Seek a major overhaul plan for reciprocating compressors
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Seek a overhaul plan for reciprocating compressors, including the details of the overhaul, inspection methods, and acceptance criteria!
Maintenance Plan for New Hydrogen Compressors 1401-K-101A/B/C
Maintenance Type: Major Overhaul
Prepared by: Zeng Huabiao
Reviewed by:
Approved by:
Date:
Maintenance Contractor: XXX Moving Equipment
Form for Review and Approval of Construction Technical Plan
Plan Name: Maintenance Construction Plan for Reciprocating Compressors in XXX Refining and Chemical Plant
Prepared by the Construction Unit: Date
HSE Department: Date
Reviewed by: Date
Construction Unit’s Operations Department: Date
Mechanical Department: Date
Safety and Environment Department: Date
Table of Contents
I. Preparation Notes 3
II. Basis for Preparation 3
III. Project Overview 3
IV. Pre-construction Preparation 4
V. Construction Organization and Coordination 4
VI. Main Construction Procedures and Key Points for Maintenance 4
1. Disassembly Sequence 4
2. Technical Requirements for Disassembly and Inspection of Major Components 5
3. Quality Assurance Measures for Construction (attached: Quality Control Table) 10
VII. Construction Layout Plan 10
VIII. HSE Management and Risk Assessment 12
IX. Construction Tools and Equipment 13
I. Preparation Notes
In accordance with Hainan Refining and Chemical Plant’s major overhaul plan for 2009, and upon commission from the Mechanical Department, this plan is prepared for the major overhaul of the new hydrogen reciprocating compressor unit 1404-K-101. It aims to ensure the quality of the overhaul and timely delivery of the unit for use. II. Bases for compilation 1. Random data and drawings 2. SHS 01010---92 \"Maintenance and Repair Procedures for Piston Compressors\" 3. \"Maintenance and Repair Procedures for Petrochemical Equipment\" – General equipment. 4. \"Safety Operating Procedures for Lifting Operations\" III. Project Overview: This reciprocating compressor is of the 4M80 model, manufactured by Shenqi; the medium transported by the compressor is hydrogen, and the drive unit is an electric motor. This unit has been in operation since October 2006, and it is now time for a major maintenance inspection. It is currently functioning well, but there are oil leaks in several parts of the lubrication system. Additionally, the hard connections between the inlet and outlet flanges of the shaft head oil pump and the pipelines subject it to significant stress, which can easily lead to damage to the shaft seals and bearings. It is planned to eliminate these leakage issues completely during this maintenance inspection, and to replace the flanges of the shaft head oil pump with soft connections. To ensure smooth operation in the next cycle, its components are thoroughly inspected and replaced in accordance with the maintenance procedures. The main inspection items are as follows: 1. Inspect all intake and exhaust valves; replace them if necessary. 2. Check for wear on the inner walls of the cylinders as well as the levelness of the cylinders. 3. Inspect the piston rings, piston rods, crossheads, crosshead pins, connecting rods, main shaft, and connecting rod bolts for wear. 4. Check the wear condition of the main shaft bearings and crankshaft bearings. 5. Check the piston clearance. 6. Inspect and replace the sealing gaskets and oil scrapper rings. 7. Check the connection bolts of the machine frame and the foundation bolts. 8. Inspect and clean the check valve of the oil injector and the filter screen of the lubricating oil pump. 9. Inspect the main shaft oil pump, auxiliary oil pump, and the oil tank. IV. Preparations before construction 1. Conduct a technical briefing for the personnel involved in the overhaul, so that they are familiar with the construction drawings, technical requirements, and related documentation; they should also master the key points of the overhaul process, the operating procedures, and the quality standards. 2. Before shutting down the machine, conduct on-site observations of the compressor, analyze the operation status of the turbine, identify existing problems, formulate corresponding solutions, determine all the necessary construction steps, and carry out all preparation work in an organized manner. 3. Check whether the machine room is suitable for lifting operations, whether the crane is in good condition, whether the lifting switches function properly, and ensure that the moving parts are lubricated and maintained. . 4. Check whether the hydraulic pump and its auxiliary components are in good condition and address any issues to ensure proper operation ； Prepare all the specialized tools required to disassemble this unit, and ensure that any missing tools are fabricated and made available as backups. 5. Plan the layout of the construction site properly, and arrange the oil pans, sleepers, and rubber materials used in construction in designated locations in accordance with the requirements for civilized construction. 6. Prepare the construction tools as well as materials such as kerosene, white cloth, red lead, lubricating oil, and grease. 7. Spare parts for vulnerable components must be prepared before maintenance. 8. Before maintenance, the operator must carry out normal shutdown procedures, apply the necessary process treatments and safety measures, and finally complete the safety maintenance handover form. V. Construction Organization and Coordination This machine operates at high pressure and has a complex structure; therefore, high standards are required in terms of maintenance techniques and quality. It is thus essential to assign experienced technicians and fitters to carry out the work, with the guidance of the company’s professional technical department. Specific organization: 1. Supervisor: Peng Muxiu (responsible for construction, technology, quality, and HSE oversight); Fitters: 4 persons; Electrical and instrumentation personnel: 2 persons; Lifting personnel: 2 persons. 2. Construction coordination (see attached diagram). VI. Main Construction Procedures and Key Points for Maintenance Operations 1. Disassembly sequence (1) Remove the inlet and outlet valves for inspection ； (2). Check the piston dead center clearance ； Open the cylinder head, as well as the slide and crankcase cover ； (3). Measure piston rod runout ； Measure the clearance between the crosshead and the crosshead slide ； Check the crankshaft deflection by measurement; remove the locking device that connects the crosshead to the piston rod, take out the piston, and inspect the wear of the piston rings and the piston itself. (4). Remove the piston rod and check for wear and bending ； (5). Check the wear of the crosshead and pin shaft ； (6). Inspect and measure the cylinder ； (7). Disassemble and inspect the lubricating oil system ； (8). Reassemble in the reverse order of disassembly. 