Chapter 1: Maintenance Summary Report
Let our company undertake 20xx maintenance project. Therefore, after receiving the bid-winning notice, our company began to carefully prepare machines and tools before the Spring Festival and organize construction personnel to prepare for timely maintenance after the Spring Festival. The maintenance time is tight, the task is heavy, the scope of work is wide, and there are more organizers than in previous years.
Let me briefly summarize the overhaul of China Shipping Asphalt (Sichuan) Co., Ltd. in 20xx. This overhaul started on February 20xx 1 day and ended on February 20xx 16, with a total construction time of 16 days. The whole overhaul project is divided into static equipment overhaul and dynamic equipment overhaul.
Static equipment maintenance mainly focuses on the device operation area, such as heat exchanger disassembly, cleaning and maintenance, tower component replacement and cleaning and maintenance, container cleaning and dirty oil maintenance, air cooler replacement and maintenance, heating furnace maintenance and technical transformation projects, high-temperature pipeline replacement and installation in the device area, evacuator pump and pipeline installation, and cooling tower component replacement and maintenance. In the process of maintenance, all our employees are not afraid of being dirty and tired day and night, and Qi Xin cooperated to ensure the successful completion of this maintenance task. In the process of equipment maintenance and construction, we encountered many unpredictable problems, spared no effort and invested material resources until the equipment was completely repaired. For example, when the heat exchanger is overhauled, the pressure test and sealing welding are repeated, and the tube bundle is seriously blocked during the cleaning process, which cannot be dredged with normal construction equipment. After our research, we transported the heat exchanger core to Chengdu overnight and found a professional cleaning manufacturer to dredge and clean it. There are also some unimaginable problems in this overhaul. After the construction began, some decompression trays fell off. After careful inspection of the pallet fittings, no problem was found in the maintenance and cleaning process at that time, and the deformation of the fittings showed that its strength could not be reached. After discovering this problem, we immediately organized more than 20 people to carry out emergency repairs. Due to the limited space in the vacuum tower, it brought great difficulties to the construction, so we worked continuously for more than 30 hours and reinstalled all the fallen trays.
Replace accessories. Our idea at that time was to minimize the loss as much as possible, and report this quality accident to the leaders of our company and various project departments as soon as possible while repairing it, and sum up the experience and lessons. Put an end to similar situations in future maintenance projects.
Maintenance of mobile devices. Since this year is the first time that we maintain mobile devices, our practical experience is limited. After the construction started, we found some problems. The mechanical seal of the oil pump is not tight. After the discovery, we replaced the seal in time, which did not affect the production. Analysis of the reasons, it should be caused by short construction period and cross construction at night.
Many problems in this overhaul project are caused by poor management. We should take responsibility in this reform. We should seriously sum up and attach great importance to the problems exposed in this overhaul, improve our construction management level, and let every employee realize the importance of overhaul quality.
To sum up, thank you for your concern and support!
Chapter II: Summary of 20xx Overhaul
According to the company's 20xx annual shutdown and maintenance work plan, the production department, with the close cooperation of all departments of the company, is responsible for the implementation of this year's shutdown and maintenance work, which lasts for one and a half months from June 4 to July 20. All employees of the company's production line completed all tasks safely and efficiently under the tight time and heavy tasks. In order to ensure the smooth progress of this overhaul, we mainly work from the following aspects:
First, safety first, measures in place
In order to ensure the smooth progress of this overhaul, the company set up a shutdown overhaul leading group headed by Mr. Wang to organize and coordinate various departments to carry out overhaul work. Five maintenance implementation teams have been set up, and each team is equipped with a part-time safety officer to carry out safety education and safety monitoring for the staff of this group to ensure that the awareness of safety maintenance is seriously implemented. In order to ensure that the maintenance work is carried out in stages, the production department and the equipment department have made detailed plans for the replacement and maintenance of production equipment for various maintenance projects. All maintenance projects are implemented item by item from tasks, time and personnel, and the responsibility lies with people. Each team made a maintenance plan for the main maintenance projects, which ensured the smooth progress of this maintenance.
Second, carefully arrange and earnestly implement the efficiency guarantee.
In order to do a good job in this overhaul, the leading group held several meetings. Before the overhaul began, the company held a mobilization meeting for shutdown overhaul. During the overhaul, four special meetings on overhaul work and six meetings of overhaul group were held, with the participation of relevant leaders, workshop directors, equipment managers and relevant management personnel. Aiming at the technical status and existing problems of equipment in 140 overhaul projects, the overhaul standards and inspection were analyzed and studied item by item.
