Compilation of Power Plant Equipment Management Systems (Comprehensive~Worth Saving)

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　　Compilation of Equipment Management Systems I. Equipment Routine Inspection Management System II. Equipment Sealing Management System III. Equipment Maintenance System IV. Equipment Lubrication Management System V. Equipment Technical Foundation Management System VI. Equipment Inspection and Rating System I. Equipment Routine Inspection Management System Inspection contents: 1. Equipment vibration: Check whether there are any abnormal vibrations in the equipment. 　　2. Device noise: Is the sound produced by the device operating normally? 　　3. Equipment temperature: Check whether the equipment’s temperature is normal. 　　4. Equipment odor: Check for any odor resulting from medium leakage or other abnormal odors. 　　5. Tightness of equipment connections: Whether the foundation bolts are loose, and whether all the screws connecting the equipment are loose. 　　6. Equipment lubrication status: Check whether the oil pressure, oil temperature, and oil level are normal, and visually inspect any changes in the quality of the oil. 　　7. Sealing performance of the equipment: Check whether there is any leakage from machines, pumps, pipelines, and valves. 　　8. Corrosion condition of the equipment: Check whether the equipment is corroded and the extent of the corrosion. 　　9. Equipment instrument parameters: Check whether the parameters of various related instruments on the equipment are normal. 　　10. Equipment cleanliness: Check whether the equipment is clean and tidy. 　　11. Inspection personnel should adapt their approach based on the specific equipment at each station, being patient and meticulous, thorough and comprehensive, so as to not overlook any detail. 　　Provisions for inspection routes: 1. When an operator discovers issues with the equipment during inspections, they must promptly inform the maintenance staff to address them; major problems should be reported to the production scheduler. 　　2. Inspectors should carry an appropriate amount of tools with them during inspections (such as adjustable wrenches, hammers, temperature guns, vibration meters, etc.), and any faults that can be resolved easily should be fixed immediately. 　　3. If issues cannot be resolved by the maintenance inspector alone, they should report to the team leader after completing the inspection, and the team leader will arrange the necessary materials and personnel to handle the issue. 　　4. Operators and maintenance personnel shall promptly report any emergencies encountered during inspections, and take emergency measures based on the actual circumstances at the time. 　　5. Managers and maintenance staff at all levels of the company, when conducting inspections, have the right and obligation to require the relevant employees to make immediate corrections if they find issues such as insufficient oil in the machinery or other signs of poor maintenance. 　　Inspection records: 1. After completing the inspection along the designated route, the inspector shall fill out the equipment inspection record accurately and thoroughly. Any issues identified during the inspection, whether they have been addressed or not, must be recorded in detail. 　　2. The time for filling in the inspection record should be within 5 minutes before or after the hour, as specified by the operator on duty ； The maintenance worker should begin filling out the inspection record form established by the workshop after completing the inspection, and finish it within 5 minutes after the hour. 　　3. Keep the inspection record sheet neat; it should be filled out in the Fangsong font, with neat handwriting, and no random markings or alterations are allowed. 　　4. Equipment inspection records are collected every two days by the equipment staff in the Equipment Department, and are kept by that department ； Equipment inspection record form for maintenance staff. It is collected every two days by the workshop where maintenance is carried out, and then organized and stored by that same workshop. 　　Requirements for personnel responsible for routine inspections: Inspectors must possess extensive professional skills and theoretical knowledge, understand the performance of the equipment in their assigned roles, be able to independently diagnose basic faults in the equipment, and have the capability to handle emergency situations. 　　Proficient in using inspection equipment and instruments such as temperature guns and vibration meters, able to read the readings correctly and determine whether they fall within the normal range or if there are any abnormal changes. 　　II. Equipment Sealing Management System Classification and scope of sealing points: The following situations are not included in the classification of sealing points: 1. The joint area between two mating parts that do not have a sealing device (structure). 　　2. It is impossible to inspect and count the interior of the equipment; internal valve leaks cannot be detected. 　　3. Various pipelines buried underground. 　　Method for calculating sealing points: 1. Method for calculating dynamic sealing points: A dynamic sealing point is counted for the seal between two mating parts that are in continuous motion (rotation or reciprocation). 　　2. Calculation method for static seal points: One static seal joint is counted as one static seal point. 　　III. Equipment Maintenance System Three-level maintenance system: Level 1 maintenance (daily equipment upkeep) The maintenance tasks include, but are not limited to: daily inspection of the equipment, cleaning, refueling, replacement of consumables, and repair of simple parts; records of these replacements and repairs must be kept. 　　(a). Neat appearance. 　　(b). Check the operating condition of all components, and tighten any loose parts, including securing loose pipelines and ensuring that equipment feet are firmly fixed; address leaks caused by insufficient fastening force on flanges. 　　