Several methods for on-site equipment management

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Several methods for on-site equipment management. Equipment constitutes the material and technical foundation for a company’s production, and equipment management is an important aspect of corporate management; the quality of this management directly affects a company’s production efficiency and economic performance. Experience shows that by adopting effective methods for on-site equipment management, it is possible to increase the utilization rate and integrity of equipment, which is an important means of improving the quality, standard, and grade of a company’s products. I. Specialized Management 　　 (1) Incorporate the technical and economic indicators of equipment management into target assessments; assign specific targets and measures to individual persons, link them to economic responsibility systems, and include them in the comprehensive evaluation criteria. At the same time, the responsibilities of leaders at all levels regarding on-site equipment management were further clarified, thereby improving the organizational leadership structure. Supervisors at all levels are required to take leadership responsibility for the proper use and maintenance of the equipment, including lubrication and hygiene ； The deputy mine manager in charge of equipment, equipment managers, and the equipment managers of various grassroots teams bear leadership responsibility for the management of equipment, its maintenance, the elimination of potential equipment hazards, and the prevention of leaks ； The mine manager and the heads of various grassroots teams are responsible for the overall coordination and leadership of all aspects related to equipment management. Clarify to the operators their responsibilities regarding equipment operation, maintenance, as well as equipment inspection and handover ； Clearly define the responsibilities of maintenance personnel regarding routine inspections and scheduled inspections (for key and critical equipment). (2) Establish an on-site charter flight team to provide special care and management for key equipment and critical units at the site. A charter crew is generally composed of operators, and each member of the crew has clear job responsibilities and duties related to the charter operation. These include the routes, times, areas, methods for inspections to be carried out by the operators, as well as the requirements for keeping records; equipment lubrication, recording of equipment condition monitoring, and standards regarding cleanliness. Quantitative assessments are applied to charter flight targets, such as equipment integrity rate, leakage rate, and downtime due to failures. (3) On-site equipment management adopts a professional service commitment system, requiring professionals to be present at the site in four aspects: equipment management, equipment inspection, coordination of equipment operations, and resolution of equipment issues, thereby ensuring comprehensive professional services both horizontally and vertically at the site. For example, there are personnel on duty at the transfer stations and combined stations 24 hours a day, enabling prompt resolution of any issues or failures and ensuring the high integrity and utilization rate of the operating equipment. II. Standardized Management 　　 By establishing and improving various equipment management systems, the on-site management of equipment is systematically and comprehensively regulated, ensuring that such management is carried out in accordance with established rules and can be verified with relevant records. In accordance with the \"Regulations on the Management of Equipment in State-owned Industrial and Transportation Enterprises\" issued by the State Council, as well as the \"Equipment Management System\" of China National Petroleum Corporation, the factory has formulated more than 20 specialized management systems. Based on the actual conditions of on-site equipment management in mines, a professional manual on on-site equipment management totaling over 300,000 words was systematically compiled, thereby enabling strict and detailed regulation of equipment management across the entire factory. 　　 (1) Based on their long-term experience in equipment management, factories and mines have established unified standards for on-site equipment management. Operators are required to have a thorough understanding of on-site equipment in terms of ’four understandings, three abilities, and three requirements’, that is, understanding the structure, performance, principles, and applications of such equipment ； Able to operate, maintain, and troubleshoot faults ； Use it well, manage it well, maintain it well. 　　 (2) On-site equipment maintenance requires adhering to the principle of “three frequences and one certainty”, namely frequent inspection, frequent cleaning, regular maintenance, and accurate recording at set intervals. It is required to strictly implement the ten-step equipment maintenance method of \"cleaning, lubricating, tightening, adjusting, and anti-corrosion\". When conducting on-site inspections of equipment, the five-step inspection method of \"listening, touching, smelling, comparing, and observing\" should be followed. During the inspection, it is necessary to carry three essential items: a wrench (for tightening), a rag (for cleaning), and a stethoscope (for listening). The operation of equipment must adhere to the \"four no’s\" (no overheating, no overpressure, no overspeed, no overload) and the \"four no-leaks\" (no water leakage, no air leakage, no oil leakage, no liquid leakage). Ensure that the equipment site meets the requirements of \"one level, two clean, three visible, four absent, and five not lacking\": the ground should be level, the doors and windows’ glass should be clean, the surrounding walls should be clean as well; the ditches should be bottomless, the shafts should be visible, and the equipment should show its original color. There should be no garbage, weeds, waste materials, or unnecessary equipment. There