2. Technical requirements for the disassembly and inspection of major components: (1) Check the piston top clearance for each cylinder (unit: mm). Inspect the cooling water pipes, oil pipes, as well as the intake and exhaust valves of each cylinder level. To measure the top clearance, use wrenches of sizes 46, 50, 55, and 60 for the nuts of the intake and exhaust valves on each cylinder level. The piston top clearance should be 5±0.5 on the shaft side, and 2 on the cylinder side. (2) Disassemble the head covers and the locking devices that connect the crosshead to the piston rod, then lift out the piston (unit: mm). 1) Measure the radial clearance between the cylinder and the piston body ； 2) Axial clearance between piston rings ； 3) Axial clearance between the support ring and the piston ring groove 4) Opening clearance of the piston ring ； 5) Support ring opening clearance: Piston and cylinder mirror clearance Piston body diameter Ф326 Ф326 Ф232 Ф311.5 Cylinder mirror diameter Ф330H7 Ф330H7 Ф235H7 Ф315H7 Radial clearance 3.5-3.7 3.5-3.7 2.65-2.85 3.5-3.7 Axial clearance between piston ring and piston ring groove Piston ring width 10 10 12 15 Piston ring groove width 10.05 10.05 12.05 15.05 Axial clearance 0.24-0.39 0.15-0.30 0.24-0.39 0.24-0.39 Axial clearance between the support ring and the ring groove Support ring width 80 80 65 65 Support ring groove width 80.05 80.05 65.05 65.05 Axial clearance 0.81—1.05 0.81-1.0 0.52-0.76 0.81-0.10 Piston ring counterpart clearance 1.4 1.4 1.0 1.4 Piston ring counterpart limit clearance 5 5 4 5 (3) Piston and piston ring maintenance 1) The surface of the piston and piston ring should be smooth, and there should be no deformation, casting, machining and other defects. 2) The piston ring should move freely in the piston ring groove and have a certain expansion force. 3) The counterpart positions of the piston rings at all levels installed in the groove should be staggered by 120 degrees. 4) The contact line between the outer diameter of the piston ring and the cylinder should not be less than 60% of the circumference, and the gap should not be greater than 0.05mm. 5) Check the wear of piston ring groove and support ring groove Note: When disassembling and assembling, use a special tool high-pressure oil pump to disassemble and assemble the piston rod and the cross-head nut. When disassembling and assembling, the maximum pressure of the high-pressure oil pump shall not exceed 150Mpa. The whole tightening process needs to be completed three times, with an interval of one hour each time. The tightening method is the same each time. Lift out the piston rod. A piston rod sheath must be used when lifting the piston rod to avoid damaging the oil scraper ring, packing seal, and cylinder mirror. (4 ) Remove the piston rod and check the cylinder, piston rod wear and bending 1) Check the roundness and cylindricity of the cylinder, A. Allowable value of roundness:: 0.8D/1000－D/1000 Note: D is the cylinder diameter B. Cylindricity allowable value: C. Level of cylinder and slide: D. Maintenance of the cylinder E. The inner surface of the cylinder should be smooth and free of defects such as cracks and holes. F. The radial cylindrical degree inside the cylinder must not exceed the standard. G. When the surface of the cylinder is damaged by more than 1/4 and there are serious grooves, it should be dealt with in time. The surface roughness of the cylinder should be Ra 1.6. H. The increase in cylinder diameter must not exceed 2% of the original design diameter. I. Check the wear of the cylinder mirror 2) Maintenance of the piston rod A. The piston rod must not have cracks or other defects, the surface roughness is Ra 0.8, and non-destructive testing is performed if necessary. B. The straightness tolerance of the piston rod is 0.06mm/m, and the maximum shall not exceed 0.1mm/m. The horizontal runout of the piston rod shall not exceed 0.064 mm, and the vertical runout shall not exceed 0.1 mm. Note: When tightening the nut on the piston rod, you must use the electric heating rod that comes with the machine. You cannot use other tools to forcibly loosen the nut. When reassembly, you must add anaerobic glue (5) Check the clearance of each component of the crosshead (unit: mm) 1) Clearance between the column pin and the cross head seat shoe 2) Clearance between the column pin and the small head shoe of the connecting rod 3) Clearance between the cross head slide plate and the slideway 4) Roundness of the column pin Radial clearance between the connecting rod large head shoe and the column pin Diameter of the large head shoe column pin Ф359.855Ф359.895 Ф359.855Ф359.895 Ф359.855Ф359.895 Ф359.855Ф359.895 Connecting rod big head tile inner diameter Ф360-Ф360.206 Ф360-Ф360.206 Ф360-Ф360.206 Ф360-Ф360.206 Radial clearance 0.25-0.37 0.25-0.37 0.25-0.37 0.25-0.37 Radial clearance between connecting rod small end shoe and cross head pin Diameter of cross head pin Ф199.90-Ф199.93 Ф199.90-Ф199.93 Ф199.90-Ф199.93 Ф199.90-Ф199.93 Small head bushing diameter Ф200-Ф200.135 Ф200-Ф200.135 Ф200-Ф200.135 Ф200-Ф200.135 Radial clearance 0.19-0.24 0.19-0.24 0.19-0.24 0.19-0.24 Radial clearance between the crosshead slide plate and the slideway Crosshead slideboard diameter Ф539.45-Ф539.53 Ф539.45-Ф539.53 Ф539.45-Ф539.53 Ф540H7 Slide diameter Ф540H7 Ф540H7 Ф540H7 Ф400-Ф400.057 Radial clearance 0.4-0.5 0.4-0.5 0.4-0.5 0.4-0.5 Pin roundness 0.02-0.03 (6) Inspection of the crosshead, slide plate and slideway 1) Crosshead, crosshead pin, slideboard should be free of defects such as cracks 2) The contact point between the slideway and the slideway should be no less than 2 points per square centimeter, and the clearance requirements are as shown in the figure above (7) Check the packing seal and oil scraper ring (unit: mm) 1) The combined sealing packing should be smooth and scratch-free, with a surface roughness of Ra0.8. 2) The contact area between the sealing ring and the piston rod reaches more than 70%, and the contact points should be no less than 4-5 points per square centimeter. It is strictly forbidden to use emery grinding. 3) The contact gap of the combined sealing packing is generally not less than 1mm, and the packing openings of each ring should be evenly staggered for assembly. For three- and six-lobed sealing rings, the three valves are close to the high-pressure side. The six petals are on the cross head side. 4) The axial end surface of the packing should be in even contact with the stuffing box. 5) The contact surface between the scraper ring and the piston rod is not allowed to have grooves or damage. The contact line should be evenly distributed and greater than 70% of the circumference. The axial gap between the scraper ring and the box is 0.05-0.10 mm. 6) The axial gap of the packing is 0.53-0.66mm (8) Disassembly and inspection of the intake and exhaust valves. 