-, overhaul preparation: In order to improve the quality of overhaul, to ensure the progress of overhaul, fast and economical completion of the overhaul task, we must do a good job of overhauling the construction of the preliminary preparatory work. Overhaul of equipment and other overhaul projects can not be completed on their own, should be contacted early to do a good job of overhaul outsourcing.
1, in order to complete the overhaul of special projects, especially some of the major special projects, it is necessary to early and planned arrangements, from the material, process technology to prepare. Overhaul five months before the relevant professional should fill out the overhaul project table, sent to the department leader audit, audit conclusions as the basis for ordering;
2, machine and furnace in the overhaul three months before the deputy manager of the Department of Thermoelectricity organized by the relevant professional inspection of the overhaul of the preparations for checking the major special projects related to the ordering of equipment, materials, spare parts, the arrival of the situation, the design, processing progress and technical and technological preparations to implement one by one to ensure that the realization of the schedule, the technical and technological preparations, and to ensure the implementation of the overhaul of the project. Item by item implementation, to ensure the realization of the schedule;
3, 45 days before the overhaul of the overhaul supervisor to finalize the overhaul project list, fill out the overhaul material application form, sent to the departmental leadership review of the vice president in charge of the approval of the Department of Warehousing to purchase materials.
Second, the preparation of equipment repair construction plan:
1, the main equipment overhaul construction plan by the overhaul technician in the 30 days before the start of work to report to the department manager for review and approval, the repair supervisor in the 20 days before the start of work to prepare the overhaul of the control schedule and network diagrams, coordination of the various professions and the outsourcing of the unit's coordination, the overall requirements of the overhaul for the approval of the department manager and the deputy general manager in charge;
2, the main equipment repair construction plan, by the maintenance technician in the 10-15 days before the start of work to compile a good report to the department manager for review, in duplicate, the department manager, the supervisor of the storage of a copy;
3, the main equipment overhaul construction plan includes overhaul project (has been ordered standard items do not have to list the contents of the standard items). Construction progress, the necessary technical measures and safety measures, quality standards, the provisions of the level of segment acceptance project, the specific requirements of the seven supervision, lifting and handling facilities and site layout, labor arrangements and organizational measures, labor, materials, costs, plans, and requests for cooperation with the brotherhood of units, etc.;
4, where the special project involves the change of the equipment, such as changes in the structure of the equipment, the system changes, it should be According to the equipment change management system for equipment change procedures;
5, the main equipment overhaul construction plan, approved by the vice president in charge, shall not be changed, such as the need for change, still need to be approved by the vice president in charge. Third, the construction of the technical briefing before the construction plan preparation, must be organized to learn, so that each maintenance team and each maintenance workers to do "three clear", "eight know" three clear: clear repair what? Why repair? How to repair? Eight know: know the items that should be repaired and should eliminate equipment defects; know the progress of the overhaul, know the materials and tools should be prepared, know the relevant technical measures, know the quality standards and methods of technology, know the acceptance system, evaluation criteria and acceptance of the person, know the relevant security measures, know the original determination of the records, instrumentation and measuring instruments and methods of reading and writing technical records. In the overhaul process, where the quality and safety problems occur due to the task is not clear, the competent leader is responsible. If the task is clear and the end in accordance with the implementation of the specific overhaul by the personnel responsible for.
Fourth, the construction of quality standards: quality standards, process methods and acceptance of the provisions of the overhaul regulations, professional repair should be dyke out of the total quality of the equipment before the repair of the size of the total quality requirements, the number of consecutive days of continuous safety after the package of repair work, repair output, technical and economic indicators, repair should be eliminated after the major defects, in order to check the assessment.
Fifth, the construction of the preparatory work of the inspection 1, the main equipment overhaul preparations for the implementation and inspection. (1), one month before the overhaul by the department manager to convene a meeting to prepare for the overhaul, the implementation of the overhaul project, check the major technical measures, commissioned overhaul, testing, research unit test project implementation, the main materials and spare parts, labor force preparation and arrangement and collaboration between the relevant departments; (2), before the overhaul of the supervisor of the contracting unit and the construction of the department of each team to prepare for a comprehensive inspection, such as construction Machinery, and tools, safety appliances and facilities, gauges, measuring instruments, test equipment, etc., prior calibration work, to prepare the technical record forms, to determine should be mapped and calibrated spare parts drawings, found that the weak links, should take measures to quickly remedy, and report to the leadership; (3), a week or so prior to the overhaul, chaired by the departmental manager of the overhaul of the preparation of various professions to participate in the inspection meeting to listen to the preparatory work The report, and evaluation and instructions on all aspects of the preparatory work; (4), four days before the overhaul, the overhaul supervisor to organize the contracting unit in charge of the relevant person in charge of the contracting unit and the department to check the implementation of the preparatory work, ready to fill in the report on the commencement of the work. Two days before the overhaul, the deputy general manager in charge of the inspection results based on all aspects of the preparatory work is considered to have the conditions for the start of work after the approval of the official start. 2, the main equipment minor repair or major auxiliary overhaul of the preparatory work, by the maintenance supervisor to check the qualified before starting.
