Equipment Management System

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(1) Management system for moving and stationary equipment I. Establishment of equipment management records 1. Records for managing moving equipment (categories A and B, i.e., specially monitored equipment such as pumps and ordinary pumps): weekly evaluations and monthly reviews; 2. Records for managing stationary equipment: updates on a monthly basis; 3. Records for three-level filtration management: weekly evaluations and monthly reviews; 4. Hygiene management records: to be maintained jointly by the equipment supervisor and the safety officer, with weekly evaluations and monthly reviews. II. Management and Evaluation Criteria
A. Moving Equipment
(Ⅰ) Standards
1. Vibration: ≯ 8 threads;
2. Noise: No obvious noise;
3. Shaft temperature: ≯ 70 ℃; Cylinder temperature: As specified in the process sheet;
4. Motor temperature: ≯ 90 ℃, as specified in the process sheet;
5. Sealing leakage: For mechanical seals, light oil: ≯ 10 drops per minute, heavy oil: ≯ 5 drops per minute; for packing seals, light oil: ≯ 20 drops per minute, heavy oil: ≯ 10 drops per minute;
6. Lubrication:
6.1 Oil lubrication
(1) Oil tank leakage: No obvious leakage;
(2) Oil level: 50–70%;
(3) Oil quality: a. The flash point of the oil should be > 100 ℃; records must be kept, and the shift supervisor and equipment manager should be informed. b. No emulsification, good viscosity;
(4) Oil change schedule:
a. Compression pumps: Oil should be changed on the 11th and 26th of each month during the day shift;
b. Main fans: Oil should be changed on the 26th of each month during the day shift;
c. Pumps: Oil should be changed every Thursday during the day shift;
d. Oil changes may also be carried out periodically depending on the specific conditions of each pump;
e. Before changing the oil in the pumps on the 26th of each month, check the quality of the spare oil first. If it does not meet the requirements, the oil needs to be replaced before starting the machines again; after shutting down the machines in use, replace the oil as well. f. Be responsible for the temporary oil change of all pumps during shift; in cases of severe issues such as emulsification or oil leakage, the causes should be identified promptly and appropriate action taken. 6.2 Grease lubrication: For pumps lubricated with grease, it is required to add grease once a month. When n≥3000 r/min, the amount of grease added is 1/3 of the bearing volume. When n≤3000 r/min, the amount of grease added is 1/2 of the bearing volume. 7. Numbering: Use pumps with designated numbers. Appendix (1) Time: Replace the pump at 8:15 a.m. on the 26th of each month; (2) Any temporary replacement of the pump must be carried out with the notification or approval of the person in charge of workshop equipment or the workshop’s on-duty staff; (3) In case of an accident, it is possible to replace the pump urgently to prevent the accident from worsening, but records of such replacement must be kept clearly and the workshop must be informed afterwards. 8. Cranking the machine: Single white and double red. 9. Preheating: Check that the hot oil pumps 205, 206, and 207 in the standby pumps must be preheated 24 hours a day. 10. Pump body and accessories: From the inlet and outlet valves of the pump down to the base – (1) The couplings must be secure; (2) The bearing caps must be properly tightened; (3) The suction and exhaust valves must function correctly; (4) The oil injection system must work properly, with the oil injection volume meeting the specified requirements; (5) The pressure gauges and temperature gauges must show accurate readings, with no missing components, and the pressure pipes must not be damaged; (6) The thermometers must be in good condition, with no missing parts; (7) The anchor bolts of the pump must be tightly secured; (8) All equipment parts must be present, with screws and nuts in sufficient quantity, properly fitted, and organized; (9) The cooling water valves, check valves, and pump vent valves must function properly, ensuring smooth flow of cooling water; (10) The rubber hoses and drainage pipes must not be damaged or missing (normal wear and tear is excluded); (11) The grounding wires must be properly connected. 11. Other matters: (1) To prevent freezing and condensation, the cooling water for standby pumps must be turned on during winter to ensure that the pumps do not freeze or get damaged; (2) For other parameters not mentioned above, such as oil pressure, water pressure, and current, the requirements specified in the process sheets must be followed; (3) There should be no unauthorized shutdowns or tripping of the equipment; (4) Comply with the requirements outlined in the inspection system as well as address any temporary issues that arise; (5) Records of operations and shift handovers must be kept promptly, accurately, truthfully, and comprehensively (evaluation will be based on these records). (II) Evaluation time: (15 minutes per item) after the routine inspections conducted in the workshop. These various items constitute the contents of daily inspections. Those who discover problems but fail to address them promptly will be punished just like those who fail to detect any problems at all, in accordance with the established rules. The specific implementation is as follows: (1) If bearing vibration and noise levels exceed the specified limits and are not addressed in a timely manner, a fine of 5 yuan will be imposed per incident. (2) A fine of 5 yuan per incident will be imposed if the pump bearing temperature exceeds the limit and no action is taken promptly. (3) A fine of 5 yuan per incident will be imposed if the temperature of the motor bearings exceeds the allowable limit and no action is taken to address it in a timely manner. (4) A fine of 