How should a good maintenance and inspection system be established for Nippon Seiki piston pumps?

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If we want to establish a sound maintenance and inspection system for the original imported Nishiyama piston pumps, how should we implement this plan? To establish an effective maintenance and inspection system for Niigata piston pumps, the following steps are necessary: The pump is the most valuable component among all the elements of a hydraulic system; without online monitoring and inspection of the pump, it is difficult to predict when and what kind of maintenance is required for it. Without recording and analyzing the data of the monitored pumps, it is almost impossible to make an accurate assessment of whether the pumps in use can operate for the specified service life. If a pump shows detectable signs of degradation, and there is enough time before a failure occurs to observe the extent of that degradation, then it is reasonable to conduct regular online inspections of the pump. Strengthening maintenance and support is necessary to increase the service life (utilization rate) of the pump. There is a well-known saying in foreign equipment management: \"Maintenance is fault management carried out to enable the use of equipment.\" Therefore, it is necessary to establish a regular inspection and maintenance system based on condition monitoring, to conduct regular daily checks on pumps in use, keep records, and create charts showing values such as pressure, temperature, noise level, and current. This enables the identification of the pump’s condition and the analysis of its performance trends, allowing for maintenance actions to be taken as appropriate. In China, foreign contractors working on projects such as the Xiaolangdi and Three Gorges Dam projects insist on flushing the hydraulic pumps and motors they use every 1,500 to 2,000 hours; when their service life reaches 8,000 hours, the bearings of the pumps and motors are replaced and adjustments are made. This is something that units using imported hydraulic equipment can take as a reference. 2. Establish preventive maintenance. The basic methods of maintenance include inspection, upkeep, replacement, and calibration. Preventive maintenance of pumps involves performing regular online flushing of the pumps; flushing should be carried out every 1,500 hours of operation. This is one of the most effective methods for extending the lifespan of pumps. 3. The common method of maintenance is to carry out repairs at scheduled times. As a typical example, the soft lifetime of a pump’s bearings is 10,000 hours; however, this soft lifetime is merely a reference value. It is possible to extend this time, but it is necessary to take into account that such an extension increases the risk of damage to the pump. The hydraulic systems in the metallurgical industry are highly complex, especially when it comes to the impact of contamination. Accurate assessment requires extensive experience. However, we can make use of computerized bearing analyzers at appropriate times, based on the pump’s service life, to examine and analyze the three pairs of friction pairs and rolling bearings that are in operation. This allows for proper evaluation and precise analysis of the working conditions of these friction pairs and bearings. By identifying trends in wear and damage, we can estimate the remaining lifespan of the pumps and bearings, and plan replacements in a timely manner to avoid economic losses resulting from unexpected failures. 4. The failure probability of hydraulic pumps increases as the pump’s service life progresses; it is necessary to keep records from the start of the pump’s operation, documenting its hard lifetime, the interval between each flushing, bearing replacements, results of maintenance tests, and various other records related to the maintenance process. 5. Appoint specialized equipment supervisors to oversee the entire process of equipment operation, maintenance, and repair, thereby making equipment maintenance management more scientific and digitalized and achieving \"zero failures\" in equipment maintenance.