主输泵改造都匀施工方案

西南成品油管道部分输油站主输泵改造工程都匀站施工方案中石化第五建设有限公司I目录一、工程概况············································································································２二、编制依据············································································································２三、施工前期准备······································································································３四、施工工艺············································································································４五、质量保证体系······································································································８1、质量方针和目标·····································································································８2、质量管理体系机构··································································································９3、中交质量目标········································································································９4、检验、试验计划实施程序·························································································９六、HSE保证体系及措施··························································································１０1、安全保证体系和措施····························································································１０2、项目经理部安全生产组织机构················································································１１3、安全生产职责·····································································································１１4、施工现场安全管理规定·························································································１２七、风险评价和(JHA)记录表······················································································１４1、风险评价与控制措施表·························································································１４2、工作危害分析记录表····························································································１５3、重大危险因素清单·······························································································１６西南成品油管道部分输油站主输泵改造工程都匀站施工方案中石化第五建设有限公司2一、工程概况中国石化销售有限公司华南分公司西南成品油管道部分输油站主输泵改造工程，都匀站第一台输油泵机组更换叶轮，由泵厂家进行安装调试，最后一台外输泵加设变频器。由于更换叶轮泵系统要接入原有系统，在施工中存在很多不可预见性的因素，为了能够保证工程的正常进行，特编制此方案。二、编制依据（1）西南成品油管道部分输油站主输泵改造工程施工承包合同。（2）华东管道设计研究院设计的都匀站施工图纸。（3）厂家提供的使用说明（4）施工规范和标准：《石油天然气站内工艺管道工程施工规范》GB50540-2009《输油泵组施工及验收规范》SY/T0403-98《泡沫灭火系统施工及验收规范》GB50281-2006《自动化仪表工程施工及质量验收规范》GB50093-2013《中国石油化工集团公司安全、环境与健康（HSE）管理体系》Q/HSE0001.1-2001《石油化工给水排水管道工程施工及验收规范》SH3533-2003《钢结构工程施工质量验收规范》GB50205-2001《压力容器焊接规程》NB/T47015-2011《承压设备无损检测》JB/T4730.1-4730.6-2005《混凝土小型空心砌块墙体建筑构造》05J102-1《接地装置安装》03D501-4《石油化工有毒、可燃介质管道工程施工及验收规范》SH3501-2002《石油化工设备和管道涂料防腐蚀技术规范》SH3022-1999《石油天然气站内工艺管道工程施工及验收规范》SY0402-2000西南成品油管道部分输油站主输泵改造工程都匀站施工方案中石化第五建设有限公司3三、施工前期准备1、施工前的技术、机具准备⑴勘查施工现场，了解现场情况，做好施工现场平面规划，落实现场运输路线，接好施工临时用电，落实施工安全措施等。