热轧E1轧机更换操作侧齿轮轴施工方案.doc

热轧E1轧机更换操作側伞齿轮施工方案一、 编制目的 为了满足ISO9002-1994及顾客的要求，确保本次热轧E1轧机操作側齿轮轴更换能安全、优质、快速、低耗、文明地进行，特制定本施工方案以指导该工程的施工。二、 编制依据1 施工图纸；2 冶金设备检修质量技术标准；3 冶金设备安装质量检验评定标准；4 建筑安装质量检验评定标准；5 顾客的要求；6 作业环境；7 现有的工艺条件（包括装备和技术能力）等。三、 适用范围 本方案适用于攀钢热轧板厂粗轧机E1操作側齿轮轴更换施工工艺和准备。四、 前期准备1 技术准备：落实施工技术方案，开工前进行技术交底，要求明确施工安装质量要求，特别是对新设备作好检查记录；2 劳动力的准备：两个班组8对8，倒班不倒活，从准备工作到试车完毕。钳工16人，架工12人，电焊工4人，气焊工4人，电工4人，分队长2人，施工管理员2人，施工经理2人。3 施工机具准备工作：齿轮轴拖运用10吨黄河板车*2台班；倒运备品用汽车吊12吨*2台班，5吨汽车*6台班；预组装用汽车吊12吨*4台班；更换用汽车吊12吨*4台班。4 租用机动公司组装厂房和50吨桥吊配合进行备品备件的预组装四天。5 提前制作倒运现场和预组装用支架4个：560kg/个。6 提前制作倒运E1操作側主传动轴放置支架，960kg。7 提前制作倒运E1伞齿轮预装时进行压装用支架，986kg。8 提前制作E1主传动轴操作側轴承复位抓具，1568kg。9 从设备科租借内外千分尺，测量E1齿轮轴各装配部位的尺寸。10 提前制作大油锅和样棍。11 提前制作小齿轮放置架。五、 场地要求1 预组装场地：租借机动公司组装厂房四天，50吨桥吊配合。2 现场施工场地：R1后到E2前运输辊道南側地坪。六、 停机位置 側压装置要求开口度最小，将两个滑架停在最中间以便拆除立辊。七、 伞齿轮预组装1 用10吨黄河汽车和12吨汽车吊配合，从厂方将伞齿轮备品备件领出，倒运到修建公司机动工程公司组装厂房内，以备组装。2 用5吨汽车将轴承两套，上部轴承压盖及螺栓M30*80=8颗，下部轴上销键，下部轴承压盖及螺栓，全部领出，倒运到位。3 查阅热轧板厂档案图纸，将上下轴承配合部位，伞齿轮与下部轴配合部位，用精密测量仪测量，检查其数据，销键同时测量，硏磨处理轴与销键。4 制作一特大型油锅，用来加热伞齿轮和轴承，油锅的尺寸2米*2米*1米高，用钢板20作底板，其余用10钢板，底部另作一框架，用25b*2.5米*8根对接拼成。5 制作一简易小齿轮放置架,主要是在热装时,应先将小齿轮固定在架内,将加热后的伞齿轮吊装到小齿轮上安装好。放置架用32b制作，高800毫米，重约800kg。6 准备木材800kg和机油8000kg，在大油锅内加热伞齿轮，测量油温，加热约2小时后，用12吨汽车吊配合吊出（6台班），用预先准备好的样棍测量，检查确认已加热达到要求后，吊出找水平，用破布抹去油污，对准销孔进行安装，一定要注意到位。7 冷却后，加热轴承，分别安装轴承。8 试装轴承压盖和螺栓。9 倒运到现场准备好。八、 拆安吊装更换方案1 厂方抽出立辊；同时，安排施工班组进入现场，拆除油管和阀门，要求拿到休息室内放好，并要求专人负责。2 开工拿到停电票后，立即拆除主传动箱箱盖上的顶罩（768kg）一件，热后拆除连接套上与连杆上部万向接轴法兰连接的双头长螺栓14颗，对称留2颗螺栓不拆。3 拆除前，分别在左右传动轴连接法兰、左右箱体连接面上作好标示，以备安装和检查更换时用。4 拆除十字万向接轴：在百吨大钩上挂上钢丝绳（要求预先插好，现场实测绳长），从大齿轮中连接套内孔由上往下通过吊住十字万向接轴的吊环；在万向接轴的下半部系上钢丝绳，放下百吨小钩，从上箱体进口外部吊住这根钢丝绳；另外，在万向接轴的上半部系上另一根钢丝绳，设一台链式起重机在百吨小钩头与连杆上半部钢绳之间，用以调整连杆吊装时的角度。吊装示意图见图一所示。 拆除连接套上的两颗剩余螺栓，然后放下百吨大钩，使万向接轴整体下移，并通过改变链式起重机链子长度来调整吊装万向接轴的角度。当万向接轴上部完全落出主传动箱时，卸去百吨大钩钢绳，用小钩将十字万向接轴吊出放到指定地点放好。要求在地面铺设好塑料布（20kg）。5 打开伞齿轮上箱盖，检查确认伞齿轮轴与上盖压盖是否能连接在一起，吊装时是否会突然分离。如未松动，可将右箱体上盖整体带大齿轮和伞齿轮一起吊出；如发现有很松动现象，特别是压盖螺栓松动，应采取第二方案，先在整体吊起约30毫米高时就将伞齿轮用铜棒敲打，让其掉出，以防吊在空中后掉下而发生安全事故。6 拆除左右箱体连接处上部的大螺栓M90*6，下部不拆，主要是上部螺栓在吊装右箱体上盖时挡害。7 拆除右箱体上盖与箱体间连接螺栓M48*160/M48*220，拆除定位销40*180=2个。8 打开右箱体中部伞齿轮窥视孔，搭设E1内側十字万向接轴部位的脚手架，见图二，需准备材料：角钢75*8=1865kg，钢跳板10块，由于拆除和安装反复拆安搭设，故材料按2次摊销。9 挂设好右箱盖四角对称吊绳，见图三，两根钢绳挂10吨起重机调平衡，钢绳与箱盖间用绳具卸扣连接，吊装时用百吨大钩起吊，小钩在尾部伞齿轮盖上吊一钢绳以起平衡作用，主要是防止大齿轮的轴承摩擦力影响而使已找平衡的箱盖失去平衡。吊装时，要求在大齿轮和伞齿轮的窥视孔中密切观察，随时向上部指挥吊装人员报告，以确定吊装指挥和调试平衡状态。10 吊出上箱体后，应静止2分钟观察无误后， 指挥吊车吊到已摆放好的放置架上，伞齿轮端应设置枕木，在放置架地面应铺设塑料布（20kg），见图四。11 拆除后，应将伞齿轮与箱盖分离，进行伞齿轮的更换。同时，处理伞齿轮上部压盖螺栓和压盖，建议厂方更换旧压盖并改造。12 搭设E1操作側端头的脚手架，拆除端盖部位的油管，以便打开右水平传动轴的端盖，清洗检查右水平传动轴， 主要是检查有无轴承串位情况。脚手架搭设材料：14b*7米*4根，75*8*3米*9根，钢跳板6块，见图五。13清洗刮硏箱盖结合表面，包括机上和已吊走箱盖下部。13 找平设置吊装钢绳，准备吊装更换后的新设备。试吊检查新齿轮和轴承的啮合情况。如情况良好，则吊出约50毫米高，在箱盖结合面加抹乐泰密封胶，完后，放入密封。注意从大齿轮和伞齿轮的窥视孔中密切观察，同时要盘动水平轴配合伞齿轮安装。14 恢复安装定位销和螺栓，水平轴接手法兰连接，端盖；拆除内側脚手架，恢复安装十字万向接轴；恢复安装上盖和油管；拆除外側脚手架。15 通油试漏，试车检查，空转1小时。无误后，交付使用。九、 试车 完工后，通知厂方试车，留人配合。保产12小时。十、 施工网络图热轧E1轧机伞齿轮更换施工网络图施工工序一班二班三班四班五班六班拆十字万向接轴拆水平轴右端法兰-拆上盖及检查小齿轮是否松动拆右端上盖整体清洗检查水平轴清洗检查箱盖拆除伞齿轮更换伞齿轮组装伞齿轮找平吊绳试吊箱盖整体加乐泰胶密封安装拔紧螺栓连接水平轴法兰拆除脚手架吊安万向接轴恢复顶盖和油管给油空试1小时投产保产12小时热轧板厂E1轧机操作側伞齿轮更换安全措施（第一页） 为了确保热轧板厂E1轧机操作側伞齿轮更换施工安全、优质、按期、顺利完成，结合施工实际情况，特制定本安全措施，望各施工班组遵守执行。1 进入施工现场，必须穿戴好劳保用品；2 上高空作业，必须系好安全带，正确使用；3 现场作业，注意防滑、防火，搭设好安全脚手架，准备好灭火器材；4 开工前，应确认好卸荷减压，停电取票等必备手续；5 机架外側和内側的脚手架，应严格搭设好施工脚手架，并检查确认，注意双跳；6 吊装，指挥专人，确认钢绳，信号、手势明确，四周上下确认，严禁未经检查确认就指挥吊车而造成事故；7 上下多层交叉作业，要求及时监护，吊物下严禁有人；8 现场注意文明卫生，要求在现场堆放设备下垫好塑料布；9 严禁乱动与检修无关的设备、水、电、汽、开关、阀门；10 吊装时，指挥吊车人员必须穿好黄色背心；11 严禁从辊道上通过；12 现场及时清理倒运，保证人行道畅通；13 组装和更换，注意吊装配合，防止伤人；14 夜间施工，注意照明足够；15 加热煮轴承和伞齿轮时，要确保现场文明卫生和火灾事故发生，注意烫伤；16 开好班前会，当班确认和消除安全隐患；17 试车时，要求远离转动设备；注意高压水、油伤人；18 未尽事宜，按有关部门规定处理；热轧板厂E1轧机操作側伞齿轮更换安全措施（第二页）19 本工程安全负责人： 机械二公司：唐 斌 生 产 股：李小波 王以斌 二 队：尹志红 修建公司机械工程二公司 2001/4/9热轧板厂E1轧机操作側伞齿轮更换设备件清单1斜齿轮轴 1811.111.2.1.00*1件 上部轴径为420P6, 下部与伞齿轮配合处的轴径为450K6,下部轴承处轴径为400P6，齿数为32；2伞齿轮*1套 上孔为450H7，大端模数30毫米，齿数为46/37，大端分度圆直径1380/1110；3上部轴承为 *1套；4下部轴承为 *1套；5销键为 ，*1块；6上部压盖 *1块；7下端压盖 *1块；8上部压盖螺栓M * =8套；9下部呀盖螺栓M * =8套；请按此领取备品备件。 