1、 第 9 頁 共 9 頁 煉油廠柴油加氫裝置螺紋鎖緊環換熱器(E101、E103)檢修施工技術方案煉油廠柴油加氫裝置螺紋瑣緊環換熱器(E101、E103)檢修施工技術方案一. 檢修情況1. 煉油廠2008年度春季檢修，我公司負責柴油加氫裝置2臺螺紋鎖緊環換熱器（E-101 、E-103）的檢修。2. 檢修工期：2008年5 月 10日至2008年 5月26 日3. 檢修內容：2臺換熱器均進行抽芯子檢查、墊片更換、試壓等。詳見附表1。二.編制依據1. 建安工程管理部下達的施工任務單和工程管理部下達的“設備制造公司2008年承擔東煉高壓換熱器檢修計劃”；2. 2臺換熱器設計施工圖：3. 現場看活；

2、4. 有關會議紀要等。三. 任務劃分1. 燕華設備制造公司二鉚車間負責E-101、E-103螺紋鎖緊環換熱器的檢修；2燕華設備制造公司一加工車間負責損壞螺栓制作、隔板密封條鉆孔等工作； 3燕華建安綜合隊負責現場搭架子工作； 4燕華建安機施公司負責吊車、卡車工作。四. 施工準備1. 熟悉換熱器的結構，現場查看施工場地，策劃各種工具、拆卸件的擺放位置。2. 熟悉各鎖緊環工裝，并進行試組裝、軸承處注油，試盤車靈活等。3. 待裝置停車并經煉油廠同意后，可向鎖緊環注油潤滑，內外圈壓緊螺栓處噴松動劑。4. 經煉油廠同意后，通知架子隊，在每臺換熱器前面搭好48米的腳手架平臺，平臺與鎖緊環下部平齊，腳手架平臺

3、必須牢固，能夠承受10噸以上的載荷。5. 由于E-101、E-103管束均重達15.8噸以上。因此抽芯機必須預先進行加固。加固方案另行確定。6. 工機具準備如下表：名 稱型 號規 格數 量備 注特制扳手特制M30（3034.6）6導鏈10T、5T、2T各2面包車解放10座2卡車斯太爾17T1運送工裝、抽芯機、道木等汽車吊車16T10臺班輔助50T吊車工作汽車吊雙鉤50T20臺班（2臺）必須用提升力顯示準確、并且受力狀態下提升力穩定不變的吊車抽芯機自制2工具棚自制2電焊機1氣焊工具1套氬弧焊機1備用鎖緊環工裝1套吊環螺釘M20806套供應-8力矩扳手700KN1件拋光砂輪10個金相砂紙100張試

4、壓閥門6個、壓力表6塊（0-20Mpa）、試壓管線、壓力表接頭等7. 材料準備，見附表1。8. 人員配備按下表：工 種人 數備 注鉚工10起重8電氣焊2氬弧焊1鉗工4力工10司機2汽車吊司機2施工管理2五. 主要施工方法1. 柴油加氫2臺換熱器的關鍵施工部位（如拆卸、安裝各鎖緊環）采用流水作業的方法進行施工，即均由熟練人員流水拆卸、安裝、提高勞動效率；2. 柴油加氫2臺換熱器的非關鍵部位則采用同時拆卸、安裝的方法進施工；3. 柴油加氫2臺換熱器均用50噸汽車吊吊住專用工裝拆卸鎖緊環、管程套筒等各件，配重適時進行增減；4. 拆卸、安裝管束采用2臺50噸汽車吊配合的方法進行；5. 由于每臺設備內件

5、較多，全部為精密加工件，拆卸后必須設專門的場地整齊擺放，并有專人看管，以免丟失。注：50噸汽車吊必須是提升力顯示準確、并且受力狀態下提升力穩定不變的吊車。六. 施工步驟 拆卸1. 拆卸施工必須待裝置停車、置換，經測試具備施工條件，并得到煉油廠有關主管人員同意后方可進行。2先松開鎖緊環上的內圈壓緊螺栓， 再松開外圈螺栓，確信兩圈螺栓不再壓緊密封盤即可，不用卸掉。3. 將內外圈固定壓圈螺栓擰緊。4. 將8條長螺栓一端固定在壓蓋上。5. 將工裝安裝到鎖緊環上。用10噸導鏈配合50噸汽車吊將工裝吊起，調整配重，找好水平。用螺栓將工裝與鎖緊環固定，同時固定壓蓋上的8條螺栓。拆卸時工裝應平穩轉動，并隨時保

