Regarding equipment management standards

Our company has equipment inspection forms, equipment operation attendance sheets, records of the operation and maintenance of key equipment, records of equipment lubrication and oiling, as well as equipment cards. For the proper operation of equipment, human factors are crucial; it is required to possess the \"four understandings\" and the \"three skills\".

Regarding the standards for equipment management, brother, there is no unified standard for this. The ISO system can provide some well-defined standards, but for equipment management, one can refer to the internal enterprise standards set by companies such as CNPC and Sinopec – they are really good; specific provisions can be found for each aspect. These include equipment inspection forms, records of the operation and maintenance of key equipment, records of equipment lubrication and refueling, equipment cards, as well as standards related to pressure vessels and lifting machinery. . . Equipment maintenance management, equipment repair management, and related record keeping. .

Equipment management essentially involves the following: 1. Procurement management: When placing an order, details such as design requirements, technical specifications, and material requirements are all listed in the contract. 2. Acceptance management: Establishing equipment records 3. Installation and commissioning 4. Operation management: Operation and maintenance. The \"five fixed principles\" for equipment lubrication: fixed location, fixed quality, fixed quantity, fixed frequency, and fixed person in charge. The \"four requirements\" for equipment maintenance: order, cleanliness, lubrication, and safety. The \"five disciplines\" for equipment operation: (1) Use the equipment only with an operation permit, and abide by safety operating procedures ； (2) Keep the equipment clean at all times, and refuel it as specified ； (3) Comply with the shift handover system ； (4) Take good care of tool accessories to prevent loss ； (5) If any abnormality is detected, stop the machine immediately; if it cannot be handled by oneself, notify someone for inspection promptly. The “three aspects of excellence” in equipment use and maintenance: proper management, effective use, and timely repair. The “four skills” required for equipment use and maintenance: the ability to use it, to maintain it, to inspect it, and to resolve common faults. 5. Repair: 6. Disposal ；

Perhaps I didn’t explain my question clearly; what you mentioned are all routine tasks, and my question is how to standardize them. For example, the standards for equipment procurement and equipment acceptance include both technical standards and management standards. The same is true for the inspections people talk about; there are also standards for equipment inspections, and these are examples of standardization ； The specific tasks and standards required for each position vary. Now it’s time to list all these things and create a complete catalog.

Standards are divided into several major systems: technical standard systems, management standard systems, and work standard systems.