⑵做好对施工班组技术交底工作。⑶根据所负责的工程项目和内容，有针对性地对施工作业人员进行培训，各工种作业人员必须掌握本工种应知应会理论知识和实操技能。⑷根据工程施工的特点及安装量，调配好足够的施工机具。2、施工现场的检查及准备⑴确认施工对象（管道、电缆、设备）是否具备施工条件。⑵准备接头的旧管线内部进行清洗。清洗完毕后，须用测爆仪进行测试是否达到动火条件。用电设备和电缆接线，要确认开关是否断开，并且挂好“禁止合闸”警示牌。⑶管道周围安全防火、防爆措施到位，灭火器已经放置在现场指定位置。⑷向都匀站申请作业许可证。⑸在动火地点设置多个干粉灭火器具。⑹氧、乙炔气瓶摆放间距达到规范要求。⑺进入施工现场，必须戴好安全帽。⑻现场作业须有监护人。３、主要机具计划序号机具名称单位数量序号机具名称单位数量1汽车吊辆19钢棒根128吨载重汽车辆110测振仪台13卷尺把511红外测温仪台14卡尺把512测速仪台15百分表块513压力表块86千分尺把1147条式水平仪把1158框式水平仪把116西南成品油管道部分输油站主输泵改造工程都匀站施工方案中石化第五建设有限公司4四、施工工艺1、开箱检验开箱检验时必须由业主代表、监理、供货商代表及施工单位代表共同参与进行，开箱检验前应具备下列技术资料：机泵叶轮的出厂合格证、质量证明书、操作使用说明书；供货单位提供的装箱清单。２、泵的解体与组装步骤１）拆卸联轴器防护罩；２）在联轴器上做好标记，拆卸联轴器中间短节；３）松开密封压盖螺栓，拆卸泵体连接螺栓，吊出泵体及端盖；４）拆卸各级密封，吊出泵转子；５）检查和清洗各零件，测量各级配合间隙；６）组装应按解体的相反步骤进行，更换叶轮。３、拆装注意事项⑴对一些重要部件拆卸前应做好记号,以备装复时定位。⑵拆卸的零部件应妥善安放,以防失落。⑶对各接合面和易于碰伤的地方,应采取必要的保护措施。４、离心泵的解体⑴关闭泵浦的吸,排截止阀;⑵将电动机的接线脱开,在联轴节处做好记号,拆除固定电动机的螺栓,然后将电动机卸下。⑶拆下泵浦、吸、排管。⑷把水泵入口短节卸下,拆掉吸入端端盖。⑸使用专用工具拆卸离心泵叶轮,用专用扳手拆下叶轮前的反扣螺母及止动垫圈(一般反扣螺母是左旋螺纹)取下止动垫圈,叶轮即可从轴上取下,如取不下来,可利用叶轮平衡孔上的丝牙用专用工西南成品油管道部分输油站主输泵改造工程都匀站施工方案中石化第五建设有限公司5具将叶轮从轴上取下,具体方法是:将专用工具的两根螺钉拧入叶轮上有丝牙的平衡孔中,丝杆顶正轴端中心,慢慢转动手柄,将叶轮从泵轴上拉出。如果叶轮锈于轴上而拉不动,可在健连接外刷上少量煤油,稍等片刻,即可拉出叶轮,取下叶轮平键。⑹使用三爪拉马拆卸滚动轴承,先拆下轴承箱上前后两只轴承盖,然后用一木块垫在联轴器端轴头上,用紫铜棒轻轻敲打木块,就可把泵轴连同轴承一起拆下。从轴上取下轴承时要注意不能损伤轴承，一般用专用工具拉马的拉勾钩住滚动轴承内圈,丝杆。⑺使用拉马拆卸联轴节,具体方法是:将轴固定好,先拆下固定联轴节的锁紧帽,再用专用工具拉马的拉勾钩住联轴节,而其丝杆顶正泵轴中心,慢慢转动手柄,即可将联轴节在钩拉过程中,可用铜锤或铜棒轻击联轴节,如果拆不下来,可用棉纱蘸上煤油,沿着联轴器四周燃烧,使其均匀热膨胀,这样便会容易拆下，但为了防止轴与联轴器一起受热膨胀,应用温布把泵轴包好。离心泵拆卸完毕后,应用轻柴油或煤油将拆卸的零部件清洗干净,按顺序放好,以备检查和测量。５、离心泵的组装离心泵更换叶轮后即可以进行装配。1.整个转子除叶轮外,其余全部在检修间正式组装完毕，这包括轴套、滚动轴承、定位套、联轴器侧轴承端盖、小套、联轴器及螺母等。2.转子从联轴器侧穿入泵内,注意填料压盖不要忘记装,轴承端盖上紧后,必须保证:⑴轴承端盖应压住滚动轴承外圈。⑵轴承端盖对外圈的压紧力不要过大,轴承的轴向间隙不能消失。用压铅法测量此项压紧力时,可在零对零基础上放出0.1-0.2MM,然后用手盘动转子,应灵活轻便。西南成品油管道部分输油站主输泵改造工程都匀站施工方案中石化第五建设有限公司6⑶把叶轮及其键、螺母等装在轴上,装上泵盖,盘动转子,看叶轮与密封环是否出现相应磨擦现象。⑷轴封的装配.该泵采用填料密封,打开填料压盖,切取与轴外周长等长度的盘根数根(其根数依说明书或依泵原旧填料的根数)，然后一根一根的压入,压入时每根接口应180错开,最后装上压盖,但不拧紧螺丝,等到泵工作时,再慢慢拧紧螺丝，直到不漏为止。⑸将泵吊入泵座并将其固定,装妥进、排管。⑹电机装复,用千分表和塞尺对联轴节进行校正。６、泵的单机试车（1）试运应具备的条件机泵试运转前，必须对试车系统进行确认，试车具备下列条件：a、泵的垫铁隐蔽和二次灌浆完，找平找正完，检查合格，并有详实齐全的记录；b、地脚螺栓、安全罩和该系统法兰上的螺栓等全部拧紧；c、轴承箱和电机加注合格的设计指定的润滑油、润滑脂，电机单试时记录电机振动情况；d、仪表安装调试完毕且保证正常操作，安装符合要求的流量计、压力表和温度计等，确定各指示灵敏、准确；e、电气安装调试工作结束，照明投用正常，电机空运转合格并有详实的记录，运转方向正确，具备单体运转条件；f、与机泵试车系统相关的工艺管线安装、试验和冲洗合格，试车管线上的安全阀已校验，与该系统相关的静设备安装、试压和内部清理合格，以上相关资料详实齐全；g、试车所需的临时管线和过滤网安装完，过滤网必须