1) The valve plate must not be deformed or cracked. Defects such as scratches 2) The sealing surface of the valve seat must not have corrosion pits, scratches, and the roughness is R 0.8. The contact line with the valve plate should be continuously closed. 3) The valve spring should have sufficient elasticity. On the same valve plate, the diameter and free height of each spring should be consistent. The valve plate can rise and fall freely without jamming. 4) The inlet and outlet valves are not damaged, and the contact line connected to the valve seat should be continuously closed. 5) The lift controller of the inlet valve can move freely. No jamming phenomenon (9) Inspection and repair of crankshaft, piston, connecting rod and bearing sleeve 1) The crankshaft, connecting rod and connecting rod bolts are not allowed to have cracks and other defects 2) The radial circular runout tolerance of the main journal is 0.02mm, and the opening and closing degree is 0-0.04mm. If it exceeds 0.1mm, it must be adjusted. 3) The scratch area of the main journal shall not be greater than 2% of the journal area, and the groove of the journal shall not be greater than 0.1 mm. The main journal and crankshaft journal should not be reduced by more than 3%. 4) The shaft and the bearing should be in uniform contact, with no less than 2---3 contact points per square centimeter. The bearing backing is evenly fitted to the machine base and connecting rod socket, and the contact area is 70%-80%. 5) The bearing alloy layer and the bearing bushing are well combined. The surface of the alloy layer must not have cracks, pores and other defects, and thin-walled bearings must not be scratched. 6) The main bearing bush clearance is controlled to 0.24-0.36mm. , the clearance between the crankshaft pin and the big head shoe is 0.25-0.37mm 7) The axial clearance of the positioning bearing is 0.22-0.45mm (10) Inspection of the auxiliary oil pump and oil injector 1) Inspection of the shaft head oil pump A. Check the bearing and seal (replace if necessary) B. Check the meshing clearance of the gear: 0.105 mm C. Check the axial clearance of the gear; 0..10---0.15 mm D. The gap between the gear and the casing: 0.15---0.25mm 2) Inspection of various parts of the shaft head oil pump A. Inspection of the casing: The roughness of both end surfaces of the casing is Ra3.2, the tolerance value of the parallelism of the two hole axis centers and the verticality of both ends is not less than IT6 level; the cylindrical tolerance value of the inner hole of the casing is 0.02---0.03mm/100mm B. Inspection of the gear: The shaft fit of the gear is H7/m6; the perpendicularity between the two end surfaces of the gear and the center line of the shaft hole or the two end surfaces of the gear and the center line of the shaft is 0.02mm/100mm; the width of the two teeth is the same, the width error of a single gear shall not exceed 0.0 5mm/100mm, the top clearance of the gear mesh. The side clearance can be measured by the lead pressure method. C. Gear and shell: The radial clearance of the gap between the gear and the shell can be checked with a feeler gauge; The clearance value is 0.15--0.25 mm, but it must be greater than the radial clearance between the journal and the bearing bush. D. Adjustment of the clearance between the gear and the pump cover: The clearance between the gear and the pump cover can be checked by the lead wire method. According to the specific measurement results, the thickness of the end cover gasket is added or subtracted to make the end face clearance between 0.10---0.15mm. E. Inspection and assembly of the shaft and bearing: There must be no scars on the journal of the gear oil pump, and the roughness requirement is Ra1.6. The journal cylindricity tolerance is 0.01 mm, and the maximum journal wear shall not be greater than 0.01D (D is the diameter of the journal) (10) Coupling 1) When the coupling is inspected, it is strictly prohibited to hammer it directly with hands to avoid damaging the coupling 2) Requirements for coupling alignment: end face circular runout: 0.03mm radial circular runout: 0.04mm 3. Construction quality assurance measures (quality control table attached) 7. Construction floor plan 8. HSE management and risk assessment 8.1. Strictly implement Hainan Refining and Chemical's "Safety Production Management Standards" and the construction company's HSE management regulations, conscientiously implement safety measures to ensure the completion of compressor maintenance tasks. 8.2. Organize the construction workers to study carefully the safety regulations related to major repair work; the HSE supervisor shall provide instructions at the safe construction site to ensure that the workers are familiar with the construction environment and the precautions to be observed. 8.3. The maintenance equipment to be delivered must be thoroughly purged; for electric equipment, the power supply must be cut off, and work may only proceed after verifying that all safety measures have been implemented. 8.4. Workers entering the construction site must wear the required personal protective equipment to ensure their health. 8.5. Machine operators should empty their pockets before entering the site, to prevent items from falling into the machines. During construction, the unit should always be covered with plastic sheeting to prevent dust and debris from entering the machine. When securing the cover, a thorough inspection should be carried out to ensure that there are no foreign objects inside the machine. 8.6. When removing or assembling components, do not use forceful blows or prying; use specialized tools instead. The removed parts should be placed on pallets or in oil trays, ensuring that they are neither exposed to the air nor in contact with the ground, thereby improving the site management practices related to civilized construction. 8.7. Fire prevention measures should be taken in the machine room, and carbon dioxide or carbon tetrachloride fire extinguishers should be placed at appropriate locations. 8.8. Crane operations must be carried out in strict accordance with the \"Safety Management Regulations for Crane Operations\" and the safety operation procedures specific to this type of work, ensuring that responsibilities are assigned to specific individuals and that there is unified command. 