1、檢修項目編號:中國石化青島煉油化工有限責任公司公用工程雨水提升格柵機檢修方案編 制：盛魯核:準:青島石化檢安公司2011年6月29日青島煉化公司施工方案會簽表: 01青島石化檢安公司大修編號：W 公-2011-qj35檢修名稱格柵機檢修合同編號致 青島煉化公用工程單元、HSE部、機動工程部：我單位已完成了公用工程雨水提升格柵機的檢修施工方案編制工作,并經我公司上級技術負責人審核批準。請予以審查。附件：1 .格柵機檢修施工方案2 .格柵機檢修施工計劃表3 .相關附圖技術經理:日期：單兀審查意見：單 元 主管：日期：HSE部審查意見：HSE部主管：日期機動工程部審查意見：機動工程部專業工程師：日期

2、：備注：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 、檢修設備概況2、編制依據3、施工組織結構4、施工準備5、施工方案6、 HSE 管理7、清潔生產8、施工進度計劃網絡圖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、檢修設備概況本設備為雨水提升格柵機（1152-GR101/102/103共3臺），型 號：GH1900。設備

13、日常運行主要問題：鏈條經常脫落，刮板、鏈輪 等部件容易變形。本次檢修主要解決以上問題。施工區域為公用工程雨水提升泵站污水池西側格柵機。具體檢修工作量：1、檢查各部連接螺栓；2、檢查傳動鏈條、 鏈輪，視情況更換；3、檢查清理格柵；4、檢查主從動軸承，視情 況更換；5、解體檢查減速機；6、回裝檢查對中；7、試運。經審批后的本方案只作為此次檢修首要規范2、編制依據2.1 石油化工設備維護檢修規程（2004年12月第2版）2.2 SY 21024-73煉油廠減速機維護檢修規程2.3 SH3505-1999石油化工施工安全技術規程2.4 JGJ46-2005施工現場臨時用電安全技術規范2.5 Q/SHS

14、0001.1-2001中國石油化工集團公司安全、環境與健康（HSE）管理體系2.6 設備安裝的吊運、防腐保溫等專業的施工均應按相應的方案和 專業規范執行。3、施工組織結構4、施工準備4.1、 員準備序號姓名性別年齡工種級別持證情況1孫士春男27鉗工、工程師2王希船男39鉗工、技師技師證、高級鉗工證3孔德山男26鉗工、高級工高級鉗工證4王祥新男36鉗工、高級工高級鉗工證5吳威海男23鉗工、高級工高級鉗工證6王振江男26鉗工、高級工高級鉗工證7盛魯男25機械專業技術員8范會祥男23鉗工、高級工高級鉗工證9童耀陽男24焊工、高級工高級焊工證4.2、 工機具準備序號名稱型號數量安全檢查情況備注1角向磨

15、光機S1M-FF-100A2件安全檢查合格2活扳手5套安全檢查合格3梅花、叉口各5套安全檢查合格4內六角扳手5套安全檢查合格5手錘、螺絲刀各5套安全檢查合格6手拉葫蘆1t、2t各1件安全檢查合格7手鋸、鑿子各10件安全檢查合格8拆卸扒子3件安全檢查合格9游標卡尺0-150, 0-300,0-5005件2件2件安全檢查合格10深度游標卡尺0-2502件安全檢查合格11塞尺3套安全檢查合格4.3、 材料準備情況目前這3臺格柵機大修所需要的鏈條及傳動銷組件已提報計劃采購部正在購買，減速機中的部分常用易損件（軸承、骨架油封）青島煉化倉庫有些庫存，其中施工過程中用到的輔材已全部到位，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：耐油橡膠板、石棉板、塑料布、棉紗、面粉、塑料袋、砂布、水磨砂紙、鋸條、硅橡膠平面密封膠、青稞紙、生料帶、鉛粉、煤油、松動劑、清洗劑等。5、施工方案5.1 施工方案5.1.1 施工工序 拆卸前準備.1 開工前先簽安全作業票。.2 檢查變速機運行狀況及存在的問題，備齊資料。5.1.

