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Detailed rules for the division of maintenance and repair tasks between the mechanical repair workshop (maintenance unit) and the production operation workshop

2016-10-08View Original

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As the title suggests, does anyone have the detailed guidelines regarding the division of responsibilities between maintenance and repair units and the maintenance teams in the production workshops? Currently, there are some tasks for which it’s difficult to decide whether they should be handled by the production and operation workshop or the mechanical repair workshop. Could you please send over some guidelines to help with this decision? Thank you!
Reply #22016-10-08
Equipment Use and Maintenance (I) The owner is responsible for the implementation of equipment maintenance. Each owner unit shall promptly carry out tasks such as preventing equipment from freezing and condensing, providing insulation and cooling, protecting against corrosion, applying lubrication, and sealing leaks ; Each owner entity must establish and improve procedures for equipment operation, use, maintenance, as well as post responsibility systems ; Equipment operators must pass the assessment before they can work with a valid certificate. (II) Strictly abide by the procedures for equipment operation, use, and maintenance. Make thorough preparations before starting, conduct repeated checks during operation, make proper adjustments while it is running, and know how to handle situations properly after shutdown. Strictly adhere to the operational specifications; operating under conditions of excessive temperature, pressure, speed, or load is not allowed. (III) Establish a equipment inspection management system for the unit; conduct thorough inspections of the equipment along predetermined routes on a regular basis, strengthen monitoring of the equipment’s condition, check for leaks at static seals, address any issues identified, ensure proper cleaning and lubrication of the equipment, and maintain the integrity of all parts, accessories, and tools. The inspection of special care equipment complies with the standards for such inspections. (IV) Formulate a equipment lubrication management system for the unit, establish a ledger for equipment lubrication management, ensure proper storage of lubricants within the unit, and strictly control the use of lubricants – it is necessary to use them in accordance with the established regulations. Strictly follow the requirements of \"three-stage filtration\" and \"five fixed principles\" for lubricants, maintain the integrity and cleanliness of the equipment’s lubrication filling holes and cups, and prevent impurities from reaching the friction surfaces and causing wear on the components. For lubrication points with automatic oiling, it is necessary to regularly check the filter of the lubrication system, oil level, oil pressure, oil temperature, and oil supply volume; any abnormalities detected should be addressed promptly. Regularly test and replace the lubricating oil in the equipment; if water accumulation or deterioration is detected in the oil in use, it should be replaced promptly. (5) Thoroughly carry out the “ten-step” tasks of equipment cleaning, lubrication, corrosion prevention, adjustment, and tightening; proactively eliminate defects such as dirt, rust, disarray, and leaks, and carefully fill out operation records. (VI) Equipment operators shall keep the equipment, pipelines, control panels, paint, and insulation in their respective positions in good condition, and ensure that the floors are clean ; Maintain the cleanliness of equipment and the surrounding area at all times, ensuring \"one level surface,\" \"two things clean,\" \"three things visible,\" \"four things absent,\" and \"five things not lacking.\"” ; Meets the equipment integrity standards. (7) Equipment handover: Equipment that exceeds standards or is faulty and in need of repair must meet one of the following two conditions in order to be handed over: 1. It is currently under repair or there are repair personnel on site ; 2. If the maintenance personnel do not carry out repairs upon arrival, they must obtain permission from the owner’s party. For the repair of critical equipment, consent from both the owner’s party and the production scheduling department is required, and signatures from the responsible persons of these parties are necessary; such approvals are valid for 24 hours. The maintenance personnel must also sign (indicating the time) as well. When using equipment that is still faulty, the maintenance personnel must sign every 8 hours; otherwise, shift handover is not permitted ; (8) The equipment shift handover records meet the standards for such records. (IX) Operators have the right to prevent personnel who are not assigned to that position from operating the equipment ; There is the right to refuse to operate equipment that requires maintenance or is faulty ; Orders that violate operating procedures can be refused to be carried out. (10) The individual trial operation of special care equipment is organized by the owner’s party, with the assistance and verification of technicians from the equipment energy-saving department and the maintenance workshop ; For routine equipment, single-unit trial operation is carried out with the cooperation of maintenance personnel who conduct inspections and confirmations. (11) For standby and long-term unused equipment, regular maintenance measures such as lubrication, turning the equipment, rust removal and anti-corrosion treatment, and nitrogen filling should be carried out to ensure that the equipment is in good condition and ready to be put into use at any time ; Hydroelectric or electric valves that have not been in use for a long time should be manually operated regularly to prevent rust and sticking. (12) Adhere to civilized construction and scientific maintenance; ensure that after maintenance the main structure is tidy, pipes are leak-free, and protective covers are clean, so that the work area is left clean with no leftover materials. Article 9 Equipment Maintenance (1) Requirements for equipment maintenance: 1. Before carrying out maintenance, a “Equipment Maintenance Work Order” must be issued in accordance with the specified requirements; maintenance can only proceed once the safety conditions for such work are met. 2. During maintenance, tools and spare parts should be neatly organized; after maintenance, the equipment must meet the standards for being in good condition. 3. Any malfunction in the equipment must be resolved immediately; the repair shop shall not refuse to carry out repairs under any pretext or reason. When difficulties arise during the repair process, the repair technicians must take proactive steps to resolve them. 4. In the case of equipment damaged due to abnormal conditions, the owner and the maintenance unit shall promptly report to the Equipment Energy Conservation Department, which will then organize an investigation into the incident to determine its cause. 5. After the repair is completed, a trial run under load is carried out; once it passes the inspection, the maintenance personnel fill in the results of the repair on the \"Equipment Maintenance Work Order\" and sign it. 6. Routine maintenance for equipment failures is carried out in accordance with the standard maintenance procedures. If the client wishes to add, modify, or remove equipment, it must be done following the equipment modification application process. 