General Technical Guidelines for Equipment Inspection

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General Technical Guidelines for Equipment Inspection General Technical Guidelines for Equipment Inspection 1. Purpose Equipment inspection aims to achieve multiple core objectives through systematic and standardized inspection procedures. The first is fault prevention, which involves using regular inspections to identify potential issues in the operation of equipment in a timely manner, thereby preventing the escalation of faults that could lead to equipment damage or production disruptions ； The second aspect is life cycle management: by continuously monitoring the key parameters of equipment, it is possible to accurately understand its operating conditions, thereby formulating scientific maintenance and replacement plans to extend the equipment’s service life ； The third is cost optimization, which aims to reduce economic losses resulting from unplanned downtime and sudden repairs, thereby lowering overall maintenance costs ； The fourth aspect is safety assurance, which ensures that the operation of the equipment complies with relevant safety standards and regulations, thereby preventing safety accidents at the source and safeguarding the safety of personnel and production processes. 2. Generally, equipment inspection is a key component of the equipment maintenance system. Its core involves making preliminary judgments using the \"five senses\" (sight, hearing, touch, smell, taste), and combining this with measurements taken by specialized instruments and data analysis to monitor the condition of critical parts of the equipment on a regular basis. By analyzing monitoring data to identify potential issues with the equipment in a timely manner and taking appropriate actions, it is possible to ensure that the equipment’s operating conditions are controllable, predictable, and manageable – which is an important means of maintaining its stable operation. 3. Differences between routine inspections and patrol inspections
Dimensional aspects: Routine inspections focus on accurately monitoring the condition of key parts and using quantitative data to identify potential problems, while patrol inspections involve a comprehensive examination of the overall operation of the equipment to detect any obvious abnormalities.
Inspection methods: Routine inspections rely on quantitative testing and professional instruments, whereas patrol inspections depend on qualitative observation, utilizing the “five senses”.
Objects of attention: For routine inspections, it is the key parts and core parameters of the equipment; for patrol inspections, it is the overall appearance of the equipment and its operating environment.
Data requirements: Routine inspections require the recording of specific quantitative data to enable trend analysis, while patrol inspections do not require precise quantification.
Personnel requirements: Those conducting routine inspections need to have expertise in equipment and the ability to operate instruments, while those performing patrol inspections only need to understand the basic operating characteristics of the equipment.
4. Scope of application: This guide applies to the routine inspection of various types of equipment in the industrial sector, including: ● Mechanical equipment such as centrifugal pumps, compressors, motors, etc., with an emphasis on parameters like vibration, temperature, and lubrication conditions ； ● Static equipment: such as pressure vessels, storage tanks, heat exchangers, etc.; special attention should be paid to aspects like wall thickness, corrosion, and leaks ； ● Industrial pipelines: Especially those operating under high temperature and pressure and transporting corrosive media, require attention to aspects such as weld quality, stress distribution, and corrosion rate ； ● Other special equipment: includes core equipment in continuous production processes, safety interlock devices, as well as equipment that is high-risk and sensitive to precision. 5. Basic methods and procedures for conducting inspections Basic methods ● Planning: Determine the inspection routes, locations, frequency, standards, and testing methods to create an actionable inspection plan ； ● Prepare tools: Equip appropriate professional instruments and tools according to the inspection plan, such as vibration meters, thermal imaging cameras, etc ； ● Conduct inspections: Carry out quantitative tests on key parts of the equipment as planned to ensure accurate and comprehensive data ； ● Data analysis: Process and analyze the collected test data, and use historical data to assess the technical condition of the equipment ； ● Formulate measures: Based on the analysis results, develop targeted repair, maintenance, or adjustment plans ； ● Record feedback: Provide feedback on the inspection results, analysis conclusions, and corrective actions to the relevant departments, while keeping complete records. Implementation process: Develop an inspection plan → Prepare tools and equipment → Conduct inspections on-site → Collect and analyze data → Formulate corrective actions → Document and provide feedback → Track and verify the effectiveness. 6. General technical standards for equipment inspection – Moving equipment ● Vibration speed: Not more than 4.5 mm/s (in accordance with ISO standards) ； ● Bearing temperature: not exceeding 75°C, or ambient temperature + 40°C (whichever is lower) ； ● Lubrication condition: The cleanliness of the oil meets the equipment requirements, with a water content of ≤0.1% and no impurities present. Static equipment ● Wall thickness corrosion: annual corrosion rate ≤ 0.12 mm (according to ASME standards) ； ● Leak detection: VOC concentration ≤ 50 ppm (meets environmental standards) ； ● Lining layer integrity: Porosity ≤ 2% (in accordance with HG/T20678 standard). Industrial pipes ● Corrosion rate: ≤0.3mm/year ； ● Weld quality: free from defects such as cracks, inclusions, and lack of fusion (in compliance with ASME B31.3 standards) ； ● Stress distribution: Should not exceed 60% of the material’s yield strength, to prevent failure due to stress concentration. 7. Common inspection tools ● Portable vibration meter: Accurately measures vibration parameters of equipment, used to diagnose mechanical faults such as those in bearings and rotors ； ● Infrared thermal imager: Detects the surface temperature distribution of equipment, quickly identifies overheated areas, and helps prevent electrical and mechanical overheating failures ； ● Ultrasonic thickness gauge: Measures the wall thickness of metal equipment, assesses the degree of corrosion, and determines the remaining service life ； ● Endoscope: A device used to examine areas inside equipment that are difficult to reach, such as the inner walls of pipes and the internal structure of containers ； ● Intelligent inspection terminal: It integrates data collection, analysis, and uploading functions to enable real-time and intelligent management of inspection data. 8. Contents of inspection records and management records ● Equipment information: includes basic information such as equipment number, name, location, model, and specifications ； ● Testing data: Actual measurement values of key parameters such as vibration levels, temperature, and wall thickness ； ● Environmental information: ambient temperature, humidity, and equipment operation conditions during inspections ； ● Abnormalities: Record any observed abnormalities and preliminary judgments ； ● Remedial measures: Repair, maintenance, or adjustment plans formulated for abnormal conditions ； ● Inspection personnel: Record the name of the inspection personnel, the inspection time, and information on the reviewer. Record Management ● Standardized Records: Uniform inspection record forms are used to ensure complete content and standardized formatting ； ● Data archiving: Archive inspection records by equipment type to create historical records of equipment operation ； ● Trend analysis: Regularly conduct trend analysis on historical data to predict changes in equipment status ； ● Traceability: Ensure that records are traceable to provide a basis for fault analysis and responsibility determination ； ● Confidentiality and security: Records related to the core technical parameters of the equipment must be properly secured to prevent information leakage. 9. Precautions ● Inspectors must receive professional training and be familiar with the equipment’s structure, principles, and inspection standards ； ● During the inspection process, it is necessary to strictly follow safety procedures and use appropriate personal protective equipment ； ● When a major hazard is detected, it must be reported immediately and emergency measures taken to prevent the accident from escalating ； ● The inspection plan needs to be adjusted dynamically based on the equipment’s operating conditions and maintenance experience to ensure its Rationality and effectiveness. This guide serves as a general technical specification for equipment inspection. In practical applications, it needs to be refined and supplemented based on the specific type of equipment, operating environment, and industry standards, in order to ensure that equipment inspection is carried out in a scientific, standardized, and efficient manner, thus providing a solid foundation for the stable operation of the equipment.