Sixth, other preparations before construction: 1, overhaul should be done before the start of the thermal test, determination of the necessary characteristics of the data, in order to determine the technical condition of the equipment before repair, to facilitate the analysis of the effect of overhaul; 2, according to the technical requirements, the material spares parts, transported to the scene, the quality of performance after acceptance, complete warranty; 3, before the start of the work, the analysis of the operation should be strengthened, the professional supervisors should organize Equipment masters, full-time technical staff to carry out an in-depth inspection of the equipment site, review the technical condition of the equipment, as a reference for overhaul.
VII, overhaul phase (process) management, the construction period is a highly concentrated stage of overhaul activities. 1, in the overhaul should be done before the start of the following work: (1), do a good job of overhauling the organization of personnel, overhaul projects, labor quotas, the planned duration of implementation to the class, fine to the group as well as the individual; (2), the organization of the study of safety procedures, overhaul process procedures, "quality standards" equipment manufacturing diagrams related to the construction of construction drawings overhaul of the construction management work book, etc.; (3), to prepare for the overhaul of the workplace, overhaul of the special equipment, insulating appliances, Hoisting machinery, welding machine into position, and carry out the necessary checks, tests (test rotation), ready for lighting and construction power supply; (4), ready for overhaul of the necessary materials, equipment and spare parts, and do a good job of the final acceptance of the work, to confirm that qualified; (5), equipment overhaul of the original record card, acceptance of visas, etc. ready; (6), carefully clean the site, so that there is no garbage, no debris, no coal dust.
2, disintegration stage of overhaul management: (1), should be as early as possible to do a good job of equipment disintegration inspection, timely analysis of changes in the technical condition of the equipment, disintegration inspection should be careful, careful, comprehensive, can not be omitted, found that the problem, we must find out the reasons for the disintegration of the measurement of the original records; (2), the opening of the professional disintegration of the analysis of the meeting, and the development of repair and adjustment programs.
3, repair, adjustment stage of the inspection and management: (1), repair, adjustment stage is an important stage of overhaul quality management, should strictly adhere to the quality standards for repair and adjustment, timely intermediate quality acceptance, the organization of the necessary sampling, and timely acceptance of the visa formalities; (2), repair personnel should adhere to the quality first policy. In the progress and funding and quality contradictions should be subordinate to the quality of the requirements to adhere to the strict style of craftsmanship; (3), the strict implementation of the process regulations, careful repair, careful inspection, to ensure the quality of overhaul.
4, the stage of overhaul management: (1), strictly prevent the tools, workpieces and other miscellaneous items left inside the equipment; (2), the installation process should be rigorous, in particular, to prevent the quality of rework due to sloppiness; (3), the installation of the time pieces do not miss the installation, signboards, instructions, signals, numbering and so on, complete; (4), to do a good job of auxiliary divisions of the trial and the necessary test work. Requirements for all professions to take the initiative to cooperate in a timely manner to fill out the "test turn application form". Convinced that the work has been completed before countersigning; (5), in a timely manner to do a good job when the whole machine start the necessary tests, adjustments and other preparatory work.
5, to strengthen the technical records, to be correct and complete, timely, clear handwriting, must faithfully reflect the situation, the record should include the technical condition of the equipment, the system or structure of the change in the measurement and testing of data, etc., and are signed by the relevant personnel to improve the thermodynamics, electrical secondary system as-built drawings.