should be no shortage of insulation paint, bolts or handwheels, doors and window glass, light bulbs or lampshades, nor ditch covers. III. Dynamic Management 　　 The factory has basically achieved dynamic management and predictive maintenance for the maintenance and repair of equipment in operation on site. By employing a range of new technologies and methods such as equipment condition monitoring and fault diagnosis, as well as pressure-based leak sealing without shutting down the equipment, dynamic monitoring and maintenance of on-site equipment are carried out. This effectively prevents equipment downtime and leaks, ensuring the continuous and stable operation of the on-site equipment. For example, a certain factory employs advanced technologies and methods such as vibration monitoring, dynamic balancing, and thermal imaging to conduct regular on-site inspections of the operating condition of key equipment on a monthly basis. These inspections are used to assess the technical condition of the equipment, analyze the nature of any faults or defects, and to provide timely feedback in the form of monitoring reports. Through comprehensive equipment diagnosis, 9 equipment defects were identified in a timely manner. Among them, the oil deficiency fault detected in the reducer box of Mill No. 5 was addressed promptly, which prevented a serious equipment damage incident. In 2007, the factory implemented dynamic management of equipment on-site, achieving a zero failure rate for key units; the number of unplanned shutdowns decreased by 5% compared to the previous year, thus ensuring normal production. Fourthly, with regard to equipment maintenance: in light of the aging of equipment and outdated installations, the factory launched widespread campaigns across the entire facility to create well-maintained equipment, well-maintained workstations, well-maintained installations, as well as to organize competitions in technical management. 　　 (1) Define the on-site integrity standards for equipment. All equipment on site is required to be in good condition, with all operating parameters within acceptable limits; the main unit must be intact and all accessories present, without any signs of dirt, disarray, missing parts, rust, or leaks ； On-site equipment, pipelines, valves, electrical wiring panels, etc. are installed properly, in a neat and orderly manner, arranged in rows and lines ； It is required to strictly implement the specialized system for equipment management as well as various rules and regulations regarding equipment maintenance ； Equipment lubrication should follow the \"five fixed principles\" and employ \"three-stage\" filtration; the lubrication containers must be kept clean and in good condition ； Maintenance tools, safety equipment, and fire-fighting devices are all available in full quantity, easy to use, and neatly arranged ； It is required that the four walls, ceiling, floor, and the area in front of and behind the dashboard at the site be clean, and that the window and door glass be clear and free of defects ； The trenches reach the bottom, the shafts are exposed to light, the equipment shows its true color, and items are arranged in an orderly manner ； It is required that equipment operation records, shift handover logs, and various rules and regulations be complete, the records accurate, the handwriting neat, without any alterations, and properly stored. (2) Introduce competition, incentive, and restraint mechanisms into the field of on-site equipment management. Within the equipment system, competitions aimed at achieving excellence in eight different areas such as pumps, electrical systems, pressure vessels, and instrumentation are held, with the goal of identifying outstanding individuals in these fields – namely, excellent equipment maintenance specialists, excellent equipment repair experts, excellent energy-saving specialists, excellent metrologists, excellent equipment operators, and excellent equipment managers. The selection process combines random inspections with evaluations, as well as spiritual rewards with material rewards. 　　 (3) Take advantage of the comprehensive inspection campaign for post responsibility systems across the plant to carry out thorough on-site inspections of equipment. In addition to conducting two comprehensive on-site inspections of all equipment throughout the plant each year, the plant also carries out quarterly specialized on-site inspections. In response to the problems existing on-site at the equipment, corrective measures are formulated promptly, with a set deadline for implementation. Through on-site inspections, rectifications, and improvements of the equipment, efforts are made to carry out evaluations for “well-maintained workstations” and “well-maintained equipment.” Those that receive the “well-maintained” designation are awarded honor plates along with certain material and spiritual rewards. Regarding the naming of “intact posts” and “intact equipment”, the principle of “finalize one, name one, establish one, and consolidate one” is adhered to; no ** practices are engaged in. During each thorough on-site inspection of the equipment, the designated \"well-maintained stations\" and \"well-maintained equipment\" are rechecked and re-verified; stations and equipment whose maintenance level has declined have their honor plaques removed. Through carrying out activities to maintain equipment in good condition on-site, a large number of \"inspection-free positions\" and \"well-maintained equipment\" have emerged across the plant, resulting in a continuous improvement in the level of equipment management on site. V. Conclusion: Equipment operators and managers must maintain the equipment to ensure its proper operation. Methods for improving equipment on-site performance have been proposed, which can effectively reduce the equipment maintenance rate and increase its availability and utilization rate. Statistics show that the on-site ‘intact’ rate of the plant’s equipment remains above 90%, and all 12 economic and technical indicators of its equipment meet the standards set by CNPC.