How is the quantity of spare parts planned for everyone?
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For example, in the case of a compressor, when creating a procurement plan for spare parts, how many sets of spare first, second, and third grade piston rings as well as support rings should be kept on hand for maintenance and replacement? We managed to do it about 4 times; too many or too few times won’t work, as it’s very difficult to plan for spare parts. For piston compressors, which are widely used, aren’t the spare parts too expensive? Even an aluminum gasket costs over 10 yuan each. Sigh, I really don’t know what to do
Reciprocating machines are prone to wear and have a high failure rate; therefore, a larger stock of spare parts is required. It is advisable to follow the recommendations outlined in API618 when stocking these parts. Our unit usually has a larger stock than that specified in API618; for example, there are more gas seals, oil seals, rod bolts, piston rings, support rings, gas valves and corresponding gaskets available. For the piston rod, piston body, and bearings, there is generally one spare part for each one in use.
The amount of spare parts needed generally depends on the actual operating conditions of the machine as well as the lead time for purchasing them. Small, fragile components such as valve springs and aluminum gaskets can be produced in bulk, with orders of at least a hundred pieces each time. Of course, this also takes into account the actual consumption rate of the machine; usually, one order is sufficient to last three months or even longer. The lower the quantity ordered, the lower the price per piece； As for piston rings, gaskets, bearings, piston rods, etc., one set per machine is usually sufficient; they can be purchased immediately when needed. If they break down frequently, the required quantity should be increased accordingly ； Crossheads, connecting rods, etc. are usually provided in one or two units as a backup in case of need ； The piston body, cylinder (cylinder liner), and crankshaft are generally not provided; whether they are included depends on the results of the major overhaul inspection. Furthermore, if the units are quite important, there are many of them, and there are no spare units, then spare parts should be available for all of them.