【Lean Chemicals】147 items in 10 categories! Useful workshop maintenance tips that come in handy at any time!

Thread Content

　　As the saying goes, companionship is the most sincere form of confession! Colleagues who eat together and work side by side surely spend a lot of time together! There are 147 tips in 10 categories related to maintenance work; be sure to share these with your colleagues in the workshop, as they are crucial for ensuring safety! ▲ Working together, sharing safety 1. Responsibilities of a maintenance electrician 1. Be familiar with one’s own work area, and be responsible for the maintenance of all electrical equipment as well as outdoor transformers in that area. Conduct regular inspections to ensure the proper functioning of the equipment. 　　2. Maintenance must be documented, with tests and inspections conducted. Any maintenance work that requires power shutdown, furnace shutdown, or machine shutdown must involve contacting the relevant personnel, and such work can only be carried out upon their approval. 　　3. When performing maintenance and shutting off or restoring power supply, it is necessary to strictly enforce the \"Power Supply Shutdown and Restoration Management System\" and the \"Signage and Registration System\". Dedicated personnel will be assigned to handle power shutdown/restoration and tag registration. Whenever a sign reading “Personnel are working; do not close the switch” is visible on the switch, it is strictly prohibited to supply power without authorization. During a power outage, the load switch should be turned off first, followed by the isolating switch; the reverse order is used when restoring power. 　　4. After a power outage, before starting work, it is necessary to test for electricity, discharge the charge, and attach ground wires. When performing power on/off operations in the high-voltage chamber and electromagnetic station, follow the dispatch instructions accurately; one person shall carry out the operations while another acts as a supervisor. Before powering on, make sure to coordinate and confirm who will attach the tag and who will remove it. 　　5. Indoor wiring must meet safety technical requirements; when installing lighting fixtures, the lamp socket screw terminals should be connected to the neutral wire, while the switch should control the phase wire. 　　6. Flammable and explosive workshops must use explosion-proof electrical equipment, and newly installed electrical facilities must be constructed in accordance with safety technical regulations and electrical installation standards. 　　7. Temporary wiring must not be haphazardly installed at the production site. When necessary, it may be installed in a safe location where it does not impede passage, and must be removed immediately after use. 　　8. To prevent low voltage from feeding high voltage through the secondary side of the instrument transformer, the relevant transformer should be disconnected from the high voltage circuit. 　　9. When maintaining a bridge crane, a fence and warning signs must be installed below the work area to prevent objects from falling and injuring people. 　　10. When the motor is in operation, it is not allowed to adjust or repair the rotating parts, nor should the wiring box be opened arbitrarily; the incoming cables of high-voltage motors must be equipped with protective guards. 　　11. When maintaining switchgear, the power supply should be disconnected with the assistance of the duty personnel, and the cables and capacitors should be discharged. Maintenance personnel are not allowed to enter the cabinet without permission. 　　12. In high-voltage rooms and electromagnetic stations, electricity must be cut off when using blowtorches, gas welding, or electric welding. When a partial power outage occurs, it is necessary to maintain a safe distance or set up protective barriers. It is strictly prohibited to place oxygen and acetylene cylinders inside the room, or to connect the electric welder’s ground wire to the cable insulation. 　　13. When servicing electric equipment with automatic control, the control circuit must be completely disconnected to ensure that no accidental operation will occur before work can begin. 　　14. When working at heights, it is necessary to wear a safety belt, check that the supports are firm and reliable, no one should stand below, and there must be a dedicated person to supervise. 　　15. When working on the indoor ceiling, be careful to avoid collapse or sinking, and pay attention to fire safety. 　　16. When working at heights or operating high-voltage switches on a transformer platform, it is prohibited to touch the ground wire; safety goggles must be worn when turning power on and off. 　　17. Mine electricians are prohibited from going up or down while the excavator is in motion. When inspecting and handling the collector ring, a dedicated person must be assigned to monitor the power-off switch. When moving live high-voltage rubber cables, insulating tools must be used as specified. 　　18. When measuring insulation with a megohmmeter, the power supply must be disconnected, and discharge must be performed after the measurement. 　　19. When working in unfamiliar locations, it is necessary to fully understand the conditions on site; taking risky actions is strictly prohibited. 　　20. Outdoor work or work at heights is strictly prohibited during thunderstorms, strong winds, and heavy snowfall. 　　2. Responsibilities of a Maintenance Fitter
