Clean - Oil - Guide 油品清洁指南
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Clean Oil 油品清洁 Guide 指南
ADDING ENERGY 为您增添动力 100 micrometres 100微米 Grain of salt 盐粒 40 micrometres 40微米 Naked eye visibility 肉眼可见 3 micrometres 3OIL 2 micrometres 2Bacteria 8 micrometres 8Coal dust 70 micrometres 70Human hair 25 micrometres 25Pollen
Clean Oil Guide Second Edition 2003 Published by: C.C.Jensen A/S C.C.Jensen Svendborg, Denmark. Layout: Novatesa, s.l. Novatesa, s.l. Barcelona, Spain. Revision layout, print: SvendborgTryk, SvendborgTryk, Denmark.
微米 油
微米 细菌 微米 煤尘 微米 人的毛发 微米 花粉 油品清洁指南 第二版 2003 版权所属:
公司 斯芬博格市, 丹麦 设计:
巴塞罗那, 西班牙 修订, 印刷: 丹麦 1
Sources: 来源:
“Chemistry in electrical apparatuses” 电子仪器化学 Lars Arvidson
V?steras PetroleumKemi AB 西西延森
Lars Arvidson
V?steras PetroleumKemi AB 西西延森
Contents 目录
0 Introduction 0 介绍
1 Wear and tear in oil systems 1 油质系统中的磨损
2 Oil sampling 2 油品取样
Where to take an oil sample 何处取得油样
How to take an oil sample 如何取得油样
3 Oil sample analysis 3 油样分析
ISO standards ISO 标准
NAS classes
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NAS 分级
Evaluation of particle count 颗粒数量的评估
Frequency of analysis 分析的频率
4 Oil cleaning methods 4 油品清洁方法
Filter types 过滤器的类型
The surface filter 表面型过滤器
The depth filter 深度型过滤器
5 Basic filtration definitions 5 过滤的基本定义
Nominal filtration 标准过滤精度
Absolute filtration 绝对过滤精度
?x value ?x值
Dirt capacity 纳污容量
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By-pass 旁路
6 Installation methods 6 安装方式
Off-line filtration 离线过滤
Full-flow 完全流量
7 Economy 7 经济性
8 Ordering a filtration system 8 定购一套过滤系统
9 Handling of oil and oil systems 9 油品及油质系统的处理
New oil in containers 容器里的新油
Oil in the system 系统中的油品
10 Recommendations for buying oil 10 关于购买油品的建议
Oil test certificates and test sampling 油品的检测证书及测试取样
Claims 我们的权益
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Sampling 取样 Page 页码
2 Introduction 2 介绍
3 Wear and tear in oil systems 3 油质系统中的磨损
4 Oil sampling 4 油品取样
8 Oil sample analysis 8 油样分析
12 Oil cleaning methods 12 油的清洁方式
16 Basic filtration definitions 16 过滤的基本定义
18 Installation methods 18 安装方式
20 Economy 20 经济性
21 Ordering a filtration system 21 订购一套过滤系统
22 Handling of oil and oil systems
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22 油品及油质系统的处理
23 Recommendations for buying oil 23 关于购买油品的建议
Introduction 介绍
Maintenance is the largest single controllable expense in a manufacturing plant.
对一个从事制造生产的工厂或企业来说,设备维护的开销是最大的一笔独立支出并可控制的费用。
With as many as 80% of all machine failures related to contamination in the oil, pro-active methods are saving industries considerable costs every year. 80%的机械故障是由油品的污染所引起的,提前做好预防措施就可以节省这笔可观的开支。
This booklet offers an introduction to the problems with insufficient oil cleanliness, the causes and the remedy of the problems.
这本小册子介绍了由于油品清洁度问题引起的故障,以及故障的原因和补救的方法。
All the information presented is generally known and accepted. 这里所有提到的信息都广为人知并被认同。
It was compiled and published by people within the company C.C. Jensen A/S. 本指南是由西西延森公司的人员编辑及出版的。
We invite you to take advantage of the experience we have gathered over the past 50 years with oil maintenance within various types of industrial and marine applications.