8.9. When two or more people work together, one person must be designated to be responsible for safety to ensure coordinated work and achieve the principle of \"no harm to oneself, others, or the environment.\" 8.10. Carry out construction in a civilized manner and ensure proper environmental protection during construction. Used parts and construction pollutants must be removed promptly; oil stains should be discharged at designated locations, and upon completion of work, the area must be left clean with no leftover materials. 8.11. In light of the characteristics of this maintenance work, an HSE risk assessment and analysis of control measures have been carried out; details are provided in the attached table. 9. Construction tools, tools, materials, name, model, specification, unit quantity, remarks, random special tool set 1 (full set), adjustable wrenches 8″, 10″, 12″, 15″, 5 sets each, 5.5~32mm box spanner sets, 3 sets, heavy socket sets, 1 hammer, 1 pound, 1.5 pound handles, 2 each, screwdriver (including iron handle), 5 handles, file handle 5, manual hoist 1T, 2T, 3T, 2 each, feeler gauge handle 3 Dial indicator 2, depth caliper and vernier caliper handle 2 each Micrometer handle 2 Sleeper bar 10 Wire rope root 6 Pipe clamp handle 3 Construction unit: Maohua Jianyangpu Branch Working hours Analyst name: Huang Zhiyong Work location: Xinhydro compressor room Work content: Compressor overhaul appraiser name: Peng Muxiu Work steps Hazard factor analysis Hazard consequence analysis Risk level Planned control measures Preparation work 1.1 Construction equipment is not intact 1.2 Employees do not dress as required1.3 Lifting equipment is not available1.4 Work tickets are not issued according to Yuanqu regulations1. Equipment cannot be used causing accidents, or other personal accidents are caused by equipment problems2. Chaotic management of the construction site can easily cause equipment and personal accidents3. Safety measures are not implementedⅢⅢⅢⅢ 1. Hoisting machinery used on site must be inspected. Maintenance and inspection must be carried out to confirm that the mechanical performance is intact before it can be sent to the construction site for use2. Strengthen supervision and management 3. Strictly implement the work ticket system and implement safety measures during the work process 1. Employees do not wear labor protection equipment as required by regulations 2. Failure to take protective measures as required when disassembling and assembling anti-lifting parts 3. Not wearing safety belts when working at heights 4. Grease falls to the ground on site 5. Tools and spare parts are not stored as required 1. Causing personal injury and damage to health 2. Causing personal casualties. Equipment damage accidents 3. Construction workers fall from heights 4. Construction workers slip and cause personal injuries 5. Loss and damage of parts Ⅱ Ⅲ Ⅲ Ⅰ Ⅰ 1. Strictly require on-site personnel to wear labor protection equipment in accordance with regulations 2. Use force when lifting, and use special tools to disassemble and assemble overweight parts. Hoisting 3. Scaffolding must be firmly erected according to regulations and inspected for qualified use. When working at heights, construction workers must wear safety belts 4. Strictly implement the three no-nos, clean up the site in time, and keep the site tidy. 5. Measurement tools and spare parts must be placed in accordance with regulations, and disassembled parts and accessories must be locked after work. 1. Leave the power switch without turning off the power switch after work. The power switch must be turned off after get off work and after work. 2. After get off work, count personnel and items, arrange for personnel to clean up the site, ensure that the site is clean after work, and Party A is satisfied. 1401-K-101 Maintenance Quality Control Table Table-1 Serial Number Control Point Maintenance Content Standard Values Actual Measured Values Maintenance Team Leader Unit Operation Maneuvering Department Team Leader Control Level Remarks 1 Main Bearing Radial Clearance Radial Clearance (One Column) 0.24~0.36 A Radial Clearance (Two Columns) 0.24~0.36 A Radial clearance (three rows) 0.24~0.36 A Radial clearance (four rows) 0.24~0.36 A 2 Positioning bearing axial clearance (one row) 0.22~0.45 B Axial clearance (two rows) 0.22~0.45 B Axial clearance (three rows) 0.22~0.45 B Axial clearance (four rows) 0.22~0.45 B 3 Radial clearance between crankshaft pin and connecting rod big end bushing (one row) 0.25~0.37 A Radial clearance (two rows) 0.25~0.37 A Radial clearance (three rows) 0.25~0.37 A Radial clearance (four rows) 0.25~0.37 A 4 Radial clearance between cross head pin and connecting rod small end bushing (one row) 0.19~0.24 A Radial clearance (two rows) 0.19~0.24 A Radial clearance (three rows) 0.19~0.24 A Radial clearance (four rows) 0.19~0.24 A 5 Radial clearance between crosshead shoe and slideway (one row) 0.4~0.5 A Radial clearance (two rows) 0.4~0.5 A Radial clearance (three rows) 0.4~0.5 A Radial clearance (four rows) 0.4~0.5 A 6 Radial clearance between piston body and cylinder (one row) 3.5~3.7 A Radial clearance (two rows) 2.65~2.85 A Radial clearance (three rows) 3.5~3.7 A Radial clearance (four rows) 3.5~3.7 A 7 Axial clearance between piston ring and ring groove (one row) 0.24~0.39 B Axial clearance (two rows) 0.15~0.30 B Axial clearance (three rows) 0.24~0.39 B Axial clearance (four rows) 0.24~0.39 B 8 Axial clearance between support ring and ring groove (one row) 0.81~1.05 B Axial clearance (two rows) 0.52~0.76 B Axial clearance (three rows) 0.81~1.0 B Axial clearance (four rows) 0.81~1.0 B 9 Axial clearance between the scraper ring group and the box (one row) 0.05~0.10 B Axial clearance (two rows) 0.05~0.10 B Axial clearance (three rows) 0.05~0.10 B Axial clearance (four rows) 0.05~0.10 B 10 Axial clearance between packing seal ring group and box (one row) 0.3-0.38 Axial clearance (two rows) 0.3-0.38 Axial clearance (three rows) 0.3-0.38 Axial clearance (four rows) 0.3-0.38 11 Piston stop point one row 5±0.5 Second row 5±0.5 Third row 5±0.5 Fourth row 5±0.5 12 Inspection of delivery documents 1. Delivery documents and technical documents are complete and must be neat and clear. 2. The data organization meets the standard requirements. A Note: A – Joint inspection by the Mechanical Department, production unit operations, and Maohua Jian Dong Equipment; B – Joint inspection by the production unit operations and Maohua Jian Dong Equipment; C – Self-inspection by Maohua Jian Dong Equipment
Maintenance Type: Major Overhaul
Prepared by: Zeng Huabiao
Reviewed by:
Approved by:
Date:
Maintenance Contractor: XXX Moving Equipment
Form for Review and Approval of Construction Technical Plan
