How much spare parts should be kept?
Thread Content
As the title suggests, what spare parts should be kept on hand, including both moving and stationary equipment? Do stationary equipment require spare parts for their flanges, and if so, how many should be stocked? How many spare parts are needed for an initial drive, and what about for two years of operation? How to formulate a plan for the procurement and storage of spare parts, so as to ensure that there are always parts available for replacement during maintenance, while avoiding unnecessary inventory that would tie up capital
There are already many related posts on the forum. Regarding daily spare parts during operation, it depends on your ability in preventive maintenance – that is, your capacity to predict when equipment failures will occur – as well as on the lead time for supplying these spare parts, and on the process importance of a particular piece of equipment. For regular spare parts, the supplier usually provides a list, which is then reviewed by the owner. It should be noted that there have been many suppliers who lower the price of the main equipment, but provide a large amount of spare parts for two years, while raising the price of those spare parts. Owners need to pay special attention during the review. For commissioning spare parts, the static equipment mainly refers to gaskets; generally, 200% of such spare parts are required, along with some valves. Moving equipment, mainly machine seals, filters, and special gaskets, etc. It also depends on how your contract with the supplier is drafted. In a project we carried out previously, the spare parts for trial operation were provided free of charge by the supplier. After the project is completed, they send back the unused spare parts to their own warehouse.
Based on whether it is a vulnerable part, in general, it’s better to have extra stock of vulnerable parts!
For items with a long procurement cycle, prepare an extra set of non-perishable parts!
What should be prepared, and in what quantity, for the initial startup test run of each pump? Is a two-year operation guarantee provided?
It is generally divided into spare parts for startup and those for a two-year period. For static equipment, the main items are gaskets and bolts, especially those made of special materials; gaskets require 100% coverage for the first year of operation plus 100% coverage for the next two years, while bolts require 10% coverage based on their specifications. These details are usually specified in the technical agreement. Mechanical seal (packing) for rotating equipment, oil cup, end cover gasket, bolts, pressure gauge, mouth ring. It should also be noted that there are some specialized tools.
How is it possible to ensure that spare parts are available for replacement at any time during maintenance, without simultaneously having excess inventory that ties up capital?:o:o
Cost, production time, and on-site requirements need to be taken into account; years of experience in the chemical industry are required to handle this skillfully.
To answer your question, one would need to be a senior project manager who has been involved in the entire project lifecycle, has more than 2 years of experience in ensuring stable operation, has handled equipment maintenance, and is also responsible for storage management. Only such a person can fully address your questions. Leveraging maintenance experience, identify which components of the equipment are prone to failure as well as those that require long-term procurement; during the negotiation of technical agreements, include spare parts for startup and those for a two-year period. Inventory controls are implemented in warehousing to minimize the risk of excess inventory, while ensuring a safe level of stock that guarantees the stable operation of the equipment. They are all large-scale systems engineering projects that cannot be accomplished in a day. It’s impossible to understand without about 5 years