我们真诚地邀请您参考和利用我们这50年来在船舶业以及其他各行业中积累的油品保养应用的经验。
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The perfect oil cleaning system will control the level of all types of contamination.
这个完美的油品清洁系统将能够控制各种类型污染的等级。
For further information, we recommend that you visit www.cjc.dk or
www.ccjensen.com, where you can also order a CJC Oil Sampling Kit including materials and instructions for sampling your oil.
如需要更详尽的内容及信息,请访问我们的网站www.cjc.dk 或 www.ccjensen.cn,您同时也可以在线订购CJC油样提取工具包,其中包含如何进行油样提取的说明。
Wear and tear in oil systems 油系统中的磨损
Any machine using oil for power transmission or lubrication will be affected by the condition of the oil.
任何使用油进行动力传输或润滑的机器都会受到油品状况的影响。
The oil comes into contact with all the other components in the system and should be considered the most important.
油会与系统中的其它所有部件接触,因此油品应该受到最大的重视。
Contamination in the oil is anything that should not be there, like solids and chemicals.
任何污染物,包括固体或化学产物,都不应该出现在油品里。
Mechanical Wear 机械磨损
Solid particles typically cause 50% of all failures and multiply by destroying the surface of even very hard metal.
设备的各种失效故障中有50%是由于固体颗粒引起的,这种磨损还会因为设备元件表面被破坏而加剧,哪怕是材质非常坚硬的金属。
The most harmful particles are the ones trapped in the dynamic tolerance like in bearings (figure 1).
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最有害的颗粒是那些在集中在动态配合的位置上(例如轴承处)的颗粒。(图1)
Fig. 1图1
Roller滚子
Oilgroove 油沟 ? 1μm:? 1微米 ? 5μm: ? 5微米 Force压力
Source: 来源:
V?steras PetroleumKemi AB
Chemical Wear化学磨损
Chemical contamination includes w,ater and oxidation products and certain metals (e.g. copper).
化学污染物包括水份、氧化物和某些金属(例如铜)。
Water typically accounts for 20% of mechanical failures. 水是最典型的化学污染物,20%的机械故障是由水所引起.
It reduces the lubricity of the oil and results in corrosion and erosion leading to spalding (figure 2).
水份降低了油的润滑性能,导致了部件的腐蚀和局部的碎裂。(图2)
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Fig. 2 图2
Furthermore, it acts as a catalyst in the oxidation of the oil, just as copper does.
此外,某些化学污染物在油品的氧化过程中,还充当了催化剂的角色,例如铜。 Oxidation products form a sticky layer on
metal surfaces and is often referred to as varnish. 氧化产物形成的粘性膜覆盖在金属的表面,常被认为是涂层。
Hard particles of all sizes get caught in the sticky layer, creating a sandpaper like, grinding surface.
各种尺寸的硬质颗粒集中在这种粘性膜上,会象砂纸一样磨损着金属的表面。
Oil sampling 油品取样
The purpose of oil sampling is to achieve the highest level of machine performance and reliability at the lowest possible cost.
为了在尽可能少花费的同时,使机械的性能表现和可靠性达到最高水平,我们需要先对油品取样。
The initial samples serve to establish benchmarks and to identify the machines with critical levels.
最初的油样用于建立基准和认定评估的等级。
The routine sampling is done to document that goals are met and can also provide indication of abnormal wear that needs to be addressed.
常规取样是用于证明(过滤的)目标已达到,同时也能在出现需要引起注意的非常规磨损时,提供警示。
The quality of analysis results depends first on correct sampling and
handling of the sample, secondly on the quality of the laboratory performing the analysis.