6, the requirements of overhaul process style: strict implementation of overhaul quality standards, seriously comply with the dismantling process to achieve the "three no, three Qi, three do not mess up, ten rectification." Three noes: refers to the overhaul operation, "no oil, no water, no ash". Three Qi: refers to the overhaul site "removed another piece of neatly stacked, overhaul machine placed neatly, materials and equipment stacked neatly. Three not messy: refers to the overhaul of the site cable not pulling, pipeline not put, garbage not throw. Ten rectification: refers to the rectification of ten key points of the repair process style. (1), the oil system overhaul to do not leak oil, no vibration (no obvious vibration phenomenon); (2), the valve overhaul to do inside and outside of no leakage, the switch is not sluggish, the openness of the instructions and the actual match; (3), the electrical switch overhaul to do a good contact, the action of the correct, qualified insulation; (4), the pipeline tidy up to do the arrangement of the horizontal and vertical, Shunslope support intervals in line with the requirements of the color of the paint (heat preservation) insulation to meet the requirements; (5), the rotating machinery overhaul to do the list of No oil seepage, vibration standards, no unusual sound and heat phenomenon; (6), precision instruments, gauges and processing parts to do not take, do not use, do not put; (7), disassembly of flange screws to do the disassembly to symmetry, the force distance to grasp the teeth to be consistent; (8), lifting to do the "three do not hang": lifting capacity is not clear do not hang, the rope safety coefficient is not enough do not hang The corners of the lifted objects are not wrapped up not to hang; (9), welders to do "three do not weld". Material process is not clear not welded, counterpart cleaning is not required not welded, unqualified test not welded; (10), insulation to do the "four to", adiabatic properties to be qualified, inside and outside the quality to be good, near the bearings should be oil-proofing measures, thermal insulation tin to be all loaded back.
7, after the start of the overhaul, should be as soon as possible to do a good job of equipment disintegration inspection, analysis of changes in the technical condition of the equipment, disintegration inspection should be serious, careful, comprehensive, can not be omitted, found that the problem, but also to find out the reasons for it, professional supervisors, full-time technicians should be in-depth on-site mapping of the bottom of the report, the inspection and analysis of the disintegration of the meeting will be held in a timely manner. Detailed report by the shift manager. Supervisor and full-time technical staff to consider, for the actual situation of the equipment, factual adjustment of overhaul projects, the implementation of overhaul methods, processes and progress, reported to the supervisor for approval after the implementation of the leadership. Equipment dismantling or seven major problems found in the supervision, the manager of the Department of Thermoelectricity should be organized on-site testing of relevant personnel to decide countermeasures; 8, scheduling balance will be: (1), overhaul process, the Department of Thermoelectricity should be held on a regular basis scheduling balance will be, at any time, to grasp the quality of the construction, the progress of the timely adoption of appropriate measures to rationally organize the work process, and to do a good job of the labor force, special types of work, repair and processing, the Department of the work project, the construction of machines and materials, supplies and other aspects of the balance of scheduling Balanced scheduling of all aspects of the contracting unit in charge and technical personnel and the company's relevant professionals to participate. The meeting should be concise, the first whole, after the department, the meeting time is generally no more than two hours; (2), the impact of quality, control progress and the entire project of the key projects, maintenance supervisors should be directly mastered, day by day to analyze the completion of the situation, to take the necessary measures to ensure the quality and progress through the various levels of scheduling, to be implemented; (3), the professional supervisors and full-time technicians, should be in-depth inspection of the work of the team. During the overhaul period, the team leader or the person in charge of the work should be convened regularly every day to meet, systematically summarize the day's overhaul situation, solve the specific progress, labor, equipment balance, quality and safety requirements, layout key projects, check technical records, understanding and coordination of the construction unit and the collaboration between the department and between the team, etc.; (4), the overhaul of the team, the pre-shift and post-shift will be presided over by the head of the team, the pre-shift will be set up for the day's task Convey the instructions of superiors, put forward key requirements and safety precautions, etc., after the meeting to understand and summarize the day's maintenance tasks and safety plans against the maintenance plan to solve the problem.