1. Before starting work, check all tools and equipment to be used, tidy up the workplace, and promptly resolve any issues that arise. 　　2. While the equipment is in operation, maintenance is prohibited. Before maintenance, it is necessary to contact the operator (for special equipment, a maintenance tag must be attached). After the maintenance is complete and all safety devices have been restored, testing can proceed. 　　3. When working at heights, fasten your safety belt to a secure location. The tools and materials used must not be thrown up or down. Safety warning signs should be placed on the work area floor, along with a supervisor. 　　4. When assembling bearings, it is prohibited to strike the quenched workpiece directly. 　　5. In assembly work, it is prohibited to test holes with fingers. 　　6. Gloves are not allowed when using a hammer; check that the area where the hammer is used is free of people and obstacles. It is prohibited to use hammers of different sizes as padding. 　　7. When using a portable flashlight, it must be a low-voltage safety lamp of 36 volts or less. 　　8. When maintaining the crane, the power supply must be cut off and a maintenance sign must be placed; climbing on the crane tracks is prohibited. 　　9. When using a crane to lift items, appropriate rope shackles should be used. Inspect carefully before use. During lifting, swing it a few centimeters off the ground several times; when multiple people are working, there must be a person in charge to give instructions. 　　10. When using a hydraulic jack, the padding under the jack head must be flat; the use of brittle items such as cast iron is prohibited. 　　11. When scraping, the workpiece must be held firmly. When more than two people are working together, care should be taken to ensure that the scrapers do not scrape in opposite directions at the same time. 　　12. In accordance with the technical requirements, properly use tools such as wrenches, shovels, and files. 　　13. When cleaning parts with gasoline or cleaning oil, open flames are prohibited at the work site, and used oil must be poured into designated areas. 　　3. Responsibilities of Gas Welders 　　1. Gas welders must be familiar with the structure and performance of gas welding and cutting equipment, be able to troubleshoot faults, and only after passing the relevant examinations and obtaining a \"Special Job Operation Certificate\" can they work independently. 　　2. Oxygen and acetylene cylinders must not be placed near power sources or electrical equipment or high-voltage lines, nor on insulators such as rubber. They should be kept in well-ventilated areas that do not impede traffic. Smoking is prohibited in their vicinity, and oils, flammable and explosive substances must not be used there; all tools used must be free of oil stains. 　　3. Oxygen cylinders must not be struck, collided with, or inverted; they should also not be exposed to direct sunlight. Safety gear such as goggles must be worn before use. 　　4. The distance between oxygen cylinders and acetylene cylinders must be at least 5 meters, and the distance from open flames must be at least 10 meters. 　　5. When conducting a short-term blowdown test on an oxygen cylinder, one should stand to the side, ensuring that the head and chest are not directly facing the cylinder valve; when installing a pressure reducer, the head and chest must be kept away from the cylinder nozzle. 　　6. Acetylene gas cylinders must be equipped with a dedicated pressure reducer and flashback arrestor. When opening them, one should stand to the side and behind the valve opening, and perform the action gently. 　　7. When using an acetylene cylinder, it is strictly prohibited to use it in a horizontal position; when the working location is not fixed or changes frequently, it should be placed on a dedicated trolley. 　　8. When lifting and transporting, special fixtures and shock-absorbing transport vehicles should be used; it is strictly prohibited to use electromagnetic cranes and chains for lifting and transportation. 　　9. When the valve of an acetylene gas cylinder freezes, it is strictly prohibited to thaw it using fire; if necessary, warm water at a temperature below 40°C may be used for thawing. 　　