分析结论的质量首先取决于正确的取样和样本的处理,其次是实验室的分析的能力。 The importance of the knowledge about where and how to take a sample is paramount and requires special attention. 何处取样和如何取样至关重要,请特别注意。 Where to take an oil sample 何处取油品样本
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Referring to figure 3 derive the oil from a preferably upwards pointing pipe with continuous and ample flow to produce a representative sample.
参见图3,在油管的上部某点取样,这里油的流动持续且充分,可以取得具有代表性的样品。
Sampling points fitted on the lower perimeter of a pipe tend to allow depositing of particles in the sampling valve. 如果在油管的低处取样,会使颗粒的沉淀物进入取样阀。
Fig. 3: 图3:
Pipe cross section with sampling valves 取样阀位置示意图(油管的横截面方向) Source: 来源: V?steras PetroleumKemi AB Correct 正确 Wrong 错误
The best sampling point is between the pump and the filter housing of an off-line filter, which is normally the worst contaminated part of the oil system. 最佳的取样点在泵和离线过滤器的过滤室之间,这里通常是整个油质系统中污染最严重的地方。
A satisfying result from such a sample is the best guarantee.
如果来自污染最严重处的油样都有令人满意的测试结果,那么这将是对油系统清洁度最好的保证。
If no off-line filter system is installed a vacuum type sampling pump is a valid option.
如果没有安装离线过滤系统,那么也可以使用真空取样泵。
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Oil sample analysis 油品样本分析
As a minimum an oil analysis should include: 作为油样分析,最少应包含: ? A particle count 颗粒数量
? Water content in ppm 水份含量(ppm,百万分之) ? Viscosity 粘性
? Acidity level 酸性等级
If the oil additive content is of interest a spectral analysis should be included.
如果需要了解油品添加剂,则需要作光谱分析。
This test is best carried out by the oil supplier as they have the detailed knowledge of the initial additivation of the oil.
这类测试最好能由油品的供应商执行,因为他们了解油品的原始添加剂。
It is recommended that the initial tests are performed by an independent laboratory with special knowledge on lubricants.
推荐:初步的测试交由具有润滑品专业知识的独立实验室进行。
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Fig. 6: 图6:
Particle analysis颗粒物分析 Source: 来源:
Filtrex Services BV, Holland Filtrex Services BV,荷兰 Particle counting 颗粒物计数 每100ml颗>2微米 313650 粒物数量 >5微米 87211 >15微米 8137 Colour test filter disc I.grey 滤片颜色测试 I级.灰色 ISO 4406 19/17/14 Paticles identification颗粒鉴定 黑色金属:70% 焊屑: %
亮色金属:10% 锈:5% 沙粒:% 纤维:5% 合成物:5% 铜:5%
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1 DIV=15 MICRON 1刻度=15微米
ISO Standards ISO标准
The ISO 4406/2000 classification of particle contents was introduced to facilitate comparisons in particle counting.
ISO 4406/2000 颗粒物等级标准被引入,用于颗粒物的比较。
Sudden break down in an oil system is often caused by large particles (>14 μm) in the oil while slower, progressive faults,
e.g. wear and tear, are caused by the smaller particles(4-6 μm). 油质系统的突然崩溃通常是由系统中的大颗粒(>14 μm)引起,
而缓慢的、累积性的故障,例如磨损,则是由更小的颗粒(4-6 微米)所引起
This is one of the explanations why the particle reference sizes were set to 4 μm, 6 μm and 14 μm in ISO 4406/2000.
这也是之所以在ISO 4406/2000标准中,将颗粒按4微米, 6微米和14微米分类的原因。 A typical sample from a wind turbine gearbox, for example, contains in every 100 mL of oil:
以风力涡轮机的齿轮箱中取得的一个典型油品样本为例,每100ml油品中含有: 450,000 particles >4 micron 120,000 particles >6 micron 14,000 particles >14 micron 450,000个颗粒>4微米 120,000 个颗粒 >6 微米 14,000 个颗粒 >14 微米
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Fig. 7: 图7:
Contamination classes according to the new ISO 4406/2000 standard. 依据新ISO 4406/2000标准的污染等级。 More than多于 Till 最多 Class等级
Max:number of particles per 100ml fluid after their size ranges Max:每100毫升液体中超过其颗粒范围的颗粒数量。
Introduced in the ISO classification table (on the right), this oil sample has a contamination class of 19/17/14.