Plan Name: Maintenance Construction Plan for Reciprocating Compressors in XXX Refining and Chemical Plant
Prepared by the Construction Unit: Date
HSE Department: Date
Reviewed by: Date
Construction Unit’s Operations Department: Date
Mechanical Department: Date
Safety and Environment Department: Date
Table of Contents
I. Preparation Notes 3
II. Basis for Preparation 3
III. Project Overview 3
IV. Pre-construction Preparation 4
V. Construction Organization and Coordination 4
VI. Main Construction Procedures and Key Points for Maintenance 4
1. Disassembly Sequence 4
2. Technical Requirements for Disassembly and Inspection of Major Components 5
3. Quality Assurance Measures for Construction (attached: Quality Control Table) 10
VII. Construction Layout Plan 10
VIII. HSE Management and Risk Assessment 12
IX. Construction Tools and Equipment 13
I. Preparation Notes
In accordance with Hainan Refining and Chemical Plant’s major overhaul plan for 2009, and upon commission from the Mechanical Department, this plan is prepared for the major overhaul of the new hydrogen reciprocating compressor unit 1404-K-101. It aims to ensure the quality of the overhaul and timely delivery of the unit for use. II. Bases for compilation 1. Random data and drawings 2. SHS 01010---92 \"Maintenance and Repair Procedures for Piston Compressors\" 3. \"Maintenance and Repair Procedures for Petrochemical Equipment\" – General equipment. 4. \"Safety Operating Procedures for Lifting Operations\" III. Project Overview: This reciprocating compressor is of the 4M80 model, manufactured by Shenqi; the medium transported by the compressor is hydrogen, and the drive unit is an electric motor. This unit has been in operation since October 2006, and it is now time for a major maintenance inspection. It is currently functioning well, but there are oil leaks in several parts of the lubrication system. Additionally, the hard connections between the inlet and outlet flanges of the shaft head oil pump and the pipelines subject it to significant stress, which can easily lead to damage to the shaft seals and bearings. It is planned to eliminate these leakage issues completely during this maintenance inspection, and to replace the flanges of the shaft head oil pump with soft connections. To ensure smooth operation in the next cycle, its components are thoroughly inspected and replaced in accordance with the maintenance procedures. The main inspection items are as follows: 1. Inspect all intake and exhaust valves; replace them if necessary. 2. Check for wear on the inner walls of the cylinders as well as the levelness of the cylinders. 3. Inspect the piston rings, piston rods, crossheads, crosshead pins, connecting rods, main shaft, and connecting rod bolts for wear. 4. Check the wear condition of the main shaft bearings and crankshaft bearings. 5. Check the piston clearance. 6. Inspect and replace the sealing gaskets and oil scrapper rings. 7. Check the connection bolts of the machine frame and the foundation bolts. 8. Inspect and clean the check valve of the oil injector and the filter screen of the lubricating oil pump. 9. Inspect the main shaft oil pump, auxiliary oil pump, and the oil tank. IV. Preparations before construction 1. Conduct a technical briefing for the personnel involved in the overhaul, so that they are familiar with the construction drawings, technical requirements, and related documentation; they should also master the key points of the overhaul process, the operating procedures, and the quality standards. 2. Before shutting down the machine, conduct on-site observations of the compressor, analyze the operation status of the turbine, identify existing problems, formulate corresponding solutions, determine all the necessary construction steps, and carry out all preparation work in an organized manner. 3. Check whether the machine room is suitable for lifting operations, whether the crane is in good condition, whether the lifting switches function properly, and ensure that the moving parts are lubricated and maintained. . 4. Check whether the hydraulic pump and its auxiliary components are in good condition and address any issues to ensure proper operation ； Prepare all the specialized tools required to disassemble this unit, and ensure that any missing tools are fabricated and made available as backups. 5. Plan the layout of the construction site properly, and arrange the oil pans, sleepers, and rubber materials used in construction in designated locations in accordance with the requirements for civilized construction. 6. Prepare the construction tools as well as materials such as kerosene, white cloth, red lead, lubricating oil, and grease. 7. Spare parts for vulnerable components must be prepared before maintenance. 8. Before maintenance, the operator must carry out normal shutdown procedures, apply the necessary process treatments and safety measures, and finally complete the safety maintenance handover form. V. Construction Organization and Coordination This machine operates at high pressure and has a complex structure; therefore, high standards are required in terms of maintenance techniques and quality. It is thus essential to assign experienced technicians and fitters to carry out the work, with the guidance of the company’s professional technical department. Specific organization: 1. Supervisor: Peng Muxiu (responsible for construction, technology, quality, and HSE oversight); Fitters: 4 persons; Electrical and instrumentation personnel: 2 persons; Lifting personnel: 2 persons. 2. Construction coordination (see attached diagram). VI. Main Construction Procedures and Key Points for Maintenance Operations 1. Disassembly sequence (1) Remove the inlet and outlet valves for inspection ； (2). Check the piston dead center clearance ； Open the cylinder head, as well as the slide and crankcase cover ； (3). Measure piston rod runout ； Measure the clearance between the crosshead and the crosshead slide ； Check the crankshaft deflection by measurement; remove the locking device that connects the crosshead to the piston rod, take out the piston, and inspect the wear of the piston rings and the piston itself. (4). Remove the piston rod and check for wear and bending ； (5). Check the wear of the crosshead and pin shaft ； (6). Inspect and measure the cylinder ； (7). Disassemble and inspect the lubricating oil system ； (8). Reassemble in the reverse order of disassembly. 2. Technical requirements for the disassembly and inspection of major components: (1) Check the piston top clearance for each cylinder (unit: mm). Inspect the cooling water pipes, oil pipes, as well as the intake and exhaust valves of each cylinder level. To measure the top clearance, use wrenches of sizes 46, 50, 55, and 60 for the nuts of the intake and exhaust valves on each cylinder level. The piston top clearance should be 5±0.5 on the shaft side, and 2 on the cylinder side. (2) Disassemble the head covers and the locking devices that connect the crosshead to the piston rod, then lift out the piston (unit: mm). 