修建公司机械工程二公司 2001/4/859（英文版 ） Two regulations promulgated for implementation is in the party in power for a long time and the rule of law conditions, the implementation of comprehensive strictly strategic plan, implementation in accordance with the rules and discipline to manage the party, strengthen inner-party supervision of major initiatives. The two regulations supporting each other, the < code > adhere to a positive advocate, focusing on morality is of Party members and Party leading cadres can see, enough to get a high standard; < rule > around the party discipline, disciplinary ruler requirements, listed as "negative list, focusing on vertical gauge, draw the party organizations and Party members do not touch the" bottom line ". Here, the main from four square face two party rules of interpretation: the first part introduces two party Revised regulations the necessity and the revision process; the second part is the interpretation of the two fundamental principles of the revision of laws and regulations in the party; the third part introduces two party regulations modified the main changes and needs to grasp several key problems; the fourth part on how to grasp the implementation of the two regulations of the party. < code > and < Regulations > revised the necessity and revised history of the CPC Central Committee the amendment to the Chinese Communist Party members and leading cadres honest politics several guidelines > and < Chinese Communist Party discipline and Punishment Regulations > column 1 by 2015 to strengthen party laws and regulations focus. Two party regulations revision work lasted a Years, pooling the wisdom of the whole party, ideological consensus, draw historical experience, respect for the wisdom of our predecessors, which reflects the unity of inheritance and innovation; follow the correct direction, grasp the limited goals, adhere to the party's leadership, to solve the masses of the people reflect a focus on the problem. The new revision of the < code > and < rule >, reflects the party's 18 and the eighth session of the third, the spirit of the fourth plenary session, reflecting the experience of studying and implementing the General Secretary Xi Jinping series of important speech, reflects the party's eighteen years comprehensive strictly practice. (a) revised two regulations of the party need of < the ICAC guidelines > in < in 1997 Leaders as members of the Communist Party of China clean politics certain criteria (Trial) > based on revised, the promulgation and implementation of January 2010, to strengthen the construction of the contingent of leading cadres play an important role. But with the party to manage the party strictly administering the deepening, has not been able to fully meet the actual needs. Content is too complicated, "eight prohibition, 52 are not allowed to" hard to remember, and also difficult to put into practice; the second is concisely positive advocated by the lack of prohibited provisions excessive, no autonomy requirements; the third is banned terms and discipline law, both with the party discipline, disciplinary regulations repeat and Criminal