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根据ISO标准的表格,此油样的污染物等级是19/17/14。
NAS Classes NAS 等级
NAS 1628 is a American standard that translates approximately into ISO Codes.
NAS 1628是一个美国的标准,可以近似的转化为ISO代码。
The difference is that the NAS gives a more detailed breakdown of the different particle sizes.
不同之处在于NAS给出了更为细致颗粒尺寸分类。
Fig. 8: 图8: NAS 1628 Size 尺寸
Classes NAS 1628 NAS 1628等级
Evaluation of particle count 颗粒数量的评估
The obtained ISO code is an indication of the cleanliness of the oil in the gearbox and can be verified in the contamination charts shown below.
ISO代码可以标示出齿轮箱内油品清洁度,并且能在以下的污染物表格中对应查询。
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常规设计的表面型过滤器,采用相对薄的滤材,允许大流量通过滤芯。
The filter element is pleated in order to increase the surface area and reduce the pressure drop.
这种滤芯通常是褶状的,以增加表面积,减少压力损耗。
The filter is capable of removing solid particles only – and as it utilizes only the surface area, it has a restricted dirt holding capacity.
这种过滤器只能去除固体颗粒,而且因为它只能利用表面,所以纳污容量有限。 See illustrations on pages 14 & 15. 请参看14&15页插图。
Modern oil systems often combine the two cleaning systems, where the depth filter removes the contamination and the surface filter serves as security filter.
现代的油质系统通常综合这两种清洁系统,使用深度型过滤器清除污染,而表面型过滤器作为保障过滤器。
Surface Filter 表面型过滤器
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Element housing O-Ring 壳体O型环 End cap seal 端盖密封 Core 核心
Pleat support band 褶状支撑 Medium support 滤芯支撑 End cap 端盖
Filter element 滤芯
Unfiltered oil entry 未过滤的油的入口
Filtered oil returned to oil circuit 已过滤的油进入原回路 Support layer 支撑层
Filter medium layer 过滤媒介层 Outer filter casing 外滤罩 Oil flow 油液流
Trapped particles 集中的颗粒物 Filter medium 过滤媒介 Support layer 支撑层
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Surface filters have a limited contamination holding capacity, usually between 1 and 100 grams, which makes filter, insert replacement at short intervals necessary in order to ensure efficient filtration.
表面型过滤器的纳污能力有限,通常在1~100克,所以需要经常更换滤芯,以保证过滤的效率。
Surface filters removing particles <20 μm ensure effective protection when installed before an important machine part.
安装重要的机械部件前,表面型过滤器可去除<20 μm的颗粒,起到有效的保护作用。Surface filters do not absorb water. 表面型过滤器不能吸收水份。
Surface filters do not remove oxidation residual deposits. 表面型过滤器不能去除氧化物的残余沉淀。
Depth Filter 深度过滤器
Filter element:滤芯:
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Made as a sandwich of corrugated wood cellulose discs rotated at 90° to the next and bonded together.
由多个波纹状木质纤维片组成,纹路方向正交90°相叠加,就如三明治一样。
This gives a series of connected surfaces with corrugations running north-south and east-west.
如此一系列纹路方向正交的表面相连接。
Two-disc filter sandwich 两片滤片 Filtered oil returned to the oil circuit 已过滤的油回到回路
Unfiltered oil enters under pressure 未过滤油在压力下进入
Outer filter housing 过滤器外壳 Function 功能
Particles pass through the filter maze until they are trapped 颗粒物进入过滤器,直到它们被截留在滤片上
The CJCTM depth filter has a contamination holding capacity of approximately 2 L and only needs replacing every 12 months.