5 yuan per incident will be imposed for excessive leakage in the pump seals that is not addressed in a timely manner. (5) If the oil level in the oil cup or oil tank is below the specified level, a fine of 5 yuan will be imposed per occurrence. (6) If the lubricating oil becomes emulsified or deteriorates, a fine of 10 yuan will be imposed per occurrence upon discovery. (7) If the vibration or displacement of the bearings of the main fan exceeds normal values and this is not addressed promptly, a fine of 10 yuan will be imposed per occurrence. (8) If there are abnormalities in the air pressure, oil pressure, or oil temperature and these are not dealt with in a timely manner, a fine of 5 yuan will be imposed per occurrence. (9) If the main fan and air compressor are not operated within the specified parameters, a fine of 5 yuan will be imposed per occurrence. (10) If a serious malfunction occurs in the equipment, affecting the stable operation of the facility, and the on-duty staff fail to notify the workshop or duty personnel in a timely manner, a fine of 50 yuan will be imposed per occurrence. B. Static equipment: No assessment is carried out for these devices; the on-duty staff are responsible for conducting inspections. C. Third-level filtration (I) Standards: 1. First-level filtration: Operate as required. 2. Second-level filtration: Operate as required. 3. Third-level filtration: Operate as required. Random inspections are conducted for the above items; 4. Lubrication equipment: (1) The surfaces of oil tanks, oil containers, trays, and filtering funnels should be free of oil stains and kept clean; (2) The filtering screens must be free of dirt, kept clean, and undamaged; (3) No equipment shall be damaged or missing (otherwise, 50% of the original price will be compensated); 5. Oil level in storage tanks: It should not be below the red mark and must not overflow the filtering screens. The oil levels in the two tanks in the main machine room are the responsibility of both the pump operator and the main machine. For the above items in 4.5, handover checks are carried out, with the party taking over being evaluated; (II) Evaluation: (1) If there are oil stains or dirt on the surfaces of oil tanks, oil containers, trays, and filtering funnels, a fine of 5 yuan will be imposed per occurrence. (2) If the third-stage filter screen is dirty or damaged, a fee of 5 yuan will be charged per occurrence. (3) All appliances must be intact and not missing (otherwise, 50% of the original price will be compensated). D. Hygiene: (1) If the pumps are dirty, a fine of 5 yuan will be imposed per occurrence. (2) If the floor of the pump room is not kept clean, a fine of 5 yuan will be imposed per occurrence. (3) If the pressure gauge fitting at the pump outlet or the pressure gauge itself is dirty, a fine of 5 yuan will be imposed each time this is detected. III. Allocation of assessment results 1. Subjects of assessment: Hosts, air compressors, and pump operators. 2. Bonuses set for the records of mechanical equipment: 20 yuan for pump operators, 10 yuan for hosts, and 10 yuan for air compressors; 3. Allocation ratio: In each of these records, the team leader and the employees in various positions share the responsibility, with the team leader accounting for 30% and the employees accounting for 70%. 4. The above issues require rectification within a specified time frame; if the rectification is not completed by that deadline, the penalty will be doubled. IV. Equipment Handover System: Moving equipment, three-stage filtration systems, and hygiene-related equipment shall be handed over in accordance with the following requirements: 1. Equipment that is within specified parameters may be used, maintained, and handed over normally. 2. Equipment that exceeds the specified parameters is in poor condition and requires repair; it can only be handed over if one of the following conditions is met: (1) It is currently under repair or there are repair personnel on site; (2) If repair is not carried out upon the arrival of the repair personnel, approval from the workshop is required. For important equipment, repairs must be approved through consultation between the workshop and the dispatch department, with both parties’ signatures (or acknowledgment) required, valid for 24 hours. The repair personnel must also sign, indicating their name and time. For equipment that is used despite being in poor condition, the repair personnel must sign every eight hours; otherwise, the standard handover procedures shall apply. 3. Those who delay addressing issues once they are identified will be subject to doubled penalties upon discovery. 4. A maintenance ticket must be issued before repairing any equipment; those who violate this rule will have 5 yuan deducted from their wages by the shift supervisor. 5. The evaluation procedures are in accordance with the “Shift Handover System”. V. How to handle equipment that is not operating within specified parameters: 1. If there are problems with the pump operator’s post, the pump operator must inform the shift supervisor, who will then contact the dispatch center by phone; 2. When maintenance personnel arrive, they should first approach the shift supervisor, who will assign a pump operator or someone from the relevant post to assist the maintenance staff; 3. If the maintenance personnel have not arrived after 15 minutes, the shift supervisor must inform the person in charge of the equipment or the on-duty staff, who will then contact the dispatch center to coordinate the resolution of the issue and provide updates to the shift supervisor; 4. During weekdays from Monday to Friday during the day, contact the person in charge of the equipment; on weekdays at night, as well as on Saturdays and Sundays, contact the on-duty staff in the workshop. VI. Regulations