23、1.1.3 備齊檢修工具、配件、材料等。.4 切斷電源及附件，放凈機內潤滑油，符合設備檢修條件。 拆卸與檢查.1 將減速機拆卸下來。.2 將傳動軸、刮板、鏈輪、軸承座、及支撐架拆下。.3 檢查減速箱內有無缺陷和損壞，測量檢查減速箱骨架油封磨損情況。.4 清洗減速箱內油垢及雜物，檢查齒輪盤、滾針的磨損情況，及嚙合情況。.5 檢查軸承，測量、調整間隙。.6 檢查更換骨架油封。5.1.2 施工難點本次大修的格柵機外形尺寸大，鏈條安裝困難，必要時可將機體吊起5.2 質量控制5.2.1 傳動機

24、構 將鏈條刮板及連接柱拆下整型。 拆卸減速機及傳動鏈條16A,保證相互連接的鏈輪在同一平 面上。5.2.2 軸承 拆卸軸承應用專用工具，嚴禁直接敲打。 滾動軸承內外圈滾道、滾動體表面應無腐蝕、坑疤與斑點。接觸平滑，滾動無雜音。 滾動軸承內圈必須緊貼軸肩或定位環，用 0.05mm塞尺檢查 不得通過。 軸承內徑與軸的配合為H7/js6 ,外徑與軸承座的配合為J7/h6。5.2.3 行星擺線針輪 針齒殼的針齒銷孔直徑允許磨損的公差標準為 0.016-0.019mm , 磨損極限為 0.030mm。5.2

25、.3.2 針齒銷孔圓心對針齒殼中心圓跳動公差值為0.030mm。 針齒銷孔應均勻分布，兩相鄰孔距允許最大偏差為0.05mm。 針齒殼兩端面的針齒銷孔同軸度公差值為0.03mm ,針齒銷孔軸心線對針齒殼兩端面垂直度公差值為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. 擺線齒輪表面粗糙度為Ra1.6,無毛刺、劃痕、裂紋等缺陷。 擺線齒輪內孔與軸承配合間隙為0.05mm ，極限間隙為0.10mm 。 擺線齒輪齒面磨損極限值為0.05mm. 擺線齒輪軸向間隙為 0.20.25mm。 兩擺線輪要按標記準確裝配。0 針齒套、針齒銷不得有毛刺、裂紋、傷痕等缺陷，表面粗糙度為Ra0.8。1 針齒輪與針齒套的使用標準間隙為0.075-0.085mm ， 極限間隙為0.13mm。2 銷軸、銷套應無毛刺、裂紋、傷痕

34、等缺陷，表面粗糙度為Ra0.8。3 銷軸與銷套的圓柱度允許公差值為0.005-0.009mm ， 極限公差值為0.014mm 。4 偏心套應無毛刺、傷痕、 裂紋等缺陷，表面粗糙度為Ra0.8。5 偏心套內徑與外徑的圓柱度公差值為0.015 mmo5.2.4 骨架油封：所有密封處的骨架油封全部更換。5.2.5 試車與驗收 試車前準備。 審查檢修記錄，確認檢修質量合格。 盤車檢查無卡澀和異常聲音，刮板固定牢固。 潤滑油符合要求，附件齊全好用。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 試車。 空負荷試車，檢查刮板的運行情況，應無偏斜現象，運轉平穩。 各聯接、緊固件有無松動。 檢查軸承溫度，滾動軸承溫度不大于 70 Co 運行平穩，不得有沖擊、振動和異常響聲，電流不超過額定值。振動值符合S

40、HS01003 2004石油化工旋轉機械振動標準5.2.7 驗收。 池內進水后，各項性能指標達到技術要求或能滿足生產需要。 設備狀況達到完好標準。 檢修記錄齊全、準確。按規定辦理驗收手續。5.3 現場布置本次大修的格柵機位于雨水提升污水池西側。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戶：. -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污水池格柵機污水池格柵機格柵機6、HSE管理6.1 HSE管理理念6.2 HSE管理目標中石化公司的HSE目標是：追求最大限度的不發生事故、不損害人身健康、不破壞環境，創國際一流的HSE業績5.4 工作危險性分析（JHA）報 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 序號施工活動潛在危險嚴重性可能性風險性具體控制措施備注1工作區域現場氣體不合格224化驗分析氣體2檢修準備勞保用品穿戴不足224工作前檢查佩戴安全帶224工作前檢查違反“四不開工”248工作前檢查3設備解體繩扣捆扎不結實236專人監護加強責任心扳手滑動224加強責任心4設備清理清洗清理銹蝕使用磨光機326戴口罩、防護眼鏡地表油污236監督機件清洗劑亂倒236監督5設備測量、組裝軸承加熱224加強責任心各種量具使用方法不對224加強責任心6施工結束施工現場打掃22

47、4加強責任心5.5 安全管理、安全措施5.5.1 由安全組織網絡人員對施工進行風險評價和危害分析，包括工作危害分析表JHA、安全檢查表SCL及環境因素識別評價表。組織 對施工人員進行HSE安全制度的教育和具體施工的安全教育。5.5.2 參檢人員在進入現場前，必須對自己施工所使用的工具、設備、 吊拉機具等進行認真的檢查和準備，符合標準方可使用；現場環境 必須先進行化驗，等化驗分析報告合格后方可進入現場；5.5.3 所有施工人員進入施工現場，必須按規定著裝，穿戴好個人防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