10. The operating pressure of acetylene gas cylinders shall not exceed 0.15 Mpa, the gas flow rate shall not exceed 1.5–2.0 m3 per hour per cylinder, and the ambient temperature shall not exceed 40°C; cooling measures should be taken if the temperature exceeds 40°C. 　　11. Copper, silver, mercury, and their products must not come into contact with acetylene; if a copper alloy must be used, its copper content should be less than 20%. 　　12. Welding guns, cutting guns, pressure reducers, and temper prevention devices must be in good condition; otherwise, they shall not be used. 　　13. When there is a leak of oxygen, do not use rags or wood chips as padding; instead, use asbestos rope. It is strictly prohibited to blow oxygen into acetylene cylinders. 　　14. When the gun nozzle becomes clogged during operation, work must be stopped immediately; operations can only resume after it has been repaired. When lighting a welding or cutting torch, the oxygen regulator should be opened first, followed by the acetylene regulator; when shutting it down, the acetylene regulator should be closed first, and then the oxygen regulator. 　　15. Welding and cutting of fuel tanks or pressurized containers that may cause explosions are prohibited. When welding or cutting empty oil drums, they must be thoroughly cleaned with warm water and alkaline solution, and filled with water before such operations can be carried out. 　　16. When welding or cutting on the surface or sides of a temporarily erected structure, it is necessary to check and ensure that the support is firm and stable before proceeding with the work. It is forbidden to work under a crane lifting objects. 　　17. Welding or cutting of objects directly on cement surfaces is prohibited. 　　18. When performing welding and cutting work in flammable and explosive areas, it is necessary to comply with relevant regulations regarding safety and fire prevention. 　　19. Sufficient lighting must be available at the work site; when welding or cutting in sealed containers, lighting lamps with a voltage of 36 volts or less should be used. 　　20. When working at heights, it is necessary to wear a safety belt and a helmet, and pay attention to whether the area below is safe and secure. 　　21. The gas in the cylinder must not be exhausted completely; an residual pressure of 0.5–1.0 Mpa should remain in the oxygen cylinder, while the acetylene cylinder should have a residual pressure that is not lower than the value specified in the table. 　　22. After the work is completed, the valves of the oxygen and acetylene cylinders must be closed promptly. 　　4. Job Responsibilities of Welders 　　1. One must be familiar with the structure, performance, maintenance, and operation methods of welding equipment; only after passing the relevant tests and obtaining a \"Special Occupation Operation Certificate\" can one work independently. 　　2. Before starting work, check whether the welder’s power cable, lead wires, grounding wire, etc. are in good condition; the electrode clamps must be insulated, and any wires that cross roadways should be elevated or covered with protective covers. 　　3. Welding machines should be placed in a clean, well-ventilated, and dry area; in outdoor locations, measures should be taken to protect them from rain and snow. 　　4. The welding site must be at least 10 meters away from flammable materials and at least 20 meters away from explosive materials. Welding of flammable, explosive materials, as well as objects under voltage is prohibited. 　　5. Personal protective equipment must be worn properly while working, and it is forbidden to touch the welding machine and wires with hands. 　　6. When working in humid areas, measures must be taken before starting work. 　　7. During work, the enclosures of welding machines, transformers, and current regulators should be checked regularly; operations must be stopped immediately when the temperature exceeds 60 degrees. Before working, check the insulation of the electrical wires. 　　8. When welding empty oil drums and other oil-containing containers, they must be thoroughly cleaned with alkaline water before welding can proceed. When welding various cylinders and seals, gaps for air to pass through should be left; when welding pipes, the ends must be kept open to prevent explosions and poisoning. 　　9. When working inside a boiler or other metal containers, all ventilation openings must be opened to ensure proper ventilation and prevent explosions or poisoning. Someone needs to be present outside to prevent electric shock. 　　10. When working in enclosed containers, tunnels, or deep ditches, a 12-volt safety lamp must be used; take a 5–10 minute break every hour while working inside the container to go outside and breathe fresh air. 　　11. When working at heights, it is necessary to wear a safety harness and follow the safe operating procedures for working at heights. 　　