7. The maintenance workshop should regularly inspect the mechanical, electrical, and instrumentation equipment within its jurisdiction, and promptly identify and address any potential issues with such equipment. (II) Outsourcing of equipment maintenance 1. Scope of equipment for outsourced maintenance: Equipment maintenance that requires specialized technical skills or qualifications that the company does not possess, such as elevator maintenance. 2. Principles for outsourcing equipment maintenance: Equipment that falls within the scope of maintenance workshop operations shall have applications submitted by the maintenance workshop ; For equipment outside the scope of repair in the maintenance workshop, an application must be submitted by the owner entity. The relevant signing procedures must be carried out strictly in accordance with the \"Application Form for Outsourcing Equipment Maintenance\" (see Attachment 1); the application form is valid for one month from the date of submission. 3. Before entrusting external parties with the maintenance of the equipment, the owner’s workshop or the maintenance workshop shall preliminarily determine the maintenance budget and the contractor based on the nature of the repairs; the actual maintenance costs shall not exceed the approved budget. All costs related to maintenance projects must be approved by the company’s general manager. 4. The owner’s unit or maintenance workshop fills out the \"Application Form for Outsourcing Equipment Maintenance\", submits it to the relevant supervisors for approval. Once approved, it is forwarded to the Equipment Energy Conservation Department, which is responsible for drafting the technical agreement (maintenance contract) and conducting a qualification review of the maintenance contractor. 5. For equipment maintenance projects that have been approved, the bidding and evaluation processes shall be carried out in strict accordance with the company’s bidding management regulations. Those that fall under the category of price comparison are handled by the Equipment Energy Conservation Department, while those that require bidding are handled by the Corporate Management Department. 6. The owner’s entity or maintenance workshop is responsible for the overall supervision and control of the quality of equipment maintenance, as well as for the collection and archiving of maintenance-related documents ; If necessary, the maintenance workshop should cooperate with the owner’s party to carry out joint supervision. 7. The spare parts replaced as part of equipment maintenance are the responsibility of the entity that submitted the maintenance request, which shall also maintain records of these replaced and discarded spare parts ; If a problem occurs with the equipment under warranty, the equipment owner shall contact the maintenance provider to handle it. 8. After the equipment maintenance is completed, the Equipment Energy Conservation Department shall organize relevant technical personnel to inspect the quality of the repairs; for concealed works, inspections shall be carried out in stages along with taking photographs ; The acceptance documents are archived by the Equipment Energy Conservation Department. 9. The equipment owner is responsible for arranging the necessary permits and procedures such as ground work, hot work, and lifting during the maintenance process, as well as ensuring proper safety measures are in place. 10. Upon completion of the maintenance, the maintenance provider must issue a VAT invoice, and the owner must submit this invoice to the Equipment Energy Conservation Department within two working days after it is issued. 11. The maintenance request form is issued in two copies: one is kept on file by the Equipment Energy Conservation Department, and the other is kept on file by the property owner.
Reply #32016-10-08
Division of responsibilities for equipment accessories: Cooling system – All cooling water lines connected to the equipment via the inlet and outlet main pipes of the cooling system (excluding hoses) as well as the sealing and flushing lines fall under the responsibility of the maintenance workshop, while the rest are under the responsibility of the owner’s workshop. The cleaning of the cooling systems for the equipment’s oil and water stations is the responsibility of the owner’s workshop. Lubrication system: Daily cleaning of the pump bearing housing is the responsibility of the owner’s team (if disassembly is required for cleaning, the maintenance workshop will assist); during inspection (maintenance), it falls under the responsibility of the maintenance workshop ; Tank cleaning that is integrated with the equipment goes to the maintenance workshop, while tank cleaning for standalone tanks goes to the owner’s entity ; The filter inside the fuel tank is cleaned, inspected, and repaired by the maintenance workshop, which is also responsible for installing and removing the openings in the sealed fuel tank. Process system: The first flange seal connected to the moving equipment is the responsibility of the maintenance workshop, while the process pipelines above the first flange are under the responsibility of the owner. The electric (pneumatic) valve actuators are also the responsibility of the maintenance workshop. Detection instruments: All primary on-site instruments located on the equipment itself and its auxiliary facilities are the responsibility of the owner ; Fixed instruments such as flow meters and control valves on the main body of the moving equipment and its auxiliary facilities, as well as remote secondary meters, are the responsibility of the maintenance workshop ; Special valves: the valve body itself (including the cylinder), the control system (including the control cabinet) and the electrical system, as well as the backflush steam (air) pipelines; the first seal connected to the equipment. The filtering system is the responsibility of the maintenance workshop, while other owners are responsible for the rest ; The division of responsibilities for the cooling system, process system, and lubrication system remains as before. For compressors (including power generation turbine units) and main fans: the maintenance workshop is responsible for the hydraulic control system, dry gas seal system (except for safety valves, primary gauges, liquid removal tanks, and buffer tanks), commissioning systems, and electric heaters. The owner is responsible for safety valves, liquid removal tanks, and buffer tanks (which are disassembled and assembled by the maintenance workshop during equipment repairs). As for soot blowers, the main body of the soot blower and the power air system fall under the responsibility of the owner, including the regular cleaning of filters as well as the maintenance of check valves and static seals. Motors, solenoid valves, and control cabinets are maintained by the maintenance workshop. Hydraulic coking removal section: Maintenance of the winch steel cables, lubrication of the winch, replacement of gaskets on the top and bottom covers, as well as maintenance and lubrication of the control system are the responsibility of the owner’s party. The repair and replacement of the coking cutter, water motor, winch, brakes, electrical equipment, instrument switches, and control systems, along with tightening the connections between the water motor and high-pressure pipelines, are the responsibility of the maintenance workshop.