(c). Hydraulic lubrication, cleaning of oil lines and pipelines, cleaning of filters, adding oil to or changing the oil in the tank. 　　(d). Comprehensive and reliable safety protection and indicating instruments. 　　The operators in the using department are responsible for the primary maintenance of the equipment, and bear direct responsibility for keeping it in good condition and ensuring its effective use. 　　Level 2 maintenance: (a) Level 2 maintenance involves completing all the tasks required for level 1 maintenance; it requires cleaning all the lubricated parts, checking the quality of the lubricant in accordance with the oil change schedule, and replacing the lubricant as necessary. 　　(b) Check the dynamic technical condition of the equipment and its key operating parameters (noise, vibration, temperature rise, etc.), adjust the installation level, replace or repair components, clean or replace motor bearings, measure insulation resistance, etc. After secondary maintenance, the performance is required to meet the process specifications: there should be no oil leakage, air leakage, or electrical leakage, and parameters such as noise, vibration, pressure, and temperature rise must be within acceptable limits. 　　(c) Disassemble and inspect certain parts of the equipment as planned, clean the specified areas (such as the oil filter screens and the cleaning water jackets), clear the oil circuits and pipes, replace or clean the oil pipelines and filters, and tighten all parts of the equipment. 　　(d) Before and after secondary maintenance, the dynamic and static technical conditions of the equipment should be measured, and careful records must be kept. 　　Secondary maintenance is carried out mainly by professional repair technicians, with operators participating. 　　Level 3 maintenance: Level 3 maintenance requires the Equipment Department and the Power Department to entrust the manufacturer or specialized agencies to carry out performance restoration checks or maintenance repairs. 　　Requirements for operators regarding equipment maintenance:
1. Operators must undergo training to achieve “four understandings” and “three abilities”; only after passing the assessment may they operate the equipment with a valid certificate. 　　2. Operators must strictly follow the operating procedures for starting, running, and stopping the equipment. 　　3. Operators must properly carry out equipment lubrication, maintain the integrity of the lubrication system, add lubricant as specified, and carefully keep records of equipment lubrication. 　　4. Operators must keep the equipment clean and promptly eliminate any leaks or spills. 　　5. If any abnormality is detected in the equipment during operation, the cause should be investigated immediately. A equipment maintenance ticket should be filled out promptly, and maintenance personnel should be contacted for diagnosis and repair. In emergency situations, decisive actions should be taken or the machine should be stopped immediately; the dispatcher and relevant personnel should be informed, as well as the workshop supervisor. The machine must not be restarted until the cause has been identified and the fault has been resolved. Any unresolved issues should be carefully recorded in the equipment inspection logs and shift handover records, and explained clearly to the next shift. 　　6. The equipment, pipelines, instruments, foundations, etc., within each contracted area must be kept in good condition and clean, with effective measures in place for corrosion protection, insulation, and freeze prevention. 　　Requirements for maintenance personnel regarding equipment care: 1. Maintenance workers must have clear roles assigned to them, and they are responsible for inspecting, maintaining, and repairing the equipment, pipelines, and instruments under their responsibility. 　　2. Maintenance workers must conduct inspections at regular times and locations, and proactively ask operators about the equipment’s operating conditions. 　　3. Maintenance workers must eliminate any defects that are identified promptly. For defects that cannot be fixed immediately, they should be recorded in detail and reported in a timely manner, with efforts to resolve them as part of the equipment maintenance process. 　　4. Upon receiving the equipment maintenance ticket, the maintenance technician must arrive at the site within 10 minutes (15 minutes during night shifts). In case of an emergency that poses a threat to production, repairs must be carried out immediately. If repairs cannot be carried out right away due to limitations in manpower, technology, spare parts, etc., the technician should contact the supervisor in charge of the workshop and provide the operator with a detailed explanation for the delay; the operator shall then record this information accurately on the equipment maintenance ticket. 　　5. The supporting equipment shall not be disassembled for use without the approval of the Equipment Department and the Power Department. 　　Standby equipment: There should be a designated person responsible for standby equipment. Regular inspections and maintenance must be carried out, with attention paid to preventing dust, moisture, freezing, and corrosion. For drive equipment, periodic cranking and switching operations are also necessary to ensure that all equipment remains in good working condition. For equipment that is kept in reserve for long periods or is idle, records should be maintained, dedicated personnel should be assigned to manage it, and regular maintenance should be carried out. 　　