Performance of equipment | First, the equipment site for special management First of all, the technical and economic indicators of equipment management are included in the assessment of the term goals of the factory director (manager), and the decomposition indicators and specific measures are implemented to the people, linked with the economic responsibility system, and included in the comprehensive assessment of the factory double civilisation competition…
Carry out special management of the equipment site.
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At the same time, the responsibilities of leaders at all levels for equipment on-site management were further clarified, and the organizational leadership system was improved.
- The management of production and the management of workshop of each plant are required to take leadership responsibility for the correct use and maintenance of performance of equipment (including lubrication and hygiene);
- The management of equipment and the management of workshop are responsible for the management, maintenance, elimination of hidden dangers of equipment and prevention of running and dripping.
- The director and workshop director of each factory are responsible for the overall coordination and leadership of all aspects of performance of equipment management.
- Clarify the responsibility for equipment operation, maintenance and equipment inspection and handover to the operator.
- Clarify the responsibility for patrol inspection and regular inspection (key and key equipment) for maintenance personnel.
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An on-site charter team is established to implement special care management for key equipment and key units on site. The charter unit is generally composed of operators, fitters, electricians, instrumentations, and each member has clear work content and charter responsibilities, such as the route, time, part, method, record requirements of the operator’s patrol inspection, equipment lubrication, equipment status monitoring records, sanitary areas, and standards, etc. Implement quantitative assessment of charter targets, such as equipment integrity rate, leakage rate, failure, and downtime rate, etc.
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The equipment on-site management implements a professional service commitment system, requiring professionals to “four to the site”, that is, equipment management to the site, equipment inspection to the site, equipment work coordination to the site, equipment problem handling to the site, so that on-site professional services horizontal to the edge, vertical to the end.
Example
For example, in the Heat Exchanger plant needle implements on-site 24-hour professional commitment service for thermal instruments for the problem of high failure rate of thermal instruments.
So that the failure frequency of thermal instruments has been reduced from about 30 times per month in the past to less than 10 times per month, ensuring the integrity rate and utilization rate of the instrument.
The performance of equipment site is standardized management.
Through the establishment and improvement of various equipment management systems, the main factory systematically and comprehensively standardizes the on-site management behavior of equipment. So that, the on-site management of equipment has rules to follow and evidence.
The main plant has successively formulated more than 40 professional management systems, combined with the actual management of the whole plant’s equipment, systematically compiled more than 50, <> words of equipment on-site management professional manual, and carried out strict professional refinement of the on-site management of the whole plant’s equipment.
3 Diligence
According to the long-term equipment management experience, the main plant has unified and standardized the on-site management of equipment. Operators are required to “four understandings, three skills, and three good” for field equipment, that is, understand the structure, understand the performance, understand the principle, and understand the use; Will operate, maintain, troubleshoot; Use well, manage well, repair well.
For the on-site maintenance of performance of equipment, it is required to achieve “three diligence”, that are:
Diligent inspection, frequent cleaning, diligent maintenance, and regular and accurate recording.
It is required to strictly implement the “cleaning, lubrication, fastening, adjustment, anti-corrosion” equipment maintenance cross operation method.
Three treasures
The on-site inspection of performance of equipment should follow the five-character on-site inspection method of “listening, touching, smelling, comparing and seeing”, and it is required to carry “three treasures” during the inspection process, that is, wrench hand (tight), rag (wipe), stethoscope (listen).
Equipment operation must be ” four inaccurate” (no over temperature, no over pressure, no over-speed, no overload) and ” four no leakage” (no leakage, no air leakage, no oil leakage, no liquid leakage).
Ensure that the equipment site is “one level, two net, three see, four nothing, five is not lacking”, that is, the site is flat, the doors and windows glass are clean, the surrounding walls are clean, the trench is bottomed, the shaft is light, the equipment is the true color, no garbage, no weeds, no waste, no idle equipment, no shortage of thermal insulation paint, no shortage of bolt hand wheels, no lack of door and window glass, no lack of bulb lampshades, and no shortage of gutter covers.
The equipment site dynamic management.
In order not to affect the normal production, the maintenance and overhaul of the on-site operation equipment of the main plant basically realized dynamic management and predictive maintenance.
Through the use of a number of new technologies and means such as equipment status monitoring and fault diagnosis, non-stop pressure plugging, dynamic monitoring and maintenance of field equipment, effectively avoiding equipment downtime and failure, running, dripping and leakage, and ensuring the continuous and smooth operation of field equipment.