12. Work at heights is prohibited in winds of force 6, and work outdoors during thunderstorms is not allowed. 　　13. During breaks or when leaving the post, turn off the power supply after completing work, check for any sources of fire, and ensure they are properly dealt with before leaving. 　　5. Responsibilities of a riveter 　　1. When using an air hammer, it must not be directed at people; the hammer head must be removed during breaks to prevent injury. 　　2. When driving rivets, no one should stand on the opposite side; the person who receives the rivet must stand to the side and maintain communication with the person who drives the rivet. The person who drives the rivet must be careful of pedestrians passing by to avoid injuring them. 　　3. When prying iron plates or loose parts, the pry bar must not be pointed at anyone’s head, chest, or legs to prevent flying debris from causing injury. When multiple people are working together, one person should serve as the commander. 　　4. When lifting workpieces with a crane, the staff must leave the dangerous area, and the lifting equipment used must be inspected in advance to ensure it is in good condition. 　　5. When using a sledgehammer, pay attention to the range in which the hammer head can fly; be mindful of your surroundings while striking. 　　6. When bending and shaping rivets, be careful to check for any obstacles or flammable materials in the surrounding area. 　　7. When working at heights, wear a safety belt and carefully check whether the work platform and scaffolding are securely set up. When working on circular workpieces, it is necessary to provide a backing underneath; no one should stand on such surfaces without protective measures in place. 　　8. The workplace must be adequately illuminated. When using portable lights, only safety lights with a voltage of 36 volts or less may be used. 　　9. All equipment must be operated in accordance with its safety procedures. After completing the work, clean the equipment area and arrange the items neatly. 　　6. Responsibilities of the Plumber 　　1. Before starting work, carefully inspect the equipment and tools, and address any issues found promptly. 　　2. When going to the site to work, first observe the site carefully, establish safety measures, get in touch with the relevant personnel, and only after hanging up the maintenance sign can work begin. 　　3. When conducting a hydrostatic test on the pipeline, a vent must be welded at a high point on the pipeline to remove air and prevent overpressure explosions. Staff are prohibited from standing at the ends of the pipes, and hitting the pipes in their vicinity is not allowed to prevent injury. 　　4. Before conducting air and water tests on the pipelines, it is necessary to coordinate with relevant departments. 　　5. When aligning pipes, it is prohibited to use hands or feet for testing. When aligning pipes with flanges, it is prohibited to use fingers to align the holes. 　　6. The sand used for tube drying must be dried to prevent explosions caused by moisture generated during heating. 　　7. When working in sewers, manholes, or dark areas, wear a safety helmet and light a wax candle to test the oxygen level; do not enter if the candle goes out. 　　8. When working in dark areas, adequate lighting must be provided, and working alone is prohibited. 　　9. When filling the lead ports, wear protective gear such as safety glasses, shoe covers, gloves, and dust caps to prevent moisture or water from entering the pot and causing an explosion. 　　10. When lifting pipelines and valves, it is necessary to work closely in coordination with the crane operator and lifters, under the supervision of a designated person. 　　11. When working at heights of more than 2 meters, the safety procedures for working at heights must be followed. 　　12. When carrying out operations involving multiple types of work, unified command is necessary; when welders are working in water areas, measures to prevent electric leakage must be taken. 　　13. When working in no-fire zones, it is prohibited to bring fire sources, and special tools must be used. 　　7. Responsibilities of Crane Operators 　　1. It is necessary to be well-versed in the structure, performance, and operation/maintenance procedures of the equipment used; only after receiving professional training and passing relevant examinations, and by holding a \"Special Job Operation Certificate,\" can one work independently. 　　2. Before starting work, it is necessary to wear the required personal protective equipment and tools as specified. 　　3. Before driving, it is necessary to check the mechanical and electrical components of the equipment, ensure that the steel cables meet safety standards, and verify that all protective devices are in good working condition. Lifting operations are strictly prohibited if any of these elements are malfunctioning. 　　