1) Measure the radial clearance between the cylinder and the piston body ； 2) Axial clearance between piston rings ； 3) Axial clearance between the support ring and the piston ring groove 4) Opening clearance of the piston ring ； 5) Support ring opening clearance: Piston and cylinder mirror clearance Piston body diameter Ф326 Ф326 Ф232 Ф311.5 Cylinder mirror diameter Ф330H7 Ф330H7 Ф235H7 Ф315H7 Radial clearance 3.5-3.7 3.5-3.7 2.65-2.85 3.5-3.7 Axial clearance between piston ring and piston ring groove Piston ring width 10 10 12 15 Piston ring groove width 10.05 10.05 12.05 15.05 Axial clearance 0.24-0.39 0.15-0.30 0.24-0.39 0.24-0.39 Axial clearance between the support ring and the ring groove Support ring width 80 80 65 65 Support ring groove width 80.05 80.05 65.05 65.05 Axial clearance 0.81—1.05 0.81-1.0 0.52-0.76 0.81-0.10 Piston ring counterpart clearance 1.4 1.4 1.0 1.4 Piston ring counterpart limit clearance 5 5 4 5 (3) Piston and piston ring maintenance 1) The surface of the piston and piston ring should be smooth, and there should be no deformation, casting, machining and other defects. 2) The piston ring should move freely in the piston ring groove and have a certain expansion force. 3) The counterpart positions of the piston rings at all levels installed in the groove should be staggered by 120 degrees. 4) The contact line between the outer diameter of the piston ring and the cylinder should not be less than 60% of the circumference, and the gap should not be greater than 0.05mm. 5) Check the wear of piston ring groove and support ring groove Note: When disassembling and assembling, use a special tool high-pressure oil pump to disassemble and assemble the piston rod and the cross-head nut. When disassembling and assembling, the maximum pressure of the high-pressure oil pump shall not exceed 150Mpa. The whole tightening process needs to be completed three times, with an interval of one hour each time. The tightening method is the same each time. Lift out the piston rod. A piston rod sheath must be used when lifting the piston rod to avoid damaging the oil scraper ring, packing seal, and cylinder mirror. (4 ) Remove the piston rod and check the cylinder, piston rod wear and bending 1) Check the roundness and cylindricity of the cylinder, A. Allowable value of roundness:: 0.8D/1000－D/1000 Note: D is the cylinder diameter B. Cylindricity allowable value: C. Level of cylinder and slide: D. Maintenance of the cylinder E. The inner surface of the cylinder should be smooth and free of defects such as cracks and holes. F. The radial cylindrical degree inside the cylinder must not exceed the standard. G. When the surface of the cylinder is damaged by more than 1/4 and there are serious grooves, it should be dealt with in time. The surface roughness of the cylinder should be Ra 1.6. H. The increase in cylinder diameter must not exceed 2% of the original design diameter. I. Check the wear of the cylinder mirror 2) Maintenance of the piston rod A. The piston rod must not have cracks or other defects, the surface roughness is Ra 0.8, and non-destructive testing is performed if necessary. B. The straightness tolerance of the piston rod is 0.06mm/m, and the maximum shall not exceed 0.1mm/m. The horizontal runout of the piston rod shall not exceed 0.064 mm, and the vertical runout shall not exceed 0.1 mm. Note: When tightening the nut on the piston rod, you must use the electric heating rod that comes with the machine. You cannot use other tools to forcibly loosen the nut. When reassembly, you must add anaerobic glue (5) Check the clearance of each component of the crosshead (unit: mm) 1) Clearance between the column pin and the cross head seat shoe 2) Clearance between the column pin and the small head shoe of the connecting rod 3) Clearance between the cross head slide plate and the slideway 4) Roundness of the column pin Radial clearance between the connecting rod large head shoe and the column pin Diameter of the large head shoe column pin Ф359.855Ф359.895 Ф359.855Ф359.895 Ф359.855Ф359.895 Ф359.855Ф359.895 Connecting rod big head tile inner diameter Ф360-Ф360.206 Ф360-Ф360.206 Ф360-Ф360.206 Ф360-Ф360.206 Radial clearance 0.25-0.37 0.25-0.37 0.25-0.37 0.25-0.37 Radial clearance between connecting rod small end shoe and cross head pin Diameter of cross head pin Ф199.90-Ф199.93 Ф199.90-Ф199.93 Ф199.90-Ф199.93 Ф199.90-Ф199.93 Small head bushing diameter Ф200-Ф200.135 Ф200-Ф200.135 Ф200-Ф200.135 Ф200-Ф200.135 Radial clearance 0.19-0.24 0.19-0.24 0.19-0.24 0.19-0.24 Radial clearance between the crosshead slide plate and the slideway Crosshead slideboard diameter Ф539.45-Ф539.53 Ф539.45-Ф539.53 Ф539.45-Ф539.53 Ф540H7 Slide diameter Ф540H7 Ф540H7 Ф540H7 Ф400-Ф400.057 Radial clearance 0.4-0.5 0.4-0.5 0.4-0.5 0.4-0.5 Pin roundness 0.02-0.03 (6) Inspection of the crosshead, slide plate and slideway 1) Crosshead, crosshead pin, slideboard should be free of defects such as cracks 2) The contact point between the slideway and the slideway should be no less than 2 points per square centimeter, and the clearance requirements are as shown in the figure above (7) Check the packing seal and oil scraper ring (unit: mm) 1) The combined sealing packing should be smooth and scratch-free, with a surface roughness of Ra0.8. 2) The contact area between the sealing ring and the piston rod reaches more than 70%, and the contact points should be no less than 4-5 points per square centimeter. It is strictly forbidden to use emery grinding. 3) The contact gap of the combined sealing packing is generally not less than 1mm, and the packing openings of each ring should be evenly staggered for assembly. For three- and six-lobed sealing rings, the three valves are close to the high-pressure side. The six petals are on the cross head side. 4) The axial end surface of the packing should be in even contact with the stuffing box. 5) The contact surface between the scraper ring and the piston rod is not allowed to have grooves or damage. The contact line should be evenly distributed and greater than 70% of the circumference. The axial gap between the scraper ring and the box is 0.05-0.10 mm. 6) The axial gap of the packing is 0.53-0.66mm (8) Disassembly and inspection of the intake and exhaust valves. 1) The valve plate must not be deformed or cracked. Defects such as scratches 2) The sealing surface of the valve seat must not have corrosion pits, scratches, and the roughness is R 0.8. The contact line with the valve plate should be continuously closed. 