Repair progress. Detailed arrangements are made from the aspects of project responsibility, project construction, safety responsible person, maintenance schedule and planned maintenance time. The equipment manager and the person in charge of each maintenance project put forward the spare parts plan, and the team leader is responsible for its implementation. The production department and equipment department are specially assigned to provide technical guidance for maintenance, which has laid a solid foundation for ensuring the smooth and efficient completion of this maintenance.
Third, it is everyone's responsibility to ensure quality.
From the beginning of maintenance preparation, relevant personnel have carried out strict and serious inspection of spare parts and instruments, strictly controlled the quality and strictly implemented the maintenance procedures during the maintenance process, and strived to achieve small error, good quality and high efficiency. In order to ensure the maintenance quality, the heads of relevant departments and units timely inspect and guide all maintenance projects, never let go of a subtle link, and solve problems in time to ensure the maintenance quality of various maintenance projects.
Four, a serious summary, step by step acceptance.
Through the joint efforts of all staff, under the guidance of the management concept of responsibility step by step and responsibility to people, the company has achieved the maintenance goals of "safety", "efficiency", high quality, economy and environmental protection with a rigorous and meticulous working attitude. In view of the performance of the equipment after overhaul, after the production line is put into trial operation, all units are required to conduct self-inspection first. The production department, equipment department and process quality department carefully check and accept all maintenance items one by one, and confirm and record the inspection results of key maintenance items, so that the maintenance quality of each maintenance item can be well documented. So as to further improve the management level and work responsibility of all employees and ensure the efficient and long-term operation of the production line.
Under the correct deployment of the company and the careful organization and arrangement of the maintenance leading group, the maintenance work was successfully completed through the tenacious struggle of all the employees participating in the inspection, which laid a solid foundation for the company's production in the baking season this year.
Chapter III: Summary of Annual Overhaul
20xx is the most important year for production, maintenance and construction of our factory, and it is also a year for testing and training all employees. At the beginning of 10, our factory carried out the first annual overhaul. In this overhaul, all the staff have given full play to their professionalism of being hard-working, hard-working and working overtime independently, focusing on the overall situation. Actively organize manpower and material resources, unified arrangement, unified command and clear division of labor. In order to complete the maintenance task with good quality as scheduled during the equipment parking period, we have formulated a strict and meticulous maintenance plan and daily maintenance work content according to the maintenance workload. Overhaul and technical renovation projects *** 100, with a completion rate of 100%. No safety accident occurred during the maintenance, and the maintenance task was successfully completed.
First, the main content of on-site maintenance
1, main maintenance items of water vapor workshop
(1) When the pumps of 1 # and 4# stop, they cannot stop automatically when all the inlet and outlet valves are closed, because all the outlet valves and inlet valves are leaking. 1#, 4# circulating pump inlet and outlet valves are replaced during shutdown and maintenance, and the mechanical seal of 4# circulating pump is also replaced.
(2) The circulating water volume is small, so the nozzle was originally planned to be replaced. However, after the shutdown, it was found that there was a lot of sediment in the cooling tower water pipe, which blocked more than two thirds of the pipe section. After determining the maintenance plan, the company leaders visited the site to supervise and guide. After working overtime for five days, the problems existing in the cooling tower were completely solved.
(3) In the process of shutdown and overhaul, nine dampers in the flue of steam workshop are overhauled, and the dampers can be opened and closed flexibly after overhaul. At the same time, overhaul the 12 electric valve core with serious internal leakage on the steam pipeline and water supply pipeline in the boiler area, and overhaul the 2 1 valve.
After use, the effect is good.
(4) Replace the seriously worn roller of the chain bucket slag remover, replace the seriously worn track, and straighten the track to ensure the long-term stable operation of the equipment.
(5) Conduct a comprehensive inspection of the shut-down 2# and 3# boilers:
1) The main body of No.2 boiler was replaced by two secondary air ducts and an 80 hood, the castable for the coal drop hole in the boiler was repaired, and the thickness of the water wall tube, the flue superheater support tube and the economizer tube in the boiler was measured, which ensured the smooth operation of No.2 boiler after its start.
2) The main body of 3# boiler was replaced by 250 slag dropping tube covers and retaining rings, and the thickness of water wall tube, tail flue superheater suspension tube and economizer tube in the boiler was measured. After maintenance, the operation of No.3 boiler meets the technical requirements.
