Weekly Topic - 20090303 - On the Management of Unit Equipment

1) Equipment inspection: In the past, inspectors would bring instruments and equipment to the site to inspect the equipment, and then enter the inspection results into a computer for analysis and recording. . PDA technology is mainly used nowadays. . Enter the checkpoints into the PDA in advance; during inspection, simply take the PDA to the site, save the inspection results in it, and then connect the PDA to a computer to analyze the results. 2) Maintenance equipment: Establish standards for preventive maintenance and set reminders for due maintenance tasks. Record data related to maintenance, including start-up and shutdown times, maintenance duration, fault records, maintenance logs, spare parts replacement records, information on maintenance personnel, and inspection records. Summary of maintenance activities, including downtime due to failures, failure rate, mean time between failures, equipment utilization rate, etc. Last edited by qq375170364 on 2009-3-16 14:37.]

I. Based on the work requirements of this shift, specific work standards should be established to refine and quantify those requirements. 1. Work standards for the shift: A. Strictly follow the operating procedures to ensure that the pumps operate without any abnormal noises; the flow rate and pressure at the pump outlet should remain stable, the current should not exceed the rated value, the temperature of the motor’s rolling bearings should be ≤70°C, and the temperature of the sliding bearings should not exceed 65°C. B. Strictly implement the shift handover system and routine inspection system; arrive at the post 30 minutes in advance for preliminary checks. After taking over the shift, conduct regular routine inspections along the designated routes, using methods such as listening, touching, observing, smelling, and comparing to thoroughly check parameters such as pump pressure, flow rate, temperature, current, vibration, leaks, cooling conditions, lubrication status, and noise levels. Any issues detected must be addressed and reported promptly. 2. Attendance standards for pumps: A. Keep accurate records of the operating time of pumps. B. Document in detail the causes of pump failures. C. Carefully record information regarding pump maintenance and replacement of components. 3. Pump cleaning standards: A. Thoroughly clean the pump body, the oil level gauge at the bottom of the bearing housing, the pump base, and the drainage tray. B. Thoroughly wipe the motor body, heat sinks, front cover, and base. C. Wipe away the oil stains around the pump’s cement foundation and base. D. Thoroughly clean all attached pipelines, valves, handwheels, and pressure gauges. 4. Standards for shift handover and monthly record keeping: A. Be aware of the operating status and standby condition of the equipment at the time of shift handover. B. The recorded data on pump pressure, flow rate, temperature, current, and contacts are accurate. II. The standards for execution must be meticulous; tasks such as inspecting equipment, making adjustments, recording details, and confirming handover with signatures need to be carried out carefully and accurately. III. Operating procedures for three-type pumps: namely, three diligences, three attentions, three no-exceptions principles, and three perseverance requirements. Three diligences: frequent inspections, regular maintenance, and consistent communication. Three attentions: paying close attention to temperature, listening carefully to sounds, and observing operations meticulously. Three perseverance requirements: remaining vigilant in rainy weather, hot conditions, and after pump replacement. Three no-exceptions principles: not proceeding until doubts are resolved, not stopping until problems are completely solved, and not ending work until the site is brought back to standard specifications. III. Strict requirements and rigorous evaluations. IV. Enhancing learning and training to continuously improve staff quality; on one hand, improving technical skills by encouraging pump operators to delve deeply into technical knowledge and promoting professional development at their posts, and on the other hand, enhancing their ideological quality through education that fosters a sense of ownership and strengthens accountability.

My equipment management is primarily based on the \"Daily Assessment Guidelines\": 1. Equipment cleanliness. The main body of the equipment, associated pipelines, various valves, and the outer surfaces of visible components should be free from oil stains, deposits, and dust. 2. Ensure that the pump operates without leaks; in case of any problems, contact the maintenance team promptly and supervise their timely resolution. 3. Adhere to the three-level management system for lubricants. There is no obvious leakage of lubricant from the equipment; the lubricant reservoirs and sight glasses are undamaged, and the liquid level is at 1/2 to 2/3 of the height indicated on the sight glasses or reservoirs. The pump is cooled properly, and the lubrication oil pipelines are free of blockages and leaks. Containers for lubricant storage, filtration, and refilling should be placed in an orderly manner; filler bottles and tanks must not be kept near the equipment. 4. Do not modify the operating equipment arbitrarily; in case of production needs, contact the technical management personnel promptly. 5. Operating the equipment in violation of the operating procedures is prohibited to avoid equipment damage and accidents. 6. In case of abnormal operation of the equipment, contact the superior promptly. Make accurate judgments and take decisive emergency measures to ensure safe production. 7. Actively cooperate with inspection and maintenance tasks, carrying out work thoroughly and ensuring it is implemented effectively. And thorough records must be kept to ensure clarity of facts. 8. Strictly implement the shift handover system, and adhere to the principles of “seven handovers” and “six non-acceptances”. 9. Strictly implement various equipment management systems of the branch factory and higher-level authorities. 10. All markings in the pump room are clear and complete. Such as: process tag numbers, nameplates, etc. 11. No garbage shall be piled up in the pump room; doors and windows as well as glass must be in good condition, ensuring the area is clean and free of dust on all walls. The ground should be level, with no water or oil accumulation. The gutters are clean, and the drains are not clogged. 12. The equipment’s turning marks should be clear, and the maintenance inspection records as well as the pump operation records must correspond to the actual conditions. 13. The process pipelines within the plant area should be arranged reasonably and installed neatly; leaks, spills, drips, or seepages are strictly prohibited, as is **ing, suspending, or hanging them. 14. The equipment, pipes, valves, level gauges, etc. are well insulated and free of defects. 15. Operators and maintenance personnel must conduct thorough inspections to identify problems in a timely manner, and any issues detected should be addressed promptly.

It’s my first time receiving an award; thanks to Haichuan!