law and other laws and regulations repeat; the fourth is to "clean" the theme is not prominent, not for the existing problems, and is narrow, only needle of county-level leading cadres above. < rule > is in 1997 < Chinese Communist Party disciplinary cases (Trial) > based on revision, in December 2003 the promulgation and implementation, to strengthen the construction of the party play very important role. Along with the development of the situation, which many provisions have been unable to fully meet the comprehensive strictly administering the practice needs. One is Ji law, more than half of the provisions and criminal law and other countries laws and regulations Repetition; two is the political discipline regulations is not prominent, not specific, for violation of the party constitution, damage the authority of Party Constitution of misconduct lack necessary and serious responsibility to pursue; third is the main discipline for the leading cadres, does not cover all Party members. Based on the above situation, need to < the criterion of a clean and honest administration > and < rule > the two is likely to be more relevant regulations first amendment. By revising, really put the authority of Party discipline, the seriousness in the party tree and call up the majority of Party members and cadres of the party constitution of party compasses party consciousness. (II) two party regulations revision process the Central Committee of the Communist Party of China attaches great importance to two regulations revision . Xi Jinping, general books recorded in the Fifth Plenary Session of the eighth session of the Central Commission for Discipline Inspection, on the revised regulations < > made clear instructions. According to the central deployment, the Central Commission for Discipline Inspection from 2014 under six months begin study two regulations revision. The Standing Committee of the Central Commission for Discipline Inspection 4 review revised. Comrade Wang Qishan 14 times held a special meeting to study two regulations revision, amendment clarifies the direction, major issues of principle, path and target, respectively held a forum will listen to part of the province (area) secretary of the Party committee, Secretary of the Discipline Inspection Commission, part of the central ministries and state organs Department The first party committee is mainly responsible for people, views of experts and scholars and grassroots party organizations and Party members. Approved by the Central Committee of the Communist Party of China, on 7 September 2015, the general office of the Central Committee of the Party issued a notice to solicit the provinces (autonomous regions, municipalities) Party, the central ministries and commissions, state ministries and commissions of the Party (party), the General Political Department of the military, every 3 people organization of Party of two regulations revision opinion. Central Commission for Discipline Inspection of extensive solicitation of opinions, careful study, attracting, formed a revised sent reviewers. In October 8 and October 12, Central Committee Political Bureau Standing Committee and the Political Bureau of the Central Committee After consideration of the two regulations revised draft. On October 18, the Central Committee of the Communist Party of China formally issued two regulations. Can say, two laws amendment concentrated the wisdom of the whole party, embodies the party. Second, < code > and < Regulations > revision of the basic principles of two party regulations revision work and implement the party's eighteen, ten eight plenary, the spirit of the Fourth Plenary Session of the Eleventh Central Committee and General Secretary Xi Jinping important instructions on the revised < low political criterion > and < Regulations >, highlighting the ruling party characteristics, serious discipline, the discipline quite in front of the law, based on the current, a long-term, advance as a whole, with Bu Xiuding independent < rule > and < rule >. Main principle is: first, adhere to the party constitution to follow. The constitution about discipline and self-discipline required specific, awaken the party constitution of party compasses party consciousness, maintaining the authority of the constitution. General Secretary Xi Jinping pointed out that "no rules, no side round. Party constitution is the fundamental law, the party must follow the general rules. In early 2015 held the eighth session of the Central Commission for Discipline Inspection Fifth Plenary Session of the 16th Central Committee, Xi Jinping again pointed out that constitution is the party must follow the general rules, but also the general rules." the revision of the < code > and < rule > is Method in adhere to the regulations established for the purpose of combining rule of virtue is to adhere to the party constitution as a fundamental to follow, the constitution authority set up, wake up the party constitution and party rules the sense of discipline, the party constitution about discipline and self-discipline specific requirements. 4 second is to adhere to in accordance with the regulations governing the party and the party. The Party of rule of virtue "de", mainly refers to the party's ideals and beliefs, excellent traditional style. The revised the < code > closely linked to the "self-discipline", insisting on the positive initiative, for all members, highlight the "vital few", emphasized self-discipline, focusing on the morality, and the majority of Party members and the ideological and moral standards. The revised < > Ji method separately, Ji, Ji Yan to Method, as a "negative list", emphasizing the heteronomy, focusing on vertical gauge. Is this one high and one low, a positive reaction, the strict party discipline and practice results transformation for the integration of the whole party to observe moral and discipline requirements, for the majority of Party members and cadres provides benchmarking and ruler. Third, insist on to. In view of the problems existing in the party at the present stage, the main problems of Party members and cadres in the aspect of self-discipline and abide by the discipline to make clearly defined, especially the party's eighteen years strict political discipline and political rules, organization and discipline and to implement the central eight provisions of the spirit against the four winds and other requirements into Disciplinary provisions. Not one pace reachs the designated position, focusing on in line with reality, pragmatic and effective. After the revision of major changes, major changes in the < code > and < rule > modified and needs to grasp several key problems (a) < code > < code > adhere to according to regulations governing the party and party with morals in combination, for at the present stage, the leadership of the party members and cadres and Party members in existing main problems of self-dis