《2008年炼油厂琐紧环换热器检修施工技术方案》.doc

第 9 页 共 10 页 炼油厂柴油加氢装置螺纹锁紧环换热器(E101、E103)检修施工技术方案炼油厂柴油加氢装置螺纹琐紧环换热器(E101、E103)检修施工技术方案一. 检修情况1. 炼油厂2008年度春季检修，我公司负责柴油加氢装置2台螺纹锁紧环换热器（E-101 、E-103）的检修。2. 检修工期：2008年5 月 10日至2008年 5月26 日3. 检修内容：2台换热器均进行抽芯子检查、垫片更换、试压等。详见附表1。二.编制依据1. 建安工程管理部下达的施工任务单和工程管理部下达的“设备制造公司2008年承担东炼高压换热器检修计划”；2. 2台换热器设计施工图：3. 现场看活；4. 有关会议纪要等。三. 任务划分1. 燕华设备制造公司二铆车间负责E-101、E-103螺纹锁紧环换热器的检修；2燕华设备制造公司一加工车间负责损坏螺栓制作、隔板密封条钻孔等工作； 3燕华建安综合队负责现场搭架子工作； 4燕华建安机施公司负责吊车、卡车工作。四. 施工准备1. 熟悉换热器的结构，现场查看施工场地，策划各种工具、拆卸件的摆放位置。2. 熟悉各锁紧环工装，并进行试组装、轴承处注油，试盘车灵活等。3. 待装置停车并经炼油厂同意后，可向锁紧环注油润滑，内外圈压紧螺栓处喷松动剂。4. 经炼油厂同意后，通知架子队，在每台换热器前面搭好4×8米的脚手架平台，平台与锁紧环下部平齐，脚手架平台必须牢固，能够承受10吨以上的载荷。5. 由于E-101、E-103管束均重达15.8吨以上。因此抽芯机必须预先进行加固。加固方案另行确定。6. 工机具准备如下表：名 称型 号规 格数 量备 注特制扳手特制M30（30×34.6）6导链10T、5T、2T各2面包车解放10座2卡车斯太尔17T1运送工装、抽芯机、道木等汽车吊车16T10台班辅助50T吊车工作汽车吊双钩50T20台班（2台）必须用提升力显示准确、并且受力状态下提升力稳定不变的吊车抽芯机自制2工具棚自制2电焊机1气焊工具1套氩弧焊机1备用锁紧环工装1套吊环螺钉M20×806套供应-8力矩扳手700KN1件抛光砂轮10个金相砂纸100张试压阀门6个、压力表6块（0-20Mpa）、试压管线、压力表接头等7. 材料准备，见附表1。8. 人员配备按下表：工 种人 数备 注铆工10起重8电气焊2氩弧焊1钳工4力工10司机2汽车吊司机2施工管理2五. 主要施工方法1. 柴油加氢2台换热器的关键施工部位（如拆卸、安装各锁紧环）采用流水作业的方法进行施工，即均由熟练人员流水拆卸、安装、提高劳动效率；2. 柴油加氢2台换热器的非关键部位则采用同时拆卸、安装的方法进施工；3. 柴油加氢2台换热器均用50吨汽车吊吊住专用工装拆卸锁紧环、管程套筒等各件，配重适时进行增减；4. 拆卸、安装管束采用2台50吨汽车吊配合的方法进行；5. 由于每台设备内件较多，全部为精密加工件，拆卸后必须设专门的场地整齐摆放，并有专人看管，以免丢失。注：50吨汽车吊必须是提升力显示准确、并且受力状态下提升力稳定不变的吊车。六. 施工步骤 拆卸1. 拆卸施工必须待装置停车、置换，经测试具备施工条件，并得到炼油厂有关主管人员同意后方可进行。2先松开锁紧环上的内圈压紧螺栓， 再松开外圈螺栓，确信两圈螺栓不再压紧密封盘即可，不用卸掉。3. 将内外圈固定压圈螺栓拧紧。4. 将8条长螺栓一端固定在压盖上。5. 将工装安装到锁紧环上。用10吨导链配合50吨汽车吊将工装吊起，调整配重，找好水平。用螺栓将工装与锁紧环固定，同时固定压盖上的8条螺栓。拆卸时工装应平稳转动，并随时保持平衡。如遇卡涩等卸不动现象，除重新找好水平找正外，还可以尝试将工装反转后，调整位置再正转。在平稳转动时记下吊车的提升力，以后转不动时以此为依据再找正。待锁紧环接近旋出时，注意工装与螺纹锁紧环的平衡。6. 锁紧环卸掉后应由钳工对内外螺纹进行清理检查，对安装时形成的咬扣部分进行处理。先用抛光砂轮，后用金相砂纸打磨至符合要求。无缺陷后涂防高温咬合剂，再用塑料薄膜保护以防现场灰尘等杂物影响螺纹表面质量。 7. 卸掉锁紧环后，将螺纹保护套装好。8. 继续拆卸内件。按以下顺序进行：密封盘（用工装）外密封垫圈支架（用工装）压环（用工装）顶压螺栓卡环管程内套筒压盖（用工装）拆卸管程内套筒与管板连接螺栓管程内套筒（用工装） 管束（用抽芯机）9. 抽管束前测量并记录管板距壳体端面的距离。10. 拆卸内套筒和管束时卡环槽内应垫垫板（一加工车制）。11. 抽管束时需用两台50吨吊车，分别停在换热器两侧。其中一台将抽芯机吊起，抽芯机前端顶在换热器端部，再用两个2吨导链固定在支座上。绳扣栓在管板上的四个吊环螺钉上。管板离开换热器管箱端部后，继续抽出1米后，用另一50吨汽车吊主钩上的一根绳子（主钩上应挂两根绳子）吊着管束前端，绳子与管束接触部分垫置150×150×2000mm的枕木，继续缓慢将管束全部抽出，管束全部离开壳体前用主钩上的另一根绳子加枕木和10吨导链配合吊着管束的后部，将管束与抽芯机用两个2吨导链封牢固，两吊车配合到至地面上。