Equipment management “Excellent Condition” standard I. Standards for equipment in excellent condition 1. Technical and economic indicators 1.1 The overall equipment integrity rate for all devices must be above 98%, while the integrity rate for key devices must be 100%； 1.2 The device meets the leak-free standard, with a leakage rate of less than 0.5‰ at static sealing points and less than 2‰ at dynamic sealing points ； 1.3 The three rates of plant instruments (availability rate, utilization rate, and control rate) all exceed 98%, the leakage rate is ≤0.5‰, and the utilization rate of instrument interlocks is 100% ； 1.4 The production capacity of the facility reaches the designed level, the commissioning period meets the planned targets, and the equipment does not operate under overload conditions ； 1.5 Strictly control unplanned shutdowns caused by equipment issues. (The calculation and statistics of technical and economic indicators are carried out in accordance with Document No. 34 [2002] issued by China National Petroleum Corporation.) 2. Comprehensive Management 2.1 All relevant management systems are in place and strictly implemented ； 2.2 Establish responsibility systems for each position and strictly abide by them ； 2.3 All relevant regulations and standards are in place, and they are strictly complied with ； 2.4 Zero safety accidents in equipment inspection, maintenance, and repair ； 2.5 The organization for equipment inspection, maintenance, and repair is scientific and rational, with comprehensive management mechanisms including inspection and maintenance plans, procedures, construction risk assessment, supervision by Party A, quality control, documentation, and technical summaries ； 2.6 Implement the spirit of the on-site meeting on controlled management of petrochemical production in Dalian West Pacific, and establish a technical management system for operation diagrams ； 2.7 Comprehensive data entry of various equipment management information and technical reports, with timely and accurate information feedback ； 2.8 Make rational use of modern management methods and new technologies, implement the model of \"mobile management for managers and continuous inspections by workers,\" and advance RBI (risk-based evaluation) work in a planned manner ； 2.9 Strengthen professional technical training, requiring operators to have a thorough understanding of on-site equipment in terms of the ’four understandings and three abilities’: understanding the structure, performance, principles, and applications, as well as the ability to operate the equipment, carry out maintenance, and troubleshoot faults. 3. Clean and civilized production 3.1 The equipment site must meet the requirements of “one level, two clean conditions, three visible elements, four absences, and five no shortages”: the ground should be level, window and door glass should be clean, the surrounding walls should be clean, the ditches should be bottomless, the shafts should be visible, the equipment should show its original color, there should be no garbage, no weeds, no waste materials, no unnecessary equipment, there should be no shortage of insulation paint, no shortage of window and door glass, no shortage of light bulbs and lampshades, and no shortage of manhole covers ； 3.2 All tools, equipment, and safety and fire-fighting facilities within the device are complete and properly arranged in their designated places. 4. Lubrication Management 4.1 Establish and improve a \"lubrication management system\" and implement it effectively ； 4.2 The device is equipped with a dedicated lubricating oil station, ensuring standardized hygiene conditions ； 4.3 Clarify the contents of “three filters and five fixed parameters”; the equipment shall have a lubrication logbook and records ； 4.4 The lubricating oil used in large-scale units must be regularly tested and analyzed. 5. Buildings and structures are in good condition. 5.1 The records of buildings and structures are complete and thorough ； 5.2 The foundation part shall be free from corrosion and cracks; any inclination or settlement must remain within acceptable limits, and the bolts, supports, and riveted components shall not be loose ； 5.3 The beams, columns, floor slabs, frames, and wall structures of the load-bearing framework are intact; loads, cracks, and tilts must be within acceptable limits, and the protective and shielding layers must be intact and effective ； 5.4 The floor inside the device is intact, with proper drainage and effective corrosion protection; cracks and deformations are within acceptable limits ； 5.5 The roof area is leak-free, free of debris, has proper drainage, and is free from any external loads specified in the design ； 5.6 Doors and windows glass are intact and secure ； 5.7 Fences and ladders are intact ； 5.8 The lightning protection system is complete, safe, and reliable. 6. The drawings and documentation related to the above-ground and below-ground pipeline networks within the facility are complete and accurate; the pipelines are arranged neatly with clear markings, and effective insulation and anti-corrosion measures have been applied, ensuring no leaks or spills. II. Standards for intact equipment 1. The spare parts and components of the equipment are complete and in good condition, with quality meeting the requirements. 1.1 The spare parts and components of the main and auxiliary machines are complete and in good condition, with quality meeting the requirements ； 1.2 The instruments, signal interlocks, various safety devices, and automatic control devices are complete, functional, sensitive, and accurate ； 1.3 The foundation and base are stable and reliable; the anchor bolts and various bolt connections are tight and properly arranged, meeting the technical requirements ； 1.4 Piping, fittings, valves, supports, etc. are installed properly, firmly and completely, with clear markings that meet the requirements ； 1.5 The anti-corrosion, insulation, and anti-freezing facilities are complete, functional, and meet the requirements ； 2. The equipment is operating properly and performs well, achieving the output specified on its nameplate or its approved capacity. 2.1 The equipment should be used correctly; it should be in good technical condition, with all parameters within normal ranges, without any signs of overloading or exceeding specified limits ； 2.2 The equipment is well-lubricated, the lubrication system operates smoothly, and the oil quality meets the required standards; the \"five fixed principles\" and \"three-stage filtration\" are implemented” ； 2.3 The equipment vibration is within acceptable limits, with no signs of looseness or abnormal noises ； 2.4 The operating parameters such as temperature, pressure, speed, flow rate, and current at various sections meet the requirements ； 3. Establish a equipment package mechanism, and carry out thorough maintenance and routine inspections ； 4. Important and critical equipment must be subject to top-tier maintenance management that integrates mechanical, electrical, instrumentation, operational, and management aspects ； 5. For key and large-scale rotating equipment, online condition monitoring should be implemented, a fault diagnosis database should be established, and network-based management for condition monitoring and fault diagnosis should be adopted ； 6. Strictly implement all the management regulations regarding boilers, pressure vessels, and industrial pipelines ； 7. Boilers, pressure vessels, and industrial pipelines must be under the management of qualified personnel who possess the appropriate qualifications ； 8. The electrical and instrumentation equipment is in good technical condition, the facilities are complete, and the markings are clear and accurate, meeting the requirements for use and safety standards ； 9. Strictly implement the \"Safety Interlock Management System\"; ensure that the interlock records are complete and that management is standardized ； 10. The technical documentation for the equipment is complete and accurate ； 10.1 The equipment records, registers, maintenance and inspection records are complete ； 10.2 Statistics and records are kept for the equipment’s operating time and cumulative operating time ； 10.3 Drawings are available for the vulnerable parts of the equipment ； 10.4 Complete set of equipment operation procedures and inspection/maintenance procedures ； 11. The equipment and the surrounding area are neat and clean, with no debris, and no leaks or spills.

The above mentions some principled guidelines; the specific details need to be determined based on the actual conditions of one’s own factory. 7# Zhang Jiahong

I think everything should have standards, but the workload for this would be quite substantial.