IV. Equipment Lubrication Management System Management contents and methods: 1. “Five Fixes” and “Three-Level Filtration” “Five Fixes” (a) Fixed locations: Oil should be applied to the lubrication points specified in the routine procedures, with no omissions allowed ； 　　(b) Designation of personnel: For the daily oiling of the equipment, the operator is responsible for the lubricating oil, while the maintenance worker is responsible for the grease. The record should be filled out promptly after refueling is complete ； 　　(c) Qualitative aspect: Select a type of lubricant (grease) that meets the requirements of the equipment, and ensure that its quality is satisfactory. Lubricating oil must undergo \"three-stage filtration\" to be clean and free of impurities before it can be used in the lubrication areas. The use of improper or unclean oils (greases) is prohibited ； 　　(d) Timing: The fueling areas of the equipment are refueled, cleaned, or have their oil changed at specified intervals ； 　　(e) Quantification: Add the selected lubricant (grease) in sufficient quantity according to the oil level and amount specified by the equipment. While ensuring proper lubrication, and in line with the principle of conserving oil, the fuel tank is changed as required, and lubricants are added to all lubrication points. 　　2. “Three-stage filtration” (a) First-stage filtration: Transporting the oil tank to the fixed oil storage tank ； 　　(b) Secondary filtration: from oil tank to oil canister ； 　　(c) Third-level filtration: from the oil reservoir to the lubrication points. 　　Key points and precautions for refueling: The refueling personnel should regularly check the lubricated parts, and the bearing temperature must be kept within the specified limits. The lubricant level should generally be maintained between 1/2 and 2/3 of the indicated scale; in cases with special requirements, it should be set in accordance with the technical specifications provided in the equipment documentation. 　　When a newly installed piece of equipment is put into operation for the first time (during the running-in period), the oil should be replaced once within 15 to 30 days ； Under normal operating conditions, the oil change interval should be determined based on operating conditions and the lubricating oil inspection report. 　　V. Basic Management System for Equipment Technology
Classification of basic equipment-related documents:
1. Contents included in technical standard documents
(a) Operating procedures for equipment (including operating procedures for electrical equipment)
(b) Maintenance and repair procedures for equipment (including maintenance and repair procedures for electrical equipment, instruments, and gauges)
(c) Safety technical procedures for equipment
2. Contents included in management quota documents
(a) Quotas regarding equipment maintenance cycles
(b) Quotas regarding maintenance duration
(c) Quotas regarding consumption and storage of spare parts and components
(d) Quotas regarding maintenance costs
(e) Statistics on the implementation of quotas; statistics on the achievement of quota targets
3. Reports and records
1. Equipment inventory register
2. Equipment sealing records
3. Summary table of equipment technical conditions
4. Technical files of equipment

VI. Equipment Inspection and Rating System
Equipment inspection and rating must be carried out regularly. In each workshop, such inspections are conducted once a month under the organization of the deputy workshop manager responsible for equipment. Relevant personnel are required to conduct thorough inspections and ratings of all production equipment in accordance with established rating criteria. 　　1. The results of the equipment inspection rating shall be recorded in the equipment technical file. 　　2. The Equipment Department and the Power Department conduct random inspections on the inspection and rating results of each workshop on a monthly basis. 　　3. For equipment defects identified during the equipment inspection and rating process, the workshop should promptly organize their elimination. Those that cannot be eliminated immediately should be included in the equipment maintenance plan. In cases where the defects are severe enough to affect safe production, emergency measures must be taken, and reports should be submitted promptly so that the relevant departments can handle the situation. 　　4. Equipment grading, which is divided into sound equipment and unsound equipment. 　　Standards for intact equipment: 1. All parts and components are complete, and their quality meets the requirements ； 　　(a) The parts and components of the main and auxiliary machines are complete and intact, and their quality meets the requirements ； 　　(b) The instruments, meters, signal interlocks, and various safety devices, as well as the automatic control devices, are complete, sensitive, and accurate ； 　　(c) The foundation and base are stable and reliable; the anchor bolts and all bolt connections are firm, neat, and meet the technical requirements ； 　　(d) Piping, fittings, valves, supports, etc. are installed properly, firmly and completely, with clear markings that meet the requirements. 　　(e) The anti-corrosion, insulation, and anti-freezing facilities are complete and effective, meeting the requirements. 　　2. The equipment is operating normally, with good performance, and achieves the output specified on the nameplate or the rated capacity ； 　　(a) The equipment is properly lubricated, the lubrication system functions smoothly, the oil quality meets the requirements, and the \"five fixed principles and three-stage filtration\" system is implemented” ； 　　(b) No abnormal phenomena such as vibration, looseness, or noise ； 　　(c) Operating parameters such as temperature, pressure, rotational speed, flow rate, and current of each section meet the requirements of the regulations ； 　　(d) The production capacity reaches the rated output on the nameplate or the verified capacity. 　　3. The technical documents are complete and accurate. 　　(a) The operation time of the equipment and its cumulative operation time are statistically tracked and recorded. 　　(b) Complete equipment records, maintenance, and inspection records are available ； 　　(c) There are drawings for the vulnerable spare parts of the equipment ； 　　(d) The equipment and the surrounding area are tidy and clean, with no leaks or spills.