3) The valve spring should have sufficient elasticity. On the same valve plate, the diameter and free height of each spring should be consistent. The valve plate can rise and fall freely without jamming. 4) The inlet and outlet valves are not damaged, and the contact line connected to the valve seat should be continuously closed. 5) The lift controller of the inlet valve can move freely. No jamming phenomenon (9) Inspection and repair of crankshaft, piston, connecting rod and bearing sleeve 1) The crankshaft, connecting rod and connecting rod bolts are not allowed to have cracks and other defects 2) The radial circular runout tolerance of the main journal is 0.02mm, and the opening and closing degree is 0-0.04mm. If it exceeds 0.1mm, it must be adjusted. 3) The scratch area of the main journal shall not be greater than 2% of the journal area, and the groove of the journal shall not be greater than 0.1 mm. The main journal and crankshaft journal should not be reduced by more than 3%. 4) The shaft and the bearing should be in uniform contact, with no less than 2---3 contact points per square centimeter. The bearing backing is evenly fitted to the machine base and connecting rod socket, and the contact area is 70%-80%. 5) The bearing alloy layer and the bearing bushing are well combined. The surface of the alloy layer must not have cracks, pores and other defects, and thin-walled bearings must not be scratched. 6) The main bearing bush clearance is controlled to 0.24-0.36mm. , the clearance between the crankshaft pin and the big head shoe is 0.25-0.37mm 7) The axial clearance of the positioning bearing is 0.22-0.45mm (10) Inspection of the auxiliary oil pump and oil injector 1) Inspection of the shaft head oil pump A. Check the bearing and seal (replace if necessary) B. Check the meshing clearance of the gear: 0.105 mm C. Check the axial clearance of the gear; 0..10---0.15 mm D. The gap between the gear and the casing: 0.15---0.25mm 2) Inspection of various parts of the shaft head oil pump A. Inspection of the casing: The roughness of both end surfaces of the casing is Ra3.2, the tolerance value of the parallelism of the two hole axis centers and the verticality of both ends is not less than IT6 level; the cylindrical tolerance value of the inner hole of the casing is 0.02---0.03mm/100mm B. Inspection of the gear: The shaft fit of the gear is H7/m6; the perpendicularity between the two end surfaces of the gear and the center line of the shaft hole or the two end surfaces of the gear and the center line of the shaft is 0.02mm/100mm; the width of the two teeth is the same, the width error of a single gear shall not exceed 0.0 5mm/100mm, the top clearance of the gear mesh. The side clearance can be measured by the lead pressure method. C. Gear and shell: The radial clearance of the gap between the gear and the shell can be checked with a feeler gauge; The clearance value is 0.15--0.25 mm, but it must be greater than the radial clearance between the journal and the bearing bush. D. Adjustment of the clearance between the gear and the pump cover: The clearance between the gear and the pump cover can be checked by the lead wire method. According to the specific measurement results, the thickness of the end cover gasket is added or subtracted to make the end face clearance between 0.10---0.15mm. E. Inspection and assembly of the shaft and bearing: There must be no scars on the journal of the gear oil pump, and the roughness requirement is Ra1.6. The journal cylindricity tolerance is 0.01 mm, and the maximum journal wear shall not be greater than 0.01D (D is the diameter of the journal) (10) Coupling 1) When the coupling is inspected, it is strictly prohibited to hammer it directly with hands to avoid damaging the coupling 2) Requirements for coupling alignment: end face circular runout: 0.03mm radial circular runout: 0.04mm 3. Construction quality assurance measures (quality control table attached) 7. Construction floor plan 8. HSE management and risk assessment 8.1. Strictly implement Hainan Refining and Chemical's "Safety Production Management Standards" and the construction company's HSE management regulations, conscientiously implement safety measures to ensure the completion of compressor maintenance tasks. 8.2. Organize the construction workers to study carefully the safety regulations related to major repair work; the HSE supervisor shall provide instructions at the safe construction site to ensure that the workers are familiar with the construction environment and the precautions to be observed. 8.3. The maintenance equipment to be delivered must be thoroughly purged; for electric equipment, the power supply must be cut off, and work may only proceed after verifying that all safety measures have been implemented. 8.4. Workers entering the construction site must wear the required personal protective equipment to ensure their health. 8.5. Machine operators should empty their pockets before entering the site, to prevent items from falling into the machines. During construction, the unit should always be covered with plastic sheeting to prevent dust and debris from entering the machine. When securing the cover, a thorough inspection should be carried out to ensure that there are no foreign objects inside the machine. 8.6. When removing or assembling components, do not use forceful blows or prying; use specialized tools instead. The removed parts should be placed on pallets or in oil trays, ensuring that they are neither exposed to the air nor in contact with the ground, thereby improving the site management practices related to civilized construction. 8.7. Fire prevention measures should be taken in the machine room, and carbon dioxide or carbon tetrachloride fire extinguishers should be placed at appropriate locations. 8.8. Crane operations must be carried out in strict accordance with the \"Safety Management Regulations for Crane Operations\" and the safety operation procedures specific to this type of work, ensuring that responsibilities are assigned to specific individuals and that there is unified command. 8.9. When two or more people work together, one person must be designated to be responsible for safety to ensure coordinated work and achieve the principle of \"no harm to oneself, others, or the environment.\" 8.10. Carry out construction in a civilized manner and ensure proper environmental protection during construction. Used parts and construction pollutants must be removed promptly; oil stains should be discharged at designated locations, and upon completion of work, the area must be left clean with no leftover materials. 