目 录
1.总则 ······························································································· 3 1.1适用范围 ························································································ 3 1.2结构简述 ························································································ 3 1.3主要技术性能 ··················································································· 3 2.设备完好标准 ···················································································· 3 2.1零部件完整齐全，质量符合标准 ···························································· 3 2.2设备运转正常，性能良好 ···································································· 4 2.3技术资料齐全、准确 ·········································································· 4 3.设备的维护 ······················································································· 4 3.1.日常维护 ······················································································· 4 3.2定期检查内容 ··················································································· 5 3.3.常见故障处理方法············································································ 5 4.检修周期和检修内容 ··········································································· 6 4.1检修周期 ························································································ 6 4.2检修内容 ························································································ 7 5.检修方法及质量标准 ··········································································· 7 6.试车与验收 ······················································································· 10 6.1试车前的准备工作 ············································································· 10 6.2试车 ······························································································ 11 6.3验收 ······························································································ 11
7.维护检修安全注意事项 ········································································· 11 7.1维护安全注意事项 ············································································· 11 7.2检修安全注意事项 ············································································· 12 7.3试车安全注意事项 ············································································· 12
1 总则 1.1 适用范围
本规程适用于山西建滔万鑫达化工有限责任公司工程维修部。 本规程适用于各种高压容器、阀门和管道等进行试压的电动试压泵维护和检修。 1.2 结构简述
电动试压泵为四柱塞往复式，由水箱、集水器、安全阀、两只高压水缸和两只低压水缸等组成。 1.3 主要技术性能（见表1）
表1 主要技术性能
项 目 额定压力 流量 2 设备完好标准 单位 MPa L/h 数值 25 40 项目 功率 泵速 单位 Kw r/min 数值 1.5 43 2.1 零部件完整齐全，质量符合标准
2.1.1主辅机的零部件完整齐全，质量符合要求，几何尺寸不超过允差标准。 2.1.2压力表、安全阀等装置完整齐全，动作灵敏、准确，仪表、安全阀定期检测率100%。
2.2 设备运转正常，性能良好 2.2.1设备润滑良好，油质符合要求。 2.2.2试压泵在运转中无异常声响。 2.2.3试压泵最高工作压力达60MPa。 2.3 技术资料齐全、准确
2.3.1设备档案、检修及验收记录齐全，填写及时，准确率100%。 2.3.2设备易损件100%有图纸。
2.3.3设备操作规程、检修规程、维护保养规程齐全。 3 设备的维护 3.1 日常维护
3.1.1水箱在加水前必须冲洗干净，不允许水箱内积储污物或其它杂物。 3.1.2严格执行“设备润滑管理制度”。按规定期限补充或更换润滑油。 3.1.3随时检查减速器内润滑油的温度，若温度超过85℃应立即停机，查找原因及时处理。
3.1.4工作中工作压力不允许超过60MPa。
3.1.5气瓶内应保持有一定量空气，以减低压力表指针的振幅。 3.1.6在工作中如发现有漏水情况，应立即停机，泄压进行检修。
3.2 定期检查内容（见表2）
表2 定期检查内容
项目 周期，月 内容 润滑油质 12 失效，变质 压力表 12 准确，灵敏 安全阀 12 灵敏，可靠 3.3 常见故障处理方法（见表3） 检查方法 用凝点、闪点、运动粘度测定器检查 送计量单位检定 送计量单位检定 表3 常见故障处理方法
处理方法 1拆开检查，研磨进水阀和出水阀压力表上升1进水阀或出水阀不严密 使其严密 压力不均匀2进水口滤网被堵塞或管道2清洗滤网或消除漏水 或指针摆动连接处漏水 3适当调整填料，如填料损坏，则不上升 3密封填料处漏水 应更换填料 1适当的进行放松 1柱塞密封填料太紧 所需功率过2检查和校正柱塞，必要时更换柱2柱塞弯曲与水缸发生干涉 大 塞 3回流阀未及时打开 3及时打开回流阀 4 检修周期和检修内容 4.1 检修周期（见表4）
表4 检修周期 月
检修类别 检修周期 4.2 检修内容 4.2.1小修
a 检查滑块与偏心，并测量其间隙。
b 检查滑块与滑槽间隙，间隙过大应调整修复。 c 检查各柱塞密封填料，更换损坏填料。 d 清洗检查进水口滤网。 e 清洗水箱污垢。 4.2.2中修
a 完成小修项目。
b 检查柱塞精度，修复并更换柱塞。
小修 12 中修 24 大修 60 现象 原因
c 检查水缸精度，如拉伤应进行修复。 d 清洗减速器，更换新油。 4.2.3大修
a 完成中修项目。
b 检查蜗杆和蜗轮的磨损情况。 5 检修质量标准
a 水箱内不允许有积贮污物或其它杂物。 b 滑块与滑槽间隙不得大于1mm。 c 偏心与滑块间隙不得大于0.1mm。 d 蜗杆与蜗轮的侧间隙不得大于0.30mm。 e 柱塞与水缸的配合间隙允差0.02~0.05mm。
f 安全阀的开启压力不超过最大工作压力的1.1~1.14倍。 6 试车与验收 6.1 试车前的准备工作
6.1.1清理、打扫检修现场及设备内部，减速器内加油至工艺要求位置，水箱内注满清水。
6.1.2将出水法兰口加垫密封。 6.2 试车 6.2.1空负荷试车
电机起动后，减速器无异常声响，各管道连接处不得有漏水现象。 6.2.2压力试验
试车2~4小时，减速器无异常声响，润滑油温度不超过85℃，最大工作压力达到60MPa。 6.3 验收
6.3.1试车合格，检修资料齐全方可验收。
6.3.2大修验收，由设备主管部门主持，设备使用部门、修理部门和质量检验部门参加共同验收，达到标准后移交使用部门。
6.3.3中修验收，由车间设备副主任主持，设备员、检验员、操作者参加。
6.3.4验收合格，按规定办理手续，正式移交生产。 7 维护检修安全注意事项 7.1 维护安全注意事项
7.1.1严禁违章开停车和违章操作。 7.1.2严禁使用不合格或变质润滑油。 7.1.3严禁带压治漏或松动螺栓。 7.2 检修安全注意事项
7.2.1设备检修前必须采取可靠安全措施。 7.2.2按规定停车，清洗、处理合格具备检修条件。
7.2.3切断各种电器设备电流，并挂上“有人检修，禁止合闸”标志。 7.3 试车安全注意事项
7.3.1各压力管接头必须连接可靠，不得有泄漏。 7.3.2当压力达到2.8MPa时，必须及时打开回流阀。 7.3.3工作压力不允许超过60MPa。
7.3.4安全阀必须调整在符合于被试容器所需要的试验压力。
因篇幅问题不能全部显示，请点此查看更多更全内容