6、持平衡。如遇卡澀等卸不動現象，除重新找好水平找正外，還可以嘗試將工裝反轉后，調整位置再正轉。在平穩轉動時記下吊車的提升力，以后轉不動時以此為依據再找正。待鎖緊環接近旋出時，注意工裝與螺紋鎖緊環的平衡。6. 鎖緊環卸掉后應由鉗工對內外螺紋進行清理檢查，對安裝時形成的咬扣部分進行處理。先用拋光砂輪，后用金相砂紙打磨至符合要求。無缺陷后涂防高溫咬合劑，再用塑料薄膜保護以防現場灰塵等雜物影響螺紋表面質量。 7. 卸掉鎖緊環后，將螺紋保護套裝好。8. 繼續拆卸內件。按以下順序進行：密封盤（用工裝）外密封墊圈支架（用工裝）壓環（用工裝）頂壓螺栓卡環管程內套筒壓蓋（用工裝）拆卸管程內套筒與管板連接螺栓管程內

7、套筒（用工裝） 管束（用抽芯機）9. 抽管束前測量并記錄管板距殼體端面的距離。10. 拆卸內套筒和管束時卡環槽內應墊墊板（一加工車制）。11. 抽管束時需用兩臺50噸吊車，分別停在換熱器兩側。其中一臺將抽芯機吊起，抽芯機前端頂在換熱器端部，再用兩個2噸導鏈固定在支座上。繩扣栓在管板上的四個吊環螺釘上。管板離開換熱器管箱端部后，繼續抽出1米后，用另一50噸汽車吊主鉤上的一根繩子（主鉤上應掛兩根繩子）吊著管束前端，繩子與管束接觸部分墊置1501502000mm的枕木，繼續緩慢將管束全部抽出，管束全部離開殼體前用主鉤上的另一根繩子加枕木和10噸導鏈配合吊著管束的后部，將管束與抽芯機用兩個2噸導鏈封牢

8、固，兩吊車配合到至地面上。12由煉油廠安排清洗管束。13. 仔細檢查拆卸后的各零部件。14. 殼程隔板密封條更換 鎖緊環換熱器現場拆出后，更換隔板密封條。密封條由煉廠提供，設備制造公司一加工車間負責鉆孔。 密封條上壓板由二鉚車間拆下，送一加工，由一加工車間按壓板上孔的位置配做密封條上的光孔。密封條由10層組成，每層0.1mm厚，40mm寬，總長約6m，每臺共換兩處（總長12m）。 密封條整條制作，不得分段。 一加工做專用工裝進行打孔。 回裝1. 待各項檢測合格，并經煉油廠相關單位確認合格后即可將管束回裝。回裝前將波齒密封墊套在管板后側密封面處，可涂膠與管板粘牢。回裝時仍用兩臺50噸吊車配合進行

9、。管束裝進殼體后，按前面測量的管板距殼體端面的距離確定管束是否回裝到位。2. 用工裝回裝管程內套筒、卡環等。管程內套筒就位后安裝好與管程進口之間的石墨盤根、壓緊、點焊。3. 卡環及頂壓螺栓（螺紋涂防高溫咬合劑）安裝后殼程即進行1.1Mpa的氣密試壓。在試驗壓力下保持1小時，表壓不掉壓，管頭無泄露，管板與殼體間隙無泄漏為合格。若管頭有泄漏用A132焊條進行補焊，若換熱管泄漏則堵塞不銹鋼楔子，換熱管規格為內部5排19*2.5，其余為19*2。4. 試壓合格后組裝壓環、支架。5. 拆掉螺紋保護套。6. 清理、修研殼體內螺紋，螺紋涂防高溫咬合劑。7. 安裝外密封墊圈、密封盤。外密封墊圈用膠與殼體粘牢。

10、密封盤與外密封墊圈粘牢。8. 回裝鎖緊環，注意測量回裝是否到位。必須先松開內、外固定壓圈螺栓后再擰緊外圈壓緊螺栓，內圈壓緊螺栓在確定與密封盤接觸后在倒退三扣。內外壓緊螺栓均涂防高溫咬合劑予以保護。9. 用液壓扳手進行壓緊螺栓對稱的緊固，用力盡量平均，每個壓緊螺栓壓緊量盡可能一致。直至達到圖紙要求的力矩為止。 試壓1.先將管程下管口用試壓盲板緊固，八角墊片用舊墊；2. 通過管程上管口灌水，水溫應不低于15，然后封上管口，緊固、安裝試壓管線，用厚壁管線保證試壓對管線的安全；安裝兩處壓力表，其量程在8.0Mpa以上，并經校驗合格，精度1.5級以上；擺好試壓泵位置，應用高壓試壓泵。3. 各部位檢查合格