12由炼油厂安排清洗管束。13. 仔细检查拆卸后的各零部件。14. 壳程隔板密封条更换 锁紧环换热器现场拆出后，更换隔板密封条。密封条由炼厂提供，设备制造公司一加工车间负责钻孔。 密封条上压板由二铆车间拆下，送一加工，由一加工车间按压板上孔的位置配做密封条上的光孔。密封条由10层组成，每层0.1mm厚，40mm宽，总长约6m，每台共换两处（总长12m）。 密封条整条制作，不得分段。 一加工做专用工装进行打孔。 回装1. 待各项检测合格，并经炼油厂相关单位确认合格后即可将管束回装。回装前将波齿密封垫套在管板后侧密封面处，可涂胶与管板粘牢。回装时仍用两台50吨吊车配合进行。管束装进壳体后，按前面测量的管板距壳体端面的距离确定管束是否回装到位。2. 用工装回装管程内套筒、卡环等。管程内套筒就位后安装好与管程进口之间的石墨盘根、压紧、点焊。3. 卡环及顶压螺栓（螺纹涂防高温咬合剂）安装后壳程即进行1.1Mpa的气密试压。在试验压力下保持1小时，表压不掉压，管头无泄露，管板与壳体间隙无泄漏为合格。若管头有泄漏用A132焊条进行补焊，若换热管泄漏则堵塞不锈钢楔子，换热管规格为内部5排19*2.5，其余为19*2。4. 试压合格后组装压环、支架。5. 拆掉螺纹保护套。6. 清理、修研壳体内螺纹，螺纹涂防高温咬合剂。7. 安装外密封垫圈、密封盘。外密封垫圈用胶与壳体粘牢。密封盘与外密封垫圈粘牢。8. 回装锁紧环，注意测量回装是否到位。必须先松开内、外固定压圈螺栓后再拧紧外圈压紧螺栓，内圈压紧螺栓在确定与密封盘接触后在倒退三扣。内外压紧螺栓均涂防高温咬合剂予以保护。9. 用液压扳手进行压紧螺栓对称的紧固，用力尽量平均，每个压紧螺栓压紧量尽可能一致。直至达到图纸要求的力矩为止。 试压1.先将管程下管口用试压盲板紧固，八角垫片用旧垫；2. 通过管程上管口灌水，水温应不低于15，然后封上管口，紧固、安装试压管线，用厚壁管线保证试压对管线的安全；安装两处压力表，其量程在8.0Mpa以上，并经校验合格，精度1.5级以上；摆好试压泵位置，应用高压试压泵。3. 各部位检查合格后，开始试压，缓慢升至试验压力（试验压力待定），检查严密性。合格后通知各方检查，检查通过后开始降压。4. 全部检查合格后缓慢泄压，将水放掉，拆掉盲板。5. 试压合格后清理现场，保留脚手架，现场装置联合试压时，现场保运。七. 施工安全注意事项 严格执行燕化公司、炼油厂及建安公司有关现场施工的各项安全管理规定； 进入现场必须穿工作服、配戴安全帽，高空作业必须系好安全带； 对调盲板的管线下方不得有任何人停留或行走； 拆卸锁紧环及抽管束的脚手架搭建的平台必须牢固可靠； 吊装所用绳索、导链等施工用具必须检查可靠后方可使用； 各种车辆均不得占用消防通道； 液压扳手、抽芯机、焊机用电及夜班施工照明用电等各用电部位接线应牢靠，并有防雨、防雷电设施； 现场应文明施工，坚持工完、料净、场地清； 遇有突发事件服从炼油厂有关部门的统一领导和指挥。附表1 检修内容及更换材料清单（E-101）序号名 称数 量材 料备 注1波齿复合垫片1甲供-82盘根（一）2石墨纤维编制绳甲供-83半圆垫片1膨胀石墨垫片 甲供-84盘根（二）2金属包石墨纤维编制绳甲供-85密封条20.1*10 HAYNES-25-ALLOY甲供-3-86密封带10米16膨胀石墨纤维绳甲供-87密封胶3Kg甲供-88防高温咬合剂12Kg甲供-89试压盲板4750 =185 Q235-A 见图0-3-810卡环槽垫板2Q2350-3-811吊环螺钉M204Q235供应-812螺栓4M27*50 35 GB/T5782-2000供应-813螺栓16M30*3*100 35 GB/T5782-2000供应-814螺母16M30*3 35 GB/T6170-2000供应-815双头螺柱8M20*350 35 见图供应-8附表2 检修内容及更换材料清单（E-103）序号名 称数 量材 料备 注1波齿复合垫片1甲供-82盘根（一）2石墨纤维编制绳甲供-83半圆垫片1膨胀石墨垫片 甲供-84盘根（二）2金属包石墨纤维编制绳甲供-85密封条20.1*10 HAYNES-25-ALLOY甲供-3-86密封带10米16膨胀石墨纤维绳甲供-87密封胶3Kg甲供-88防高温咬合剂12Kg甲供-89试压盲板4750 =185 Q235-A 见图0-3-810卡环槽垫板2Q2350-3-811吊环螺钉M204Q235供应-812螺栓4M27*50 35 GB/T5782-2000供应-813螺栓16M30*3*100 35 GB/T5782-2000供应-814螺母16M30*3 35 GB/T6170-2000供应-815双头螺柱8M20*350 35 见图供应-8附表3 组织机构人员名单管理职责姓 名单 位联系方式项目经理检修指挥负责人王传志设备制造公司69341636质量技术负责人检修协调负责人施工技术负责人冯玉庆生产工艺室69343116-3158施工质量负责人韩宝玲质量检查室69341798施工调度王书坡生产工艺室69342964施工车间负责人曾春平二铆车间13701175256施工车间负责人姜建伟一加工69341786安全卢宏生产工艺室69343116-3187Opinions and suggestions on the party's mass line educational practiceAccording to the central and provincial, municipal unified deployment, according to municipal Party committee "about carrying out the party's mass line educational practice activity in the city's implementation opinions, the spirit of the party's 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 party 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 CPC 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 requirements, 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, the 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 implementation 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 people 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 building 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 directly 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 leadership, 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 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 party's education.Always speak seriously as a basic attitude, adhere to positive education, to carry out criticism and self criticism 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, pay 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 county's education practice is to 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 of 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 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 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 implemented, 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 township, 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 acquisition 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 competition 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 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 group, 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 the 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 management 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 study 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.