4. Before driving, check whether there are any people or obstacles in the driving area. In case of a malfunction during driving, take safety measures: cut off the power supply and place a service sign before attempting to fix it. 　　5. Test the machine before operation and issue preventive signals. The operator’s vision must be at least 0.8. 　　6. Keep a lookout while driving; do not take your hands off the controls. Talking, fighting, eating, dozing off, or bringing children on the crane are prohibited. 　　7. It is necessary to follow the instructions of the crane operator; the crane should be started by ringing a bell first. If the signaling gestures are unclear or incorrect, one has the right to refuse to carry out the command. The vehicle must stop immediately upon receiving an emergency stop signal from anyone. 　　8. No one is allowed to stand on the objects being lifted. When lifting molten iron, tungsten, or lead alloys, the containers should not be filled to capacity; the lifting process should be carried out slowly while the bell is sounded. It is prohibited to lift the objects over people’s heads, and reversing the load is also not allowed. 　　9. Maintenance, cleaning, refueling, and other such tasks are strictly prohibited while the equipment is in operation; one must not leave their post when loads are suspended in the air. 　　10. In the event of a sudden power outage during operation, the controller must be set to zero position; it is not allowed to leave the cab unless the load has been lowered or the rigging has been disengaged. 　　11. For two cranes on the same track, the distance between them should be maintained at over 2 meters; it is prohibited for one crane to collide with another. When one crane moves in the direction where the other crane is parked, a signal must be given, and it may proceed only after obtaining permission. 　　12. When approaching the winch limit switch, when the boom and trolley reach their limits, or when encountering another crane, the speed must be reduced; the crane shall not be used as a substitute for brakes, the limit switch shall not be used in place of a stop mechanism, and the emergency switch shall not be used in place of a normal switch. 　　13. One should walk and move up and down along the designated safety walkways or special escalators; it is not allowed to walk on the tracks of the vehicles, nor to cross from one vehicle to another. 　　14. Overloading is strictly prohibited. When two vehicles lift a heavy load simultaneously, there must be a dedicated person to give unified instructions; the lifting and moving speeds of the two vehicles should be identical, and the load should be distributed evenly. 　　15. When lifting heavy objects, lift them first to a height of 10–15 centimeters off the ground, ensure that the lifting is stable and the brakes are functioning properly, and then raise them further while moving them slowly. It is not allowed to operate three control levers simultaneously. 　　16. The “Ten Prohibitions on Lifting” must be strictly enforced, and adequate lighting must be provided for night operations. 　　17. When operating a gantry crane, be careful to check for any obstacles on the tracks; when lifting tall objects that obstruct the view, dedicated personnel should be assigned to monitor and direct operations from both sides. 　　18. Cranes should cease operation and have their power supply disconnected in conditions of winds above level 6, thunderstorms, or heavy fog. Shims should be inserted in front of and behind the wheels to secure them. 　　19. Once the work is completed, the vehicle should be parked in the designated position, the hook should be raised, the trolley moved to one end of the track, the controller handle set to the zero position, and the power supply turned off. 　　8. Responsibilities of the Crane Operator 　　1. It is necessary to be well aware of the structure, performance, and operating methods of the equipment used; only after passing the relevant examination and obtaining a \"Special Job Operation Certificate\" can one start working. 　　2. Safety protective equipment must be worn before starting work; a safety helmet and gloves are required when entering the lifting area, otherwise work is not permitted. 　　3. Lifting tools should be inspected regularly to ensure they are in good condition and reliable; one must be familiar with the maximum allowable load and rejection criteria for lifting equipment and rigging. Overloading is strictly prohibited, and command signals must be mastered proficiently, with strict adherence to the \"Ten Prohibitions on Lifting\". 　　4. It is prohibited to use a single-eye crane to lift objects weighing over 800 kilograms. 　　5. When multiple people are operating, there must be a dedicated supervisor to provide unified commands and clear instructions. If the operator cannot see the command gestures clearly, a relay assistant should be assigned to convey the signals accurately. 　　