for the Maintenance and Management of Special Valves The proper operation of special valves has a direct impact on the safe production of our facility. Based on the usage patterns of these valves, these regulations for their maintenance and management are established. The maintenance of special valves is the responsibility of the shift leader and the operators in charge of reaction processes. During the first shift of each day, they must test the manual and automatic switching functions of the valves under their responsibility to ensure that such switching operates smoothly. In case of special circumstances, it is necessary to inform the workshop; those who fail to comply without reason will have 10 yuan deducted from their pay for that shift (20% for the shift leader and 80% for the operators). Equipment that fails to meet the standards for “dual civilization” during a shift will be given a score of zero. Shift 1: Electro-hydraulic double-acting slide valve. Shift 2: Conveying pipe slide valve and raw material plug valve. Shift 3: Second-stage slide valve. Shift 4: First-stage slide valve. Note: The pneumatic double-acting slide valve is switched manually to automatically by the day shift on the 1st, 10th, and 20th of each month. VII. The assessment under this system is included in the evaluation for dual civilization. (II) Instrument Management System 1. Purpose The integrity rate of instruments has a direct impact on production operations; therefore, an instrument management system is established to maintain this integrity rate and ensure safe and stable production. II. Standards: All instruments must be accurate and functional, in compliance with the relevant standards set by the head office and the Maintenance Department. The excerpts are as follows: 1. The performance of the instruments must meet the requirements of production, requiring sensitivity in response, accuracy in measurement, and stable control. The indications of the primary instruments and secondary instruments should be consistent. 2. The records are clear, and the historical curves of key instruments are fully preserved. III. Instrument maintenance procedure: When a problem with an instrument is detected during shift, the shift leader shall contact the dispatch team to arrange for instrument repair and keep proper records of the maintenance. Attached is the \"Comprehensive Record Book for Instrument Maintenance Service Quality\". If instrument repairs are not carried out in a timely manner, the shift leader shall contact the workshop supervisor (or the person on duty). IV. Shift Responsibility System: Handover is permissible under the following conditions; otherwise, handover may not take place: 1. The instruments are functioning properly. 2. The instruments have issues and are currently being repaired. 3. For instruments that cannot be repaired or require deferred repair, approval from the workshop supervisor is required, along with signatures from both the workshop and the maintenance team. V. Assessment: Instrument problems must be identified and reported promptly. Those who fail to do so will be held accountable by the shift leader and the operator on duty. The workshop may impose a fine of 5–50 yuan on the responsible persons, while the shift leader may face a fine of 2–20 yuan. 2. The team leader is responsible for keeping accurate records of instrument repairs; these records must be timely, complete, and precise. Otherwise, a fine of 5 yuan will be imposed on the team leader per incident. 3. Instrument assessments and equipment assessments are both included in the evaluation for dual civilization goals: each shift is ranked based on the amount of money deducted from it monthly; the shift with the lowest total deduction comes first and receives 10 points, the second place gets 8 points, the third place gets 6 points, and the fourth place gets 4 points. (III) Leakage rate management system 1. Objective: The leakage rate shall be less than 0.005%. There is no shortage of bolt handwheels, and the valves can be opened and closed. II. Requirements: 1. Classify the sealing points of the device and equipment maintenance by leakage into teams. Leakage points are to be inspected and addressed at any time by the respective shifts; the shift leader must be present during such handling, and accident scenarios must be anticipated in advance. Leakage points at key areas identified during the shift are to be dealt with promptly by the person on duty, who should also prepare for possible accidents. The class is required to complete the rectification of any missing items by the 1st or 16th of each month, and to report any leakage points in their area to the workshop two days in advance; the workshop will then inspect those areas on those two dates. III. Assessment: 1. The workshop conducts inspections on the 1st and 16th of each month, identifying the leakage points and leakage rates for each shift; the average value of these two inspections is used for the assessment of that month, as part of the evaluation for excellence in both workmanship and ethics. 2. A bonus of 140 yuan is provided for each shift based on the leakage rate; if the leakage rate is below 0.005%, the full amount is awarded. For every 1% increase above that level, 10 yuan is deducted. Rewards and penalties for the shift account for 30%, with the remaining amount distributed according to the progress in making corrections. The assignment is determined by the team leader based on the situation within the team. 3. A prize of 150 yuan for the leak-free area. For bolt handwheels and similar items in the workshop, inspections are carried out twice a month on the 1st and 16th; a fine of 5 yuan will be imposed for each missing inspection. A penalty of 10 yuan will be imposed for each missed item that is not reported on time.