Example
For example, in the operation of the second chemical plant to plug the leakage with pressure without stopping, the three methods of glue injection, press-in and glue were used to successfully block the leakage point 143 times, directly or indirectly recovered the loss of more than 200 million dollar, and reduced the unplanned shutdown of the device.
Usually, in Heat Exchanger plant uses advanced technologies and means such as vibration monitoring technology, dynamic balance technology, and thermal image monitoring to conduct regular on-site monitoring of the operation status of key equipment every month, judge and determine the technical status of the equipment, analyze the nature of equipment failures and defects, and timely feedback information to make a monitoring report.
Through the comprehensive diagnosis of performance of equipment, 9 equipment defects were found in time. Among them, the low oil fault monitored by the 5# furnace ball mill gearbox was found and dealt with in time, and a major equipment damage accident was avoided.
The two SZ-4 air compressors in the water supply and drainage plant and workshop, due to the long service life, large vibration, fast loss of accessories, high failure frequency, the workshop maintenance personnel often go to the equipment site, actively collect equipment status signals, carefully analyze the condition of the air compressor, and timely take measures to change the original bushing fastening nut of the equipment from single nut to double nut, so that the air compressor runs smoothly and prolongs the equipment maintenance cycle.
In 1997, through dynamic management of equipment sites, the main plant achieved zero failure rate of key units and reduced the number of unplanned downtime hours by 5% compared with the previous year.
Carry out good management of the equipment site.
In view of ageing equipment and outdated equipment, the main factory vigorously carries out mass competition activities to create perfect equipment, create good posts, create perfect equipment, create red flag machines and technical management competitions in the whole factory.
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The first is to clarify the equipment site integrity standards. It is required that all equipment on site is intact, all operating parameters are within the allowable range.
- The main body is complete, the accessories are complete, and there is no dirt, chaos, lack, rust, leakage; Field equipment, pipelines, valves, electrical circuit dials, etc. are reasonably installed, horizontal and vertical, and in rows.
- It is required to conscientiously implement the rules and regulations such as equipment management special responsibility system and equipment maintenance.
- Equipment lubrication should achieve “five-fixed” and “three-stage” filtration and lubrication containers are completely clean.
- Maintenance tools, safety facilities, and firefighting equipment are complete, flexible and easy to use, and neatly placed.
- The four walls, ceiling, floor, and instrument panel on site are required to be cleaned before and after.
- The door and window glass is bright and flawless.
- The groove sees the bottom, the shaft sees the light, the equipment sees the true color.
- Items are placed in an orderly manner; It is required that the equipment operation records, shift handover logs, various rules and regulations are complete.
- The records are accurate, the font is neat, no alteration, and it is properly kept.
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The second is to introduce competition, incentive, and constraint mechanisms into the field of equipment site management.
In the equipment system, carry out 8 individual on-site management “striving for excellence” competitions such as pumps, electrical, pressure vessels and instruments, and select excellent “three hands, two members and one”, that is, excellent equipment maintenance experts, excellent equipment maintenance, maintenance experts, excellent energy-saving experts, excellent meterers, excellent equipment personnel and excellent equipment managers. The selection activities should combine spot checks with assessments, and spiritual rewards with material rewards.
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The third is to use the post responsibility system of the main plant to vigorously carry out the on-site inspection of equipment. In addition to carrying out two plant-wide equipment on-site inspections every year, the main factory also insists on quarterly special on-site inspections.
In view of the problems existing in the equipment site, formulate corrective measures in time and rectify within a time limit.
Through the inspection, rectification, and treatment of the equipment site, actively carry out the selection activities of “good post” and “good equipment”, award honorary medals to those who have won the title of “intact and give certain material and spiritual rewards.
For the naming of “intact posts” and “intact equipment”, adhere to the principle of “mature one, name one, create one, consolidate one”, and do not engage in lifelong system.
On Site inspection
Every time to prepare for on-site inspection, the named “intact post” and “intact equipment” must be reviewed and re-accepted, and the honorary plaque will be canceled for the post and equipment with a declining level of integrity.
Through the on-site integrity activities of creating equipment, a large number of “inspection-free posts” and “intact equipment” have emerged in the whole factory, and the on-site management level of equipment has been continuously improved. According to on-site inspection statistics, the retention rate of “intact” results of the whole plant equipment is more than 90%. At present, all 12 economic and technical indicators of the equipment of the main plant have reached the standards stipulated by Sinopec.