Help with device management
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I am a new equipment technician at an oil refinery. Our plant was established with investment from a private owner and has only just started operating. At present, the company’s management focuses solely on the problems existing in the production process; there is no systematic approach to equipment management, and equipment does not receive much attention within the plant. It seems that there is no comprehensive and scientific mechanism for equipment management here. Currently, the approach taken is to repair equipment whenever it breaks down, but due to the limited skills of the maintenance staff, the quality of repairs is not very good. As a result, I am constantly dealing with various equipment issues every day, with no improvement in terms of equipment management. Therefore, I am seeking help from those who are more experienced: could you please provide me with some information and methods related to equipment management?
The refining processes chosen by local refineries are generally quite mature. It is precisely in equipment and material selection, as well as construction quality, that the device has its weaknesses. Due to the pursuit of low prices, the equipment and materials often only meet the quality standards during the performance evaluation period; thereafter, hidden defects in the equipment gradually become apparent. It is recommended to carefully study the technical specifications of the equipment as well as the performance guarantees provided by the manufacturer, to strengthen equipment maintenance, maintain an inventory of the equipment, and reduce equipment-related risks from a preventive perspective, thereby ensuring the safe, stable, long-term, efficient, and optimal operation of the installations.
I have never been in charge of equipment; my main role has been in production site management. However, many aspects of management are similar to each other. In my opinion, it can be approached from the following aspects: 1. First, it is necessary to carry out proper daily management tasks: such as the mandatory calibration of measuring instruments； (Safety valves, pressure vessels, pressure pipelines, other safety accessories) ； Effective management is necessary, as is proper verification and control; for example, the plans need to be detailed ； For example: Which devices require spare parts to be prepared? (Try to carry out related work without affecting production.) ； 2. Regular maintenance is necessary ； Pre-maintenance before addition ； Minimize downtime caused by equipment failures ； The main goal is to enhance the ability of relevant equipment and personnel to detect faults ； 3. Establish a fault information database: Analyze by type of fault; this enables determination of the frequency of equipment failures as well as the replacement frequency for certain spare parts, allowing for adjustments to the equipment maintenance plan ； 4. Strengthen employee training to improve their practical skills: This can be achieved by allowing employees to participate in as many maintenance tasks as possible ； Write the maintenance process as work standards to train employees ； Have employees use the damaged equipment or spare parts for repair training ； More operational skills competitions can also be organized to increase employees’ motivation to learn. 4.
Thank you, moderator – now we have a direction. In fact, most of the work on site is similar to what you mentioned, but it still feels like we’re far behind larger companies!
Well, that’s indeed the case; sometimes it feels like our factory isn’t actually engaged in oil refining but rather in training people