The issue of spare parts for chemical processing equipment
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How should one stock spare parts for chemical processing equipment and non-standard equipment, such as heat exchangers? If the equipment has only been in use for a year, not stocking spare parts might delay production; but doing so comes at a high cost. I’d appreciate advice from those with more experience
For non-standard or pressure vessel metal equipment, the spare parts mainly include various pipe gaskets and head gaskets. It’s also advisable to have some plugs to seal the tubes in case of leaks – these are needed when the tubes leak; if you have a lathe, then there’s no need to prepare them. As for gaskets, it’s sufficient to have those made of special materials, such as metal wound gaskets with rings, graphite gaskets, or gaskets of special shapes. For ordinary materials like asbestos or PTFE, it’s still possible to fabricate replacements if problems arise. For standard equipment, the items mentioned above are sufficient; however, special equipment requires special attention. For example, for equipment with internal wire mesh mist eliminators, some wire mesh should be prepared, and for fixed-bed reactors that contain clamps and spring clips, those should also be provided. For towers, clamps, bolts, or sieve plates, along with other vulnerable components, may be necessary (but these are generally replaced during shutdowns when it’s safer to do so). If it’s non-metallic equipment, such as fiberglass tanks, it might be useful to prepare manway covers and probes. For graphite equipment, small pipes, grills, and distribution pipes can be prepared. As for enamel-coated equipment, some adhesive can be prepared. This post was last edited by Benbenxuan on 2007-12-20 at 19:37
The service life of the equipment and the ordering cycle need to be taken into account, with special emphasis placed on having backups.
Just have some gaskets and bolts ready
Prepare two sets of gaskets (more if they are special), and have 10–20% more bolts and nuts (>4 sets) – that will be sufficient.
Spare parts – only spare vulnerable parts! ! ! Check the equipment at any time and perform regular maintenance on it. :victory: :)
Chemical processing equipment mainly refers to static equipment, which generally does not require spare parts (pipe flanges, gaskets, etc. can be used interchangeably and need to be considered separately); only some special, vulnerable components need to be stocked. As for determining what constitutes a vulnerable component, it is advisable to consult the manufacturer of the new equipment, or preferably other industry peers. After the equipment has been in use (i.e., after maintenance), adjustments should be made based on its actual condition. In principle, the lead time for purchasing such parts is long, and there are no alternatives; equipment failures have a significant impact on production facilities, making these parts essential. Conversely, in cases where a failure in a certain part of the equipment does not cause other safety issues and can be addressed by plugging the leak while the equipment is still under pressure, such parts are not necessary.
I learned a lot more as well, thank you 1
Gaskets and bolts are essential. For heat exchangers, it is advisable to prepare some tube plugs in advance; if the heat exchange tubes are damaged, the ends of the tubes can be welded shut using these plugs, which helps save time.
I’m also very troubled by the issue of spare parts. The company hasn’t even started testing with actual materials yet, but the management already demands that spare parts be prepared – it’s frustrating
I work in a manufacturing factory. When the equipment is manufactured and delivered, spare parts are usually provided. Generally, gaskets are supplied in quantities equal to 100% of what’s needed, while bolts and nuts come in quantities of 10% of each specification, with no less than 2 sets provided.
Thank you! Hehe, let’s keep the discussion going
Aside: What chemical equipment is available in the polysilicon production process system? Spare parts are prepared based on the nature of the equipment, that is, its importance in the main manufacturing process! ! !
Refer to the process design to estimate the service life and maintain an appropriate stock level; otherwise it will be a waste
For static equipment, the main items are custom-made gaskets (including those for manholes or inspection holes, as well as those for the main flanges of the equipment), and generally two sets should be kept on hand. Some bolts and nuts for manholes or inspection holes should also be kept on hand, usually around 10%.
Why are regular bolts, nuts, etc. necessary to have on hand! It is recommended not to keep such items in stock; common standard components can be stored by several distributors with whom the company has a long-term relationship, allowing for timely delivery when needed. Even some parts for machinery and equipment (provided that there are a large number of units and high demand) can be kept by the manufacturer, which helps to reduce inventory levels while ensuring production continues. This should become a trend in corporate management.