8.11. In light of the characteristics of this maintenance work, an HSE risk assessment and analysis of control measures have been carried out; details are provided in the attached table. 9. Construction tools, tools, materials, name, model, specification, unit quantity, remarks, random special tool set 1 (full set), adjustable wrenches 8″, 10″, 12″, 15″, 5 sets each, 5.5~32mm box spanner sets, 3 sets, heavy socket sets, 1 hammer, 1 pound, 1.5 pound handles, 2 each, screwdriver (including iron handle), 5 handles, file handle 5, manual hoist 1T, 2T, 3T, 2 each, feeler gauge handle 3 Dial indicator 2, depth caliper and vernier caliper handle 2 each Micrometer handle 2 Sleeper bar 10 Wire rope root 6 Pipe clamp handle 3 Construction unit: Maohua Jianyangpu Branch Working hours Analyst name: Huang Zhiyong Work location: Xinhydro compressor room Work content: Compressor overhaul appraiser name: Peng Muxiu Work steps Hazard factor analysis Hazard consequence analysis Risk level Planned control measures Preparation work 1.1 Construction equipment is not intact 1.2 Employees do not dress as required1.3 Lifting equipment is not available1.4 Work tickets are not issued according to Yuanqu regulations1. Equipment cannot be used causing accidents, or other personal accidents are caused by equipment problems2. Chaotic management of the construction site can easily cause equipment and personal accidents3. Safety measures are not implementedⅢⅢⅢⅢ 1. Hoisting machinery used on site must be inspected. Maintenance and inspection must be carried out to confirm that the mechanical performance is intact before it can be sent to the construction site for use2. Strengthen supervision and management 3. Strictly implement the work ticket system and implement safety measures during the work process 1. Employees do not wear labor protection equipment as required by regulations 2. Failure to take protective measures as required when disassembling and assembling anti-lifting parts 3. Not wearing safety belts when working at heights 4. Grease falls to the ground on site 5. Tools and spare parts are not stored as required 1. Causing personal injury and damage to health 2. Causing personal casualties. Equipment damage accidents 3. Construction workers fall from heights 4. Construction workers slip and cause personal injuries 5. Loss and damage of parts Ⅱ Ⅲ Ⅲ Ⅰ Ⅰ 1. Strictly require on-site personnel to wear labor protection equipment in accordance with regulations 2. Use force when lifting, and use special tools to disassemble and assemble overweight parts. Hoisting 3. Scaffolding must be firmly erected according to regulations and inspected for qualified use. When working at heights, construction workers must wear safety belts 4. Strictly implement the three no-nos, clean up the site in time, and keep the site tidy. 5. Measurement tools and spare parts must be placed in accordance with regulations, and disassembled parts and accessories must be locked after work. 1. Leave the power switch without turning off the power switch after work. The power switch must be turned off after get off work and after work. 2. After get off work, count personnel and items, arrange for personnel to clean up the site, ensure that the site is clean after work, and Party A is satisfied. 1401-K-101 Maintenance Quality Control Table Table-1 Serial Number Control Point Maintenance Content Standard Values Actual Measured Values Maintenance Team Leader Unit Operation Maneuvering Department Team Leader Control Level Remarks 1 Main Bearing Radial Clearance Radial Clearance (One Column) 0.24~0.36 A Radial Clearance (Two Columns) 0.24~0.36 A Radial clearance (three rows) 0.24~0.36 A Radial clearance (four rows) 0.24~0.36 A 2 Positioning bearing axial clearance (one row) 0.22~0.45 B Axial clearance (two rows) 0.22~0.45 B Axial clearance (three rows) 0.22~0.45 B Axial clearance (four rows) 0.22~0.45 B 3 Radial clearance between crankshaft pin and connecting rod big end bushing (one row) 0.25~0.37 A Radial clearance (two rows) 0.25~0.37 A Radial clearance (three rows) 0.25~0.37 A Radial clearance (four rows) 0.25~0.37 A 4 Radial clearance between cross head pin and connecting rod small end bushing (one row) 0.19~0.24 A Radial clearance (two rows) 0.19~0.24 A Radial clearance (three rows) 0.19~0.24 A Radial clearance (four rows) 0.19~0.24 A 5 Radial clearance between crosshead shoe and slideway (one row) 0.4~0.5 A Radial clearance (two rows) 0.4~0.5 A Radial clearance (three rows) 0.4~0.5 A Radial clearance (four rows) 0.4~0.5 A 6 Radial clearance between piston body and cylinder (one row) 3.5~3.7 A Radial clearance (two rows) 2.65~2.85 A Radial clearance (three rows) 3.5~3.7 A Radial clearance (four rows) 3.5~3.7 A 7 Axial clearance between piston ring and ring groove (one row) 0.24~0.39 B Axial clearance (two rows) 0.15~0.30 B Axial clearance (three rows) 0.24~0.39 B Axial clearance (four rows) 0.24~0.39 B 8 Axial clearance between support ring and ring groove (one row) 0.81~1.05 B Axial clearance (two rows) 0.52~0.76 B Axial clearance (three rows) 0.81~1.0 B Axial clearance (four rows) 0.81~1.0 B 9 Axial clearance between the scraper ring group and the box (one row) 0.05~0.10 B Axial clearance (two rows) 0.05~0.10 B Axial clearance (three rows) 0.05~0.10 B Axial clearance (four rows) 0.05~0.10 B 10 Axial clearance between packing seal ring group and box (one row) 0.3-0.38 Axial clearance (two rows) 0.3-0.38 Axial clearance (three rows) 0.3-0.38 Axial clearance (four rows) 0.3-0.38 11 Piston stop point one row 5±0.5 Second row 5±0.5 Third row 5±0.5 Fourth row 5±0.5 12 Inspection of delivery documents 1. Delivery documents and technical documents are complete and must be neat and clear. 2. The data organization meets the standard requirements. A Note: A – Joint inspection by the Mechanical Department, production unit operations, and Maohua Jian Dong Equipment; B – Joint inspection by the production unit operations and Maohua Jian Dong Equipment; C – Self-inspection by Maohua Jian Dong Equipment
I enjoy communicating; thanks for sharing! Thank you!
Refer to the original regulations of the Ministry of Chemical Industry on the maintenance of large reciprocating compressors.
Do the moderators have an electronic version? Could you provide it?
This post was last edited by A pot of fragrant tea on 2013-1-1 20:21. It really doesn’t exist. Only paper version: L
Areas that are worn can be repaired using laser cladding technology. .
Original poster, if possible, please send me an electronic version, including the maintenance plans for other types of equipment. my email address is 1184567420@qq.com. Thank you.
It would be best to include photos from the maintenance process, so that beginners like me can learn from them*