11、后，開始試壓，緩慢升至試驗壓力（試驗壓力待定），檢查嚴密性。合格后通知各方檢查，檢查通過后開始降壓。4. 全部檢查合格后緩慢泄壓，將水放掉，拆掉盲板。5. 試壓合格后清理現場，保留腳手架，現場裝置聯合試壓時，現場保運。七. 施工安全注意事項 嚴格執行燕化公司、煉油廠及建安公司有關現場施工的各項安全管理規定； 進入現場必須穿工作服、配戴安全帽，高空作業必須系好安全帶； 對調盲板的管線下方不得有任何人停留或行走； 拆卸鎖緊環及抽管束的腳手架搭建的平臺必須牢固可靠； 吊裝所用繩索、導鏈等施工用具必須檢查可靠后方可使用； 各種車輛均不得占用消防通道； 液壓扳手、抽芯機、焊機用電及夜班施工照明用電等各用

12、電部位接線應牢靠，并有防雨、防雷電設施； 現場應文明施工，堅持工完、料凈、場地清； 遇有突發事件服從煉油廠有關部門的統一領導和指揮。附表1 檢修內容及更換材料清單（E-101）序號名 稱數 量材 料備 注1波齒復合墊片1甲供-82盤根（一）2石墨纖維編制繩甲供-83半圓墊片1膨脹石墨墊片 甲供-84盤根（二）2金屬包石墨纖維編制繩甲供-85密封條20.1*10 HAYNES-25-ALLOY甲供-3-86密封帶10米16膨脹石墨纖維繩甲供-87密封膠3Kg甲供-88防高溫咬合劑12Kg甲供-89試壓盲板4750 =185 Q235-A 見圖0-3-810卡環槽墊板2Q2350-3-811吊環螺

13、釘M204Q235供應-812螺栓4M27*50 35 GB/T5782-2000供應-813螺栓16M30*3*100 35 GB/T5782-2000供應-814螺母16M30*3 35 GB/T6170-2000供應-815雙頭螺柱8M20*350 35 見圖供應-8附表2 檢修內容及更換材料清單（E-103）序號名 稱數 量材 料備 注1波齒復合墊片1甲供-82盤根（一）2石墨纖維編制繩甲供-83半圓墊片1膨脹石墨墊片 甲供-84盤根（二）2金屬包石墨纖維編制繩甲供-85密封條20.1*10 HAYNES-25-ALLOY甲供-3-86密封帶10米16膨脹石墨纖維繩甲供-87密封膠3K

14、g甲供-88防高溫咬合劑12Kg甲供-89試壓盲板4750 =185 Q235-A 見圖0-3-810卡環槽墊板2Q2350-3-811吊環螺釘M204Q235供應-812螺栓4M27*50 35 GB/T5782-2000供應-813螺栓16M30*3*100 35 GB/T5782-2000供應-814螺母16M30*3 35 GB/T6170-2000供應-815雙頭螺柱8M20*350 35 見圖供應-8附表3 組織機構人員名單管理職責姓 名單 位聯系方式項目經理檢修指揮負責人王傳志設備制造公司69341636質量技術負責人檢修協調負責人施工技術負責人馮玉慶生產工藝室69343116-

15、3158施工質量負責人韓寶玲質量檢查室69341798施工調度王書坡生產工藝室69342964施工車間負責人曾春平二鉚車間13701175256施工車間負責人姜建偉一加工69341786安全盧宏生產工藝室69343116-3187Opinions and suggestions on the partys mass line educational practiceAccording to the central and provincial, municipal unified deployment, according to municipal Party committee about

16、carrying out the partys mass line educational practice activity in the citys implementation opinions, the spirit of the partys mass line educational practice activities from 20* in January to 99 months, carried out at all levels of departments and directly affiliated institutions and grass-roots par

17、ty organizations. According to my actual County, the county to carry out the education practice put forward the following implementation opinions.First, the overall requirementsCounty county education practice to the eighteen Party of eight, the spirit of the the third Plenary Session of the 18th CP

18、C Central Committee as the guidance, conscientiously implement the spirit of general secretary Xi Jinping book series of important speech, earnestly implement the Central Committee really, opinions and advice , party implementing the guiding ideology of opinions to determine the objectives and requi

19、rements, step method, in accordance with the look in the mirror, dress up, wash bath, cure treatment, the general requirements of for the people pragmatic honest people as the theme, in carrying forward the spirit of Zhuanglang Zhuang, improve their work style, service to the masses of the people, t

20、he foundation of consolidating grassroots, promote transformation across efforts, to further implement the central eight regulations and The opposition party and government austerity waste regulations , double section provincial regulations, municipal provisions of the twelve plan and the implementa