2#, 3# boiler auxiliary machine all inspection, 2#, 3# boiler coal feeding system, slag discharge system, pneumatic ash conveying system key maintenance. The outlet of primary bellows of two boilers was reinforced, and the inlet filter screens of two return fans were replaced, and the 18 disc bearings of nine rollers of coal conveying system were cleaned and lubricated.
2. The main maintenance items of the process workshop
(1) Reconstruction of circulating water in compressor. The oil cooler in the compressor dilute oil station is often blocked. In order to ensure the stable operation of the equipment, Y-type filter and bypass are added to the water of each compressor. The blocking phenomenon of the oil cooler is eliminated.
(2) According to the process operation requirements, 27 large and small valves are always replaced, and they are checked and accepted one by one during the maintenance process, and the quality is strictly controlled, and no leakage occurs during the driving process.
(3) Inspection of converter burner and replacement of temperature measuring point sleeve. Perform two routine inspections on the burner and deal with defective parts. Due to catalyst settling, the first temperature measuring point is set.
The pipe is burnt out. During overhaul, the temperature measuring point sleeve should be replaced. It ensures the accurate monitoring of the stability in the converter furnace and provides a guarantee for good production process indicators.
3. Main maintenance items of air separation workshop
(1) The bearing box of the air compressor is seriously leaking oil, and the instrument joint of the lubricating oil station is leaking oil. After the bearing gland was removed, it was found that four compression bolts were missing at the front and rear support bearing gland and four compression bolts were missing at the thrust bearing gland during the original installation, resulting in the vibration value reaching the trip value every time the vehicle passed the first critical point, so the interlock protection must be removed. Now, after measuring the support bearing, the rectification has been carried out. When driving, the critical speed can be crossed without cutting off the interlock protection, which ensures the safe operation of the equipment.
(2) During the operation of the five gas coolers of the oxygen compressor unit, the heat exchange efficiency decreases, and the gas temperature exceeds the process index. After core-pulling in the cooler, sludge accumulation was found, and the scaling was very serious. The air separation workshop uses a high-pressure water gun to wash the sludge, and finally carries out chemical cleaning. After the equipment is turned on, the heat exchange rate is improved, which is 20℃ lower than that before maintenance, and the process operation index is met.
(3) Replace the evaporator of the refrigeration unit. Due to the internal leakage of evaporator of refrigeration unit, the heat transfer efficiency is seriously affected. In the absence of standby machine, it was replaced when it was shut down for maintenance in June of 10, and the leaked evaporator was suppressed and put into storage as spare parts.
4, mechanical and electrical instrument workshop main maintenance projects
(1) The on-site control box of the boiler slag bin chain bucket slag remover was moved from the site to the ash removal power distribution room, which is convenient for operation and maintenance, avoids dust pollution, reduces the occurrence of electrical accidents and reduces the damage rate of components.
(2) Check and block the cable access holes on the cable tray and switch cabinet in the high-voltage room.
(3) The instrument maintenance team is responsible for the maintenance, installation and debugging of all vibration, displacement and temperature measuring points of oxygen compressor and air compressor (steam turbine and compressor).
(4) Under the guidance of Jiao Shan technicians, the instrument maintenance team added the liquid level alarm point of the air compressor hot well, and the background system debugging was successfully completed.
(5) The instrument maintenance team successfully completed the work of adding alarm points to the a/b pump screen of the ice maker.
(6) Import block valves and liquid level meters are added to the tank farm.
(7) Replace the deaerator liquid level control valves A and B with pneumatic control valves, and replace the steam control valves with pneumatic control valves.
(8) All process areas are repaired and maintained with heat tracing, and some instrument pipelines are added with steam heat tracing to prepare for winter.
(9) During the maintenance period, with the joint efforts of all maintenance personnel, the maintenance tasks of air compressor, oxygen compressor, syngas compressor and coke oven gas compressor were successfully completed in 1 1 day.
Second, the work experience and shortcomings
1, maintenance experience:
(1) At the beginning of August, the company leaders and equipment system professionals determined the maintenance contents according to the actual operation of the equipment. Due to the long processing cycle of spare parts needed for maintenance, the company booked spare parts in advance to provide conditions for the maintenance work to be carried out on time.
(2) At the beginning of September, review the maintenance plan, labor allocation, progress, instruments and tools of each project.
Chapter IV: Summary Report of Main Transformer Overhaul
10 main transformer commissioning date:1987110/0 month, manufactured by Shenyang transformer factory, SFP7-240000/220, capacity 240000 KVA, voltage ratio 2422 × 2.5.
(1) Suspension days:
Plan: 20xx July 22nd to 20xx September 22nd, 63 days * * Actual: 20xx July 22nd to 20xx September 22nd, 63 days * * *.
