ik of ekctvees monteyTo nd , must sengthen -eymaag-ete-ba nd m ain, suev al "- n- .o sumutheOympcsecuiy cont

26、rol ahigher ev> hig he sa.a - a hg he eveof.-e ua ca end- on Deem be a tme>f .we.e ay gee. c - ry he a xxpowe genera-maUe a nd .mmey breathi ng.Reli ngpas -I>g, - a and fU nce Unit-, - more -dig fgtmoe s.t>.Emplyes, _ ustge he ac oss .3 UI of. nges a tcrae a gee, l owcs -e of aw o-po-we

27、geneainad wrkha d Te Fest my -nee - ta ya Wewillcontinue toimprnesspcaronmcootnetr polroinblecmontr ol;一 .1. _.11.nsur ethe busincial ,and coa lelectri clinkage, a nd e nergy-savingschetoconti nue s tostre ngtheni ng"four good" leadershi p construction,full playlev els ca dres ine nterpri

28、se devel opme ntin thereasonsanaly sisand systemhaL .L - .一 一 .to close concern finaovethe compa ny's inter nalcontrolsy- L-.- - IIIndover; to stre - I - LIngtheoyeesapplication i-I. .1- L - .>bilitiesinpla ce;tofurt-I. - -d;toim plementation State-ownec careto e nsure "zero."herstr

29、engt hen i nternalcontrTo strengtheningnywind clear,a- 一 - -chieve drisk recognition,andmean complyingwit h third -party responsi bility;toa ctively make use ofinternala udit tools detectpotentialmanagement, streamline,standardizerelated transactions, strengthe ning operati ons i n accondgas are ,an

30、d heartShun ofcultureatm osphere; strengthe ning l ove hel ped tra ppe d,care difficult empl oyees; carried outstyle a ctivities,ri ch empl oyees life;stre ngthening health a nd la bourprotesure, a nda ssessment, and report,and controlfeedbackofcl osedri ngmanageme nt,improverisk preventi on capacit

31、y.ofurtherstandar dizetradi ng,andstrive to achieve"according to lanttoensurefullw,standardieragainst;communicati on "zero resistance".ntation psychologi calwarntialemployee s "zerofly".To constantly perfect ERPning prev entionsystem,traini ng employeostrengthe n performance

32、 management,pres hea lth ofcharacter,and stablendM IS,andSCM,i. .1.1|_ . _|on informatichieveocess control ,enhanceempl oyeeevaluati onand level s ofeffective communicationto imy oprouvmeapneitrfioesrmeancemanagdeinmfenonvritm.roantimonenrte.sTooursctreeonfgutrtdaily r un mainte nance operation ofre

33、cords, _L I - - - -II. I. 摆线齿轮表面粗糙度为Ra1.6,无毛刺、划痕、裂纹等缺陷。 摆线齿轮内孔与轴承配合间隙为0.05mm ，极限间隙为0.10mm 。 摆线齿轮齿面磨损极限值为0.05mm. 摆线齿轮轴向间隙为 0.20.25mm。 两摆线轮要按标记准确装配。0 针齿套、针齿销不得有毛刺、裂纹、伤痕等缺陷，表面粗糙度为Ra0.8。1 针齿轮与针齿套的使用标准间隙为0.075-0.085mm ， 极限间隙为0.13mm。2 销轴、销套应无毛刺、裂纹、伤痕

34、等缺陷，表面粗糙度为Ra0.8。3 销轴与销套的圆柱度允许公差值为0.005-0.009mm ， 极限公差值为0.014mm 。4 偏心套应无毛刺、伤痕、 裂纹等缺陷，表面粗糙度为Ra0.8。5 偏心套内径与外径的圆柱度公差值为0.015 mmo5.2.4 骨架油封：所有密封处的骨架油封全部更换。5.2.5 试车与验收 试车前准备。 审查检修记录，确认检修质量合格。 盘车检查无卡涩和异常声音，刮板固定牢固。 润滑油符合要求，附件齐全好用。f backboneba ckbonerol e;to fu

35、llstre ngthe ning member s yout h work,full play yout h empl oyees in companydevel opme nt inthe offorcerole ;toimprove i ndepe ndentCommissionagainstcorruptionworklevel,strengthe ning onenterprisebusine ss keylink ofeffectiveness monitored.,And maintain stability. To furtherstre ngthe npublicitya n

36、d education,improvethe overalllegalsystem.We muststrengthensafety management, establish a ndim provethe e ducation, supervi sion, andevaluati on as one ofthetrafficsafety managementmechanism.o conscie ntiouslysum up theOlympicsecurity control s, pr omoting i ntegrated managementtoahigher level,hig h

37、erstandards,a hig herlevel of devel opme nt.Empl oyees,today islunarcal endaron Decem ber24,t he ox Bellis aboutto ri ng,atthis time ofyear,wecle arlyfeelthe pulse oftheXXpowergenerationcompany t oflouri sh, to more clearlyhe arXX powergenerati oncompa nies mature a nd symmetrybreathi ng. Recalli ng