6. When lifting longer and heavier items such as angle irons, channel steels, and railway rails, anti-slip wood blocks must be used and hemp ropes should be employed to prevent accidents. 　　7. Before lifting the load, check first whether it is securely tied; padding should be placed where the ropes pass over sharp edges. Then lift it slightly off the ground by 0.5 meters and swing it several times. Only after confirming that it is stable and secure may lifting proceed. 　　8. A warning line should be set up around the lifting area, and access is strictly prohibited to unauthorized personnel. Outdoor lifting operations are strictly prohibited in strong winds of force 6 or above. 　　9. Do not leave your post before the lifted object is in place and secured; do not stop working while the rigging is under stress or the load is hanging in the air. 　　10. When the load is suspended in the air, it is strictly prohibited to stay or pass under the boom; no one shall stand in front of the winch or pulleys, or beside the traction steel wire rope. 　　11. Objects stacked must not be tilted; their height should be appropriate. Items that are prone to sliding should be padded with wooden blocks, and objects must not be stacked in safety passages. 　　12. Lifting loads must not be pulled sideways, dragged, or impacted; when lifting precision equipment, wooden blocks should be used as padding. 　　9. Responsibilities of the lining worker 　　1. Before starting work, carefully inspect the work site and tools, and address any issues found promptly. 　　2. When maintaining the grinder, it is necessary to coordinate well with the duty personnel, strictly implement the maintenance tag-out system, and apply high-voltage locks. 　　3. When removing or replacing the shims, close coordination is required, with a dedicated person in charge; when using a crowbar to probe the area, keep hands away from the screw holes. 　　4. When loosening screws, make sure your feet are stable and hold the tool firmly to avoid injury; leave some screws in place as a safety measure – do not remove them all. 　　5. When removing the liner from the mill, safety measures must be taken to prevent metal fragments from falling and to avoid uneven loading of the machine. 　　6. No one is allowed to stand on the machine body while it is being ground; when releasing the rope, ensure proper communication between people at the front and back to prevent injuries caused by a broken rope. 　　7. When cutting iron inside the grinder, it is necessary to maintain communication with those outside to prevent them from looking in, which could lead to burns. 　　8. When lifting the backing iron, conduct a thorough inspection, select the appropriate rope clips, and avoid overloading it; lift it after it is 0.5 meters above the ground and after swinging it a few times. 　　9. When stacking old and new gaskets, a 1-meter-wide walkway should be left; old gaskets must be removed promptly. 　　10. When lifting the ore handling cart, the floating ore and iron balls must be cleaned thoroughly; the lifting process must be smooth without any tilting, and no one is allowed to stand below it. 　　11. After maintaining the equipment, safety facilities must be restored promptly, obstacles near the mill must be removed, and the maintenance sign must be taken down. 　　12. When approaching the equipment to attach the shims, make sure to stand firmly on the upper and lower surfaces; when using ropes to fasten the shims, verify that it is safe and reliable, and assign a dedicated person to give instructions during lifting. 　　10. Responsibilities of the warehouse keeper 　　1. Persons who are not affiliated with this warehouse are not allowed to enter without permission. Those who enter the warehouse must not bring in any flammable or explosive hazardous materials, nor may they store any other items inside the warehouse. 　　2. When multiple people are lifting heavy objects, there should be a designated person to give instructions, ensuring that everyone moves in unison and lifts and lowers the load at the same time. 　　3. The stacked materials must be safe and reliable. 　　4. When performing welding or heating work in the warehouse, it is necessary to go through the relevant procedures and take reliable safety measures. 　　5. Before and after shifts, it is necessary to check the key seals as well as the safety conditions inside and outside the warehouse; any issues found must be reported promptly. 　　6. Entering the warehouse to issue materials on rest days or at night requires approval from relevant supervisors, and at least two people must be present to enter the warehouse. END: Companionship is the most enduring form of friendship. I hope your coworkers can realize that this small reminder comes from a place of genuine deep affection