Regarding the routine equipment maintenance in petrochemical enterprises, how can the approach be shifted from \"repair\" to \"maintenance\"? Preventing the situation where changing one thing solves all problems
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This post was last edited by 328104062 on 2016-4-26 07:26. As the title suggests, current equipment maintenance focuses primarily on repairs – that is, through instrument monitoring and routine inspections. By the time a problem is detected, in most cases the equipment is already damaged and requires disassembly for repair, including replacing parts, wear items, accessories, bearings, shaft sleeves, rotors, gearboxes, impellers, rings, air valves, pistons, piston rings, motors, pumps, and so on. In short, when a problem arises, it usually involves opening up the pipeline equipment for a thorough replacement. For static equipment, the actions taken include replacement or plugging – replacing heat exchanger tubes, air-cooling fin tubes, plugging tubes in the tube bundles, replacing bolts, flanges, gaskets, valves, expansion joints, burners, igniters, filters, and more. In short: Replacing something can cure many problems, but it only solves the issues temporarily; further replacements are needed, and life goes on in a cycle of replacements. From reporting the issue, going through the ERP system, to procurement, bidding, drafting agreements and contracts, manufacturing, production, handing over the equipment for maintenance, and on-site installation, many departments are involved in this process. This increases the difficulty of managing daily spare parts and leads to more waste. Handling such issues requires shutting down the equipment in order to replace components, which is time-consuming, labor-intensive, costly, and also causes pollution. Of course, this is related to the overall atmosphere of haste, as well as to equipment manufacturing, initial design, operational procedures, and routine maintenance. 1. How are the moving equipment items maintained by everyone? Apart from lubricant filtration, lubrication of moving equipment, and interlock protection testing, what experience do you have in visual inspection, tactile examination, auscultation, and equipment testing? How can we prevent the situation from reaching a point where it’s too late to fix and an replacement becomes necessary? 2. Regarding static equipment, how to maintain it in order to reduce the frequency of repairs? Manager Discussion Group
Equipment maintenance mainly focuses on repairs
The one who did the repair must take responsibility; the new manufacturer should take responsibility!
I agree; most logistics, maintenance, and repair tasks are outsourced, with few employees and low technical skills, and sometimes even replacements aren’t available.
These days, there are many cases where repairs can’t be completed and maintenance isn’t carried out, so the amount of work keeps increasing and the costs rise as well
Let’s communicate more! I’m in the craftsmanship section; feel free to come and chat there.
Abroad, insurance is purchased directly by the manufacturers for the measuring equipment and similar items; in the event of losses caused by such equipment, it is the manufacturers and insurance companies that cover the costs! The advantage of doing this is that it forces manufacturers to improve the quality of their products and the standards of construction, ensuring that the instruments and equipment put into use can function properly. However, I have also seen manufacturers establish specific regulations regarding the parameters to be used with the equipment’s instruments; if those parameters are not followed, they are exempt from any liability for compensation! The most important thing is still the matter of mindset; spending a little money to ensure peace and stability in daily life – how many people can actually do that! There are countless requests regarding the horses – endless things that need to be done with them. . . . . . . :L
At present, equipment maintenance is basically a piecemeal approach, fixing problems as they arise!
The last edit to this post was made by ylb913 on 2016-4-27 at 06:55. Speaking of moving equipment, we mainly rely on inspections to check the level of lubricating oil, bearing temperatures, the vibration of pumps, whether there are any abnormal noises, and the outlet pressure (which is generally used to determine whether it’s necessary to clean the inlet filter). Our inspections include inspections of the workshop, professional inspections by maintenance staff, and professional inspections by electricians. Even so, it’s impossible to identify all the problems; there’s nothing that can be done about it – either due to a lack of experience or because people delay fixing them. Additionally, there are cases where sudden damage to pumps occurs due to production fluctuations. Over the past few years, there have been instances of damaged pumps: once it was due to an incorrect oil level indicated by the oil level gauge, another time the oil level was too low. In two cases, production fluctuations caused the shielded pump to experience vacuum conditions that led to wear and damage of the isolation sleeve. There were also cases where failure to clean the filter screen at the inlet of the shielded pump resulted in vacuum-related damage. Once, the seal for liquefied gas suddenly failed, and in another instance, a bolt inside one of the pumps came loose; the pump was stopped promptly after smoke was detected from the oil reservoir. ——To address these issues, a practical solution is to equip all shielded pumps with protection that enables them to shut down automatically when low current is detected; for the rest, avoidance can only be achieved by improving management, increasing the frequency of inspections by workshop supervisors and managers, and changing the approach to process adjustments.