CJCTM深度型过滤器拥有大约2L的纳污能力,并且只需要每12个月更换一次。 Depth filters filter effectively down to 3 μm absolute. 深度型过滤器能有效的过滤小到3微米的颗粒。
Depth filters absorb water and resins (oxidation residuals) 深度过滤器还可吸收水份和树脂(氧化残留物)
Basic filtration definitions 基本的过滤定义
Nominal filtration 标准过滤精度
Ratings are estimated values, indicating a particulate size range at which the filter is claimed to remove a given percentage. There is no standard for this, so consequently, different products/makes cannot be compared.
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评定标准是一个估计值,表明过滤器标称能够去除的百分比含量中所涵盖的微粒的尺寸范围。对此没有一个明确标准,因不同的产品而无法比较。
Operating pressure and concentration of contaminants will affect the retention efficiency of nominal rated filters.
操作压力和污染物的浓度会影响标准过滤精度的过滤器的去除效率。
Absolute filtration 绝对过滤精度
Ratings describe the pore size, indicating the largest size of particle which can pass through the filter. The filter need to apply to a standard test method intended for filter usage.
评定标准描述了孔径大小,标明了可以通过过滤器的最大颗粒的大小,过滤器需要经过标准化的测试方式来实现过滤使用。
The rating of depth filters is often 3 micron absolute or less. The rating of surface filters varies according to the requirements of the components to be protected.
深度过滤器的精度通常是3微米或更小。表面型过滤器的过滤精度,根据要保护的元件的要求而有所不同。
Beta values
are describing filter efficiencies at a given particle size. The value is written ?x, where the “x” represents the particle size in question and the ? is the efficiency, e.g. ?3 = 75, which means that one out of 75 particles of 3 micron size will pass through the filter (1.3% passes though and 98.7% are retained in one pass).
Beta 值是以给出的颗粒尺寸来描述过滤器的过滤效率,写作?x,x表示颗粒尺寸,?是效率,
例如:?3 = 75,意思是75分之一的3微米的颗粒会通过过滤器(1.3%通过,98.7%在一次通过中被截留)
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New oil in containers 油箱内的新油
? New oil should be considered contaminated until a sample has been analyzed.
新油应该按有污染考虑,除非进行过样本分析。
? Oils containing additives that are not necessary for the application are to be considered contaminated
含有非必要添加剂(对于应用来说)的油是有污染的油。
? New oil should always be introduced to the system via a filter, preferably a 3 μm absolute filter.
新油应该经由过滤器过滤,再进入系统,最好是3微米的绝对过滤精度的过滤器 ? Do not mix oils without previously investigating compatibility. 在了解油的兼容性前,请不要将不同的油混合。
? Keep lubricating products in closed containers to avoid ingress of contaminants.
请将润滑油放入密闭的容器,避免污染物的进入。? Oil in the system 系统中的油
? Observe the oil regularly during operation in order to discover any sudden appearance of water, air or other contaminants.
在操作过程中对油进行常规的观察,以发现水份、空气或其他污染物。 Using fresh oil as a reference may be helpful. 使用新鲜的油作为对比将会有助于观察。
? Check the oil after machine malfunctions or other incidents which might affect the oil.
在机械出错或其他会影响油品质量的事件发生后,检查油品。
? Always observe maximum cleanliness and accuracy during sampling. 取样的过程中,对最大的清洁度和精确度保持关注。
? Systems should be as sealed as possible. All permanent openings should be equipped with venting filters. All systems should be equipped with permanent filter installations.
系统尽可能的封闭。所有永久开口都应该安装通气性的过滤器。所有的系统都应该安装永久的过滤装置。
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? When changing the oil, the tank and the system should be emptied completely and the tank should be cleaned manually of settlings (sludge, etc.). 更换油时,油箱和系统需要彻底的清空,并手工清理油箱内的沉淀物。
? When replacing seals, only oil-resistant materials should be used. Compatibility with the oil should be checked.