Crane section: Lubrication of the crane’s reducer, maintenance of the crane’s steel cables and related spare parts, as well as outsourced repairs are the responsibility of the owner’s party. The maintenance of the crane’s reducer, transformers, and electrical systems, along with the repair and replacement of pulleys, wheels, gear couplings, pins, and tie rods, as well as any other tasks not covered by the owner’s party, are the responsibility of the maintenance workshop. Routine maintenance of the crane is also the responsibility of the maintenance workshop.

Elevator section: Maintenance of the equipment inside the elevator machine room, as well as maintenance parts and outsourced repairs, are all the responsibility of the maintenance workshop ; The daily maintenance of elevators is the responsibility of the property owner. Division of responsibilities for flue dampers: the mechanical components (including manual mechanisms) and pneumatic actuators (including positioners, etc.) are under the responsibility of the maintenance workshop ; Filler replacement is the responsibility of the owner’s party ; The inspection of the sealing baffles is organized by the owner’s party, with the maintenance workshop participating in the joint inspection ; Responsibilities for air coolers: Daily lubrication and maintenance, as well as the protection covers and louvers, are the responsibility of the owner’s party; the belts are under the responsibility of the maintenance workshop. Responsibilities for screw air compressors: The maintenance of separators and related components, coolers, and oil pipelines is the responsibility of the owner’s party ; Health and hygiene are the responsibility of the owner ; The three filters and instrument components are the responsibility of the maintenance workshop ; The door panels and everything beyond that are the responsibility of the owner.

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