21、tion measures for on improving the work style of close ties with the masses law, highlight style building, carry out the whole wind spirit, resolutely oppose formalism, bureaucracy, hedonism and wasteful extravagance to solve the problems, Party members and cadres of the style and the masses of peop

22、le strong, the Ministry of Party members and cadres to further improve their thinking and understanding, to further change the style of the wind, the masses to close, honest and pragmatic people honest image to further establish the foundation to further reinforce the basic level. Style of the build

23、ing of the new results to promote the construction of a powerful force of the county and the ecological culture of the county and county construction.In educational practice activities of the unit is mainly: the county and below county departments under the organs, enterprises and institutions direc

24、tly under the township, street, and community, village, non-public economic organizations, social organizations and other grass-roots organizations. Agencies and branches, each single unit, follow the rules on internal institutions. Educational practice with step by step.To adhere to the county lead

25、ership, leadership and leading cadres to focus on outstanding catch to directly contact the service of the masses of law supervision departments and window units, service industry, educational practice, pay attention to grasp the heavy towns, streets and villages, community education activities and

26、the masses of grassroots groups in close contact to strengthen, and the majority of Party members, cadres and the mass line line Marx doctrine view of the masses and the partys education.Always speak seriously as a basic attitude, adhere to positive education, to carry out criticism and self critici

27、sm group, adhere to the pragmatic, more emphasis on leadership, pay more attention to the layers of the demonstration, more focus on the four winds, solve the problem, pay more attention to open the door, the participation of the masses, pay more attention to the classification guidance. Orderly, pa

28、y more attention to the cooperation and cohesion driven, more strict requirements on injection, really supervision practice, ensure education practice is not empty is not empty is not partial, not as a mere formality.Two, the key point of the taskThe main task of the countys education practice is to

29、 seize against four wind this focus on centralized solve outstanding problems asked County, township leadership and leading cadres of the four winds, the disadvantages of the style, scale behavior to a large scale investigation, overhaul, cleaning greatly. At the same time, respond to the concerns o

30、f the masses, safeguard the interests of the masses, pay attention to solve practical problems, solve the people around the unwholesome tendencies especially on eat, take the card, Yong lazy luxury, extravagance and waste fees, privileges and other issues, timely and effective, without any discount

31、to solve, to improve the style of real implementation of the requirements of real to the grassroots, real let group Benefit the public.(a) focus on solving the four winds outstanding issuesThe central and provincial requirements, the county leadership and leading cadres of key performance concept is

32、 not correct, do not dare to play, to engage in image project, political project, a leadership guide, a set of ideas, orders and prohibitions, and a policy, there are countermeasures county. The units directly under the heavy focus on solving Yung lazy drag, buck passing skin, work is not implemente

33、d, the service is not active. The dynamic problem of law enforcement and supervision departments and window units, service industry mainly solve the door hard, ugly face, something difficult, and arbitrary charges, fines, levies, and breach of privilege, chinakayao, not the problem of law. The towns

34、hip, street The collar of leading bodies and leading cadres to solve key does nottheir own conditions to develop the correct road, the maximum to avoid investment risk, gain profit.(three) vigorously promote the brand. To establish brand awareness, awareness of the use of brand, brand value, brand a

35、cquisition performance, enhance the competitive strength. Concentrated manpower, careful planning, packaging and publicity of a number of unique, market influence and coverage of the brand, the implementation of key breakthroughs, to enhance the competitive strength, walking business road the compet

36、ition of alienation and characteristics, the pursuit of stability and development of the market.(four) to promote the integration of resources. To further broaden their horizons, effective integration of resources within the group, the city resources, other industries and regional resources, mutual

37、trust, mutual benefit, seeking win-win principle, in the framework of national policies and regulations, strict inspection and argumentation, legal consultation, examination and approval procedures, strict regulation of economic activities, attract injection the social investment to the industry gro

38、up, to achieve leveraging the development, ensure that the value of state-owned assets.(five) to strengthen the construction management personnel. Strengthen the management of education and training of cadres and workers of the existing business, firmly establish the concept of the market, enhance t

39、he sense of crisis to adapt to market competition, the sense of urgency, improve the ability to respond to market competition, improve management and operation of the market. At the same time, according to the need of industrial development, vigorously the introduction of high-quality management man

40、agement personnel, and strive to build a high-quality professional management team, hard work, and promote the entire workforce knowledge structure, age structure, structure optimization and upgrading ability, enhance core competitiveness, adapt to the need of market competition.(six) seriously stud

41、y the policy for policy. Serious research about social support the development of cultural undertakings in the country and the XX policy, especially the policy of industrial development, financial investment policy, financial policy and tax policy, and actively seek policy, projects and funds, enterprise and industry group mission to promote leapfrog development.