(2) Labor force:
Planned: 1800 working hours, actual (estimated): 1820 working hours.
(3) Overhaul cost:
Plan: 142946 yuan, actual (approximate): 17 1782 yuan.
(4) a short text summary:
1, project implementation.
The main transformer 10 was overhauled for the first time in September, 20xx, and it runs well after the overhaul. In order to cooperate with the capacity expansion and reconstruction project of 10 unit, an overhaul was carried out. During the overhaul of 10 main transformer, the power distribution team strictly controlled according to the requirements of the regulations, conscientiously implemented the overhaul process discipline and standardized operation requirements, and fully mobilized the enthusiasm of employees involved in the overhaul for standard and non-standard projects based on the principle of strong repair and good repair, thus overcoming many difficulties such as tight time and heavy tasks, ensuring the overhaul quality and time limit, and ensuring personal and equipment safety.
Standard items:
1) Bell jar overhaul body.
2) Maintenance of windings, leads and magnetic (electric) shielding devices.
3) Maintenance of iron core and iron core fasteners (piercing screws, clamps, drawstrings, straps, etc.). ), pressure nails, pressure plate, grounding plate.
4) Maintenance of oil tank and accessories, including shell and dehumidifier.
5) Maintenance of valves, pipelines and other auxiliary equipment.
6) Maintenance of safety protection devices.
7) Maintenance of oil protection device.
8) Calibration of temperature measuring device.
9) Maintenance and testing of operation control box.
10) maintenance of tap-changer without excitation.
1 1) Replace all gaskets and parts for leakage test.
12) transformer oil treatment.
13) Clean the fuel tank and paint it.
14) Fit test after repair.
Non-standard items:
1) 10 main transformer low-voltage bushing flow passage part transformation, each phase is added with 32 pieces of copper, the specification is120× 0.3mm.
2) Some oil pipelines are reconstructed and welded, and the upper and lower oil collecting headers of coolers and the lower oil inlet pipes of transformers are changed from DN 150 to DN200.
3) Replace two pressure relief valves, model YSF4II-55/130 KJTH.
4) Replace all butterfly valves, including 3 ZPF-80 butterfly valves, 8 ZPF- 100 butterfly valves, 2 ZPF- 150 butterfly valves and 4 ZPF-200 butterfly valves.
5) Replace four gate valves, including two φ 25 gate valves and 1 φ 80 and φ 50 gate valves.
6) Replace 8 coolers, model YF4-250. Including 8 oil pumps, model 6b135-5/3v; 8 flow indicators (with bellows), model BLZ4-150-135/70; ZPF- 150 Butterfly Valve16; 8 sub-control boxes.
7) Replace the cooler main control box, model XKFP-5/8.
8) Replace the power cable of the cooler with model VLV22-3×95+ 1×50.
9) 10 main transformer low-voltage closed bus insulator replacement, model DMC-20***432.
2. Main defects of equipment eliminated during maintenance.
10 # main transformer low-pressure casing leaks oil and is glued.
3. Significant improvement and effect of equipment.
Replace 8 coolers, model YF4-250. Due to its large capacity, the cooler can not only meet the cooling conditions required for transformer capacity expansion, but also has the following advantages:
1) The cooling pipe of the cooler has a large diameter and spacing, which is not easy to block and is beneficial to air circulation. At the same time, the cooler cancels the oil purifier, and the oil passage adopts the straight-through design, which reduces the oil flow resistance, accelerates the oil flow speed and increases the heat dissipation capacity.
2) The cooler adopts a low-speed and low-noise fan motor, which reduces the wear degree of the motor bearing, not only prolongs the service life of the motor, but also reduces the noise pollution to the surrounding environment.
3) The cooler pipeline is equipped with high-strength expansion bellows, which not only facilitates the installation of equipment, but also reduces the damage to the transformer caused by the impact of oil flow.
4) The new vacuum eccentric butterfly valve is adopted, which not only has good sealing performance, but also can withstand vacuum. In addition, the limiting groove is provided with a limiting locating piece and a sealing piece, which can play a secondary sealing role, locate the valve plate and prevent the valve plate from closing freely under the impact of oil flow.
4. Brief analysis of labor and cost (including labor and cost estimation of major special projects).
10 main transformer this overhaul cost is 142946 yuan, and the actual cost is 17 1782 yuan. The cost overruns are mainly used for the processing of new cooler pipes and the maintenance of 150-ton crane.
5. The main problems after maintenance and the countermeasures to be taken.
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6. Others
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