9, overhaul records: (1), overhaul records is the equipment to prepare for repair before and after the state of repair, overhaul after the test results of the technical raw materials. Through the analysis of the overhaul, can be derived from the wear and tear speed of the other parts of the equipment, replacement cycle, is conducive to grasp the situation of the equipment, but also through the analysis of the study, found that the structure of the material defects, so as to make improvements, overhaul records for the equipment ledger by the accumulation of technical files, man-hours, equipment consumption records, is to improve the technical management, and improve the economic accounting of the basic information, which must be carefully and correctly and comprehensively do a good job of overhauling the records. This must be carefully and correctly and comprehensively do a good job overhaul records. (2), overhaul records classification: ①, management records: including repair before and after the repair of equipment parts gap, size, technical condition, overhaul process, methods, components, test identification results, equipment structure, system changes, etc.; ②, management records: such as tool records, shift records, steam packet in and out of the registration, etc.; ③, economic accounting records: such as the hours consumed by each work project, materials, costs, repair and scrap, saving Records to be used. (3), the person in charge of the work is responsible for the work of overhaul records, to ensure that correct, as the acceptance of the technical information; (4), the team leader, the team technician, is responsible for the class overhaul records of the review of the work of the important technical data should be arranged for retesting the work of the person in charge of the general data measured by the sample should be retested, and to further improve the quality of the data, the team technician is responsible for all types of overhaul records within the class of the retesting, sorting, registration work (5), collated all kinds of overhaul records, should be handed over to the person in charge of the acceptance of the day before the acceptance of the subsection review, cover the cylinder needs to be delivered twenty-four hours before the review, the original records to stay in the class, some according to the acceptance of the person in charge of the views to be duplicated in triplicate as an acceptance of the visa annexes; (6), the technical records by the supervisor of the preservation of the professional professional and full-time technicians to summarize the collation, the rough and save the essence of the summary of the overhaul is written in the attached. Management records are kept by the overhaul class itself, and the relevant economic accounting records are kept for two intervals; (7) all kinds of overhaul records, should use the professional form record card, clean and complete, the record content should meet the requirements of the form, and shall not be scribbled, scribbled in the record book; (9) overhaul records are one of the main contents of the handover; (10) the technician should check the correctness and completeness of the various types of overhaul records on a regular basis or irregularly on a random basis, and at any time Analyze the data in order to find anomalies and deal with them in time.
10, overhaul personnel should adhere to the "quality first" principle, to adhere to the strict and meticulous style of workmanship, the strict implementation of the process procedures, careful inspection, careful measurement, careful repair and commissioning, to ensure the quality of overhaul, the last process should be for the next process, the last process quality is not qualified, the next process should be rejected to ensure quality;
10, the technical staff should regularly or periodically check the correctness and completeness of all kinds of maintenance records, and always analyze the data in order to deal with abnormalities. Refuse to accept, in order to ensure quality;
11, technical supervision projects should be carried out seriously, professionals should support each other, unity and cooperation, to provide convenience, timely sampling and analysis or testing. Supervision of the project found in the equipment defects or problems, technical supervisors should report to the leadership in a timely manner, in order to make judgments on the state of the equipment, put forward requirements and recommendations;
12, the entire overhaul process should be conscientiously carry out the electrical safety regulations, to prevent accidents to persons and equipment, in the dismantling, installation phase to prevent tools and other debris falling inside the equipment, such as accidentally fall into the workshop leadership to report to the timely measures to be taken. Workshop leaders to report to take measures.
13, strengthen the site parts management: (1), overhaul of small parts removed, such as screws, pins, etc. should be stored according to the type of specifications in a special box. Some should be written on the label, in order to prevent loading errors; (2), the number of parts removed should be counted, scrubbed clean, neatly stacked, found that the number does not meet, to identify the reasons; (3), for precision parts such as gears, bearings, axle shaft tiles, speed control structure, etc. should be covered by a white cloth, conditions should be put into the box cabinet; (4), the demolition of the big another piece should be neatly stored in the previously designated locations; (5), the need to supplement the new parts, should be through the Shift supervisor, the shift supervisor should find out the reason for supplementation, and verify that the specifications of the new parts, materials and the original parts match; (6), replacement or removal of old parts should be dealt with in a timely manner in general, oversized parts, such as the primary wind elbow, burner, large valves to wait for the completion of the overhaul, the completion of the regular processing; (7), in the overhaul of open equipment, piping, etc., must be blocked with special plugging boards or wooden plug plugs blocked, and some of them should be used with a white cloth will be opened to the open part of the cover Bundle and seal to prevent debris from falling in.
14, overhaul site tool management: (1), every day before the close of work or a work end, should be counted tools; (2), public tools such as electric drills, portable grinding wheel, walking light transformer, blowtorch, ladder, sledgehammer, etc., should be designated for safekeeping, borrowing, registration formalities, and returned immediately after use; (3), enter the container when working inside the container should be brought into the timely registration of the tools, the end of work to check. To carry out an inventory, such as found missing and can not be identified, should be immediately reported to the shift supervisor, to study the treatment of opinions.
15, overhaul to strengthen civilized production, timely clean up debris, keep the parts placed neatly, the site is clean, to work hard to eliminate the "seven leaks";
16, the end of the overhaul should be returned to the redundant equipment, to do the work of the material clear site net.