38、 pastonea nother acrossa raili ng,we aree nthusiastica ndful lofconfide nce.Futuredevelopmentopportunities,wemoreex citingfight more spirited.Employees,letustoget heracr oss2013 fullofchalle ngesand opportunities, tocreate agreen,l ow-cost operati on,full ofhumanecare ofaw orld -class powergeneratio

39、ncompa nyand work har d!The occasion ofthe S pring Festival,mysincere wishthatyou andthefamiliesofthestaff inthe newyea r, good he alth, happy,happyt cloe cnner ia5.2.6 试车。 空负荷试车，检查刮板的运行情况，应无偏斜现象，运转平稳。 各联接、紧固件有无松动。 检查轴承温度，滚动轴承温度不大于 70 Co 运行平稳，不得有冲击、振动和异常响声，电流不超过额定值。振动值符合S

40、HS01003 2004石油化工旋转机械振动标准5.2.7 验收。 池内进水后，各项性能指标达到技术要求或能满足生产需要。 设备状况达到完好标准。 检修记录齐全、准确。按规定办理验收手续。5.3 现场布置本次大修的格栅机位于雨水提升污水池西侧。We wl coniue to mpr. . ss.d ss-haL . L - . . . r . -.'ys ie " f.L . I L .一n- . "bingte . ing . , ad ERP, ad S”，tchnolg, .pliaic 1che ngteig t k

41、aooe - appiain i I. L _ _ bi*e. in pla ce tfurtd；t m plementaton Staeowec .to e nnue "zeo."he Segt hei tTo -eVny wndr .chi- d rik ecgniin, ad m 一f ain complyig wi h- paty esonsi b lty to a ctv- male uue I f itena a .itoocea- aat Shu help.-. .s_et and reort and cntrl ffeidaik of c os

42、d ri ng mang-eca-d ou syeactv.s- ch -pl ooe - le se. ouon caaiyI fute sanda die tadhhata icin, ogai 'tin caeent to ensue fult seng"ladesip cnsucin, ulay levw, .tana.ie 2 s；cmmunicai I n "zeo sac".o _nS.h peec es - d - i e ne"- aton ppycolg ca wa n.l-plo.e"，, , 一g - ploe

43、n pefmane management prnd M * adOn . stm bae. . .-hea ofc be. 一 . . L .- I . . . .一of mood aon ifcheve -pl ooee evauaion a d l s of elec cmmuncaton to iyo.Fncema户：. -a.""- a-1 l . .一he r - m”-etenform ain s S- one. . . . . -her - nt. a.reie - plheed busi nes e.r - of A_t role t p»-L .

44、 . . I a" adm_b_ il busie - bus opeainof ecds pans cvert.l - le ne ca cntrol污水池格栅机污水池格栅机格栅机6、HSE管理6.1 HSE管理理念6.2 HSE管理目标中石化公司的HSE目标是：追求最大限度的不发生事故、不损害人身健康、不破坏环境，创国际一流的HSE业绩5.4 工作危险性分析（JHA）报 ulply-pl oyes i cmpay roe；t mpr. i busie-ik of e.ci-es monioe saii"To u ahen -eymang-ete -bis a nd m

45、in, ev n - meymang-etmecanim.o -u te Oyhge evl highe sadars, a hghe eve of deve toays Una caenda onDecm be a .e f rwe.ealy geeat c- he a XX po-we -neatismatue and .mmey brrating Recal ng p -one a nother acoss a alg, - a and fu nce unit-,-more -ciig fgtmoe siitd.Employes, le us tgehe ac oss 20 3 Ul o

46、f UHeUte, te a gee, locs fl .e of awo- ca - po geneainadwrkha d Ie 序号施工活动潜在危险严重性可能性风险性具体控制措施备注1工作区域现场气体不合格224化验分析气体2检修准备劳保用品穿戴不足224工作前检查佩戴安全带224工作前检查违反“四不开工”248工作前检查3设备解体绳扣捆扎不结实236专人监护加强责任心扳手滑动224加强责任心4设备清理清洗清理锈蚀使用磨光机326戴口罩、防护眼镜地表油污236监督机件清洗剂乱倒236监督5设备测量、组装轴承加热224加强责任心各种量具使用方法不对224加强责任心6施工结束施工现场打扫22

47、4加强责任心5.5 安全管理、安全措施5.5.1 由安全组织网络人员对施工进行风险评价和危害分析，包括工作危害分析表JHA、安全检查表SCL及环境因素识别评价表。组织 对施工人员进行HSE安全制度的教育和具体施工的安全教育。5.5.2 参检人员在进入现场前，必须对自己施工所使用的工具、设备、 吊拉机具等进行认真的检查和准备，符合标准方可使用；现场环境 必须先进行化验，等化验分析报告合格后方可进入现场；5.5.3 所有施工人员进入施工现场，必须按规定着装，穿戴好个人防We wl coniue to mpreasns .一 . ss-haL . L - . . . r . -.'ys ie " f.L . I L .一ndve； l_e. L .nc- . a c 一heooe - appi I. L _ _ bi*e. in pla ce tfurtd;l m plementalon Slaeowec .ae to e nnue "zeo."he Segt hei tTo -eVny wnd Cea aat ShuChie-d e.gniin, ad m 一y ta civ- make uue I f itena a .itoosphee -eV help.da. of. c - d ou syea clvi