更换密封件时,只能使用抗油材料的密封。需要确认密封件与油的兼容性。
? Never apply new additives without consulting the oil supplier/consultant. Ask for written confirmation of the measures to be taken.
未向油品的供应商或顾问咨询和得到书面确认之前,请勿私自使用新添加剂。
? Always use independent analysis resources with adequate quality control. 请使用独立的有相应资质的油品分析机构。
Recommendations for buying oil 关于购买油品的建议
When buying oil in bulk, buyers have a right to set special certified requirements to ensure the quality.
购买散装的油品时,购买者有权要求给予特别的书面认证,以保证油品的质量。
Below find some examples of requirements and test for the quality of the oil, emphasizing oil cleanliness.
以下是一些对油品的质量的要求和测试的例子,重点是油的清洁度。 Oil test certificates and test sampling 油品的测试认证和测试取样。
The results of an oil test of the batch should be presented to the buyer. 此批次的油品测试的结果应该出示给购买者。
A sample should be taken during the filling of the first batch. 应该在供应第一批次期间提取样本。
Samples should be marked with the trademark, batch number and size of the consignment. 样本应该贴有商标,批号以及发货量。
The oil should be analyzed by an independent laboratory and the analysis
should include the data described in the oil analysis section of this booklet. 应由独立的实验室分析油品,并且分析结果应该包含本手册中油品分析章节中提到的数据。
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Claims 我们的权益
If the oil supplied does not fulfill requirements, returning the consignment might be considered.
如果所供应的油品没有满足要求,可以考虑退回货物。
If the problem can be corrected, new samples must be approved. 如果问题改正,新的样本也必须经过认证。
The supplier must pay all costs, including machinery failure and downtime. 同时供应商必须赔付所有损失,包括机器的失效和停工所带来的损失。
Sampling 取样
Samples must be drawn from each manufactured batch. 样本必须从每个生产批次中抽取。
The analysed sample must be a representative sample of the manufactured batch.
分析的样本必须是生产批次中的代表性样本。 Test records must be available for the buyer for at least five years. 购买者至少可以查到5年的测试记录。
An analysis certificate must be delivered together with the ordered oil and include at least the following items: 化验证书必须与所定购的油品一同交付,且需要包含以下项目: – Visual inspection – 视觉观察
– Viscosity @ 40°C – 粘度@ 40°C – Density – 密度
– Total Acid Number of finished product – 成品的总酸值
– Air bubble separation time – 气泡分离时间
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– Contaminants, gravimetric. – 污染物,重量分析
For wind turbine oils, foaming at 50°C could be included. 用于风力发电机的齿轮箱润滑油,可要求提供50°C时的发泡检测。 The oil must be delivered by tanker trucks, epoxy-painted drums or 20-litre cans.
必须用油罐车,有环氧涂层的圆桶或20升的罐来运输。 The buyer must indicate the type of container for each individual case.
购买者必须说明每个不同情况下使用的容器类型。 The container must be of
first class quality and the type generally used in the oil trade. 容器必须具有一级质量,且是油类贸易中的通常使用的类型。 The container must be marked with the buyer’s trade
description, the suppliers trade designation, net content and a continuous manufacturing batch number.
容器上必须标记购买者的交易的描述,供应商的交易名称,净含量以及连续的生产批号。
INDUSTRY 一般工业
MARINE 船舶行业
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DIESEL ENGINES 内燃机 WIND POWER 风力发电 Your local CJCTM distributor: 您当地的CJCTM产品分销商 C.C. Jensen A/S 西西延森公司
L?vholmen 13 · 5700 Svendborg · Denmark
地址:L?vholmen 13 · 5700 Svendborg · DenmarkTel. +45 63 21 20 14 电话:+45 63 21 20 14 Fax +45 62 22 46 15 传真:+45 62 22 46 15 E-mail: filter@cjc.dk 电子邮箱:filter@cjc.dk www.cjc.dk
网址:www.cjc.dk
ADDING ENERGY 为您增添动力
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