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I. Maintenance of Equipment
We can take care of pure water equipment by wiping, cleaning, lubrication, adjustment and other general methods to maintain and protect the performance and technical status of the equipment, which is called equipment maintenance.
There are four main requirements for equipment maintenance:
(1) Cleaning equipment is clean inside and outside. There is no oil stain in sliding surface, screw, rack, gear, wheel box and oil hole of medical pure water equipment. There is no oil leakage or air leakage in all parts. Chips, debris and dirt around the equipment should be cleaned up.
(2) The neat tools, accessories and workpieces (products) should be placed neatly, and the pipelines and lines should be organized.
(3) Good lubrication, timely refueling or oil exchange, continuous oil, no dry rubbing phenomenon of water equipment in chemical industry, normal oil pressure, bright oil marking, smooth oil path, oil quality meet the requirements, oil gun, oil cup, felt clean;
(4) Safely abide by safety operation rules, do not overload the use of equipment, equipment safety protection device food water equipment is complete and reliable, timely elimination of unsafe factors.
Maintenance of equipment generally includes daily maintenance, regular maintenance, regular inspection and precision inspection. Lubrication and cooling system maintenance of equipment is also an important part of equipment maintenance.
Daily maintenance of equipment is the basic work of equipment maintenance. It must be institutionalized and standardized. Regular maintenance of equipment should be formulated work quota and material consumption quota, and assessed according to the quota. Regular maintenance of equipment should be included in the assessment content of the workshop contractual responsibility system. Periodic inspection of equipment is a planned preventive inspection. Besides human senses, the means of inspection should also have certain inspection tools and instruments, which are carried out according to the periodic inspection card. Periodic inspection is also called periodic inspection. Precision inspection should also be carried out for mechanical equipment to determine the actual accuracy of the equipment.
Equipment maintenance shall be carried out in accordance with maintenance procedures. Equipment maintenance rules are the requirements and regulations for the daily maintenance of equipment. Persisting in the implementation of equipment maintenance rules can prolong the service life of equipment and ensure safe and comfortable working environment.
Its main contents should include:
(1) The equipment should be neat, clean, firm, lubricated, anticorrosive, safe and so on, including its working contents, working methods, tools and materials used, standards met and matters needing attention;
(2) The parts, methods and standards of routine inspection, maintenance and regular inspection;
(3) Examining and evaluating the contents and methods of maintenance equipment of operators.
II. Three-level Maintenance System of Equipment
The three-level maintenance system is a kind of maintenance and repair system which has been gradually perfected and developed since the mid-1960s in China. It reflects the transformation of the focus of equipment maintenance management from repair to maintenance, and reflects the progress of equipment maintenance and management in China. Preventive maintenance management policy is more clear.
The three-level maintenance system includes the daily maintenance of equipment, the first-level maintenance and the second-level maintenance. The three-level maintenance system is a mandatory maintenance system, in which the operator is the main factor and the maintenance is equal. The three-level maintenance system is an effective way to rely on the masses, give full play to their enthusiasm, implement group management and group repair, combine special groups and do well in equipment maintenance.
(1) Daily maintenance of equipment
Daily and weekly maintenance of equipment, also known as daily and weekly maintenance.
1. days warranty
"Daily routine insurance" is mainly carried out by water equipment operators on duty, earnestly achieving the first four things in class, the fifth attention in class and the fourth thing after class.
(1) Digest the drawing data and check the handover record in the first four events of the class. Wipe equipment, lubricate and refuel according to regulations. Check whether the position of the handle and the manual operation are correct and flexible, and whether the safety device is reliable. Low-speed operation check whether the transmission is normal, lubrication, cooling is smooth.
(2) Class 5 should pay attention to the sound of operation, the temperature, pressure, liquid level, electrical, hydraulic and pneumatic systems of equipment, instrument signals, and whether safety insurance is normal.
(3) Turn off the switch four things after class and put all the handles in zero position. Clean up iron scraps and dirt, wipe off oil stains on the guide surface and sliding surface of the equipment, and refuel. Clean up the work site and tidy up accessories and tools. Fill in the handover record and the turntable record, and go through the handover formalities.
2. "Weekly Insurance"
Weekly maintenance is carried out by equipment operators every weekend. The maintenance time is 2 hours for general equipment and 4 hours for fine, large and sparse equipment.
(1) Appearance cleaning equipment guide rail, transmission parts and exposed parts, cleaning the work site. To achieve internal and external cleanliness, no dead angle, no rust, clean surrounding environment.
(2) Manipulate the transmission to check the technical condition of each part, fasten the loose part and adjust the fit clearance. Check interlocking and safety devices. To achieve normal transmission sound, safe and reliable.
(3) Hydraulic lubrication cleaning oil line, dustproof felt, oil filter, oil tank add oil or change oil. Check the hydraulic system to achieve oil cleanliness, smooth oil path, no leakage.
(4) Electrical system wipes the surface of motor and snakeskin pipe, inspects insulation and grounding, and achieves integrity, cleanliness and reliability.
(2) First-level maintenance and first-level maintenance is based on operators, with the assistance of maintenance workers, to disassemble and inspect parts of equipment according to plan, to clean prescribed parts, to dredge oil pipelines and pipelines, to replace or clean oil lines, felt and oil filters, to adjust the coordination clearance of various parts of equipment, and to tighten all parts of equipment. The first-level maintenance time is 4-8 hours. After the first-level maintenance is completed, records should be made and the defects that have not been cleared should be noted. The workshop mechanic organizes acceptance. The scope of the first guarantee shall be all the equipment in use by enterprises, and the key equipment shall be strictly enforced. The main purpose of the First Guarantee is to reduce equipment wear and tear, eliminate hidden dangers, prolong the service life of equipment, and provide guarantee for the completion of production tasks until the next "First Guarantee" period in terms of equipment.
(3) Secondary Maintenance
Secondary maintenance is mainly done by maintenance workers, with the participation of operators. Secondary maintenance is included in the equipment maintenance plan, which includes partial disassembly, inspection and repair of equipment, replacement or repair of worn parts, cleaning, oil exchange, inspection and repair of electrical parts, so that the technical condition of equipment can fully meet the requirements of the required equipment integrity standards. Secondary maintenance takes about 7 days.
After the completion of "two guarantees", the maintenance workers shall fill in the maintenance records in detail, which shall be accepted by the workshop mechanics and operators, and the acceptance form shall be submitted to the equipment power section for filing. The main purpose of the second guarantee is to make the equipment meet the intact standard, improve and consolidate the intact rate of the equipment, and prolong the overhaul cycle.
In order to implement the "three-level maintenance system", it is necessary for the operators to achieve the "three good", "four meetings" and "four requirements" for the equipment and abide by the "five disciplines". The "three-level maintenance system" highlights the status of maintenance in equipment management and planned maintenance work, makes the requirements of "three good" and "four meetings" more specific, and improves the knowledge and skills of operators in maintaining equipment. The three-level maintenance system breaks through the relevant provisions of the former Soviet Union's planned pre-repair system, improves some shortcomings of the planned pre-repair system and is more practical. In the implementation of the three-level maintenance system, we have also learned some methods of military weapons management, and emphasized group management and group repair. The three-level maintenance system has achieved good results and experience in Chinese enterprises. Due to the implementation of the three-level maintenance system, the intact rate of enterprise equipment has been effectively improved, the accident rate of equipment has been reduced, the period of equipment overhaul has been prolonged, the cost of equipment overhaul has been reduced, and good technical and economic results have been achieved.
3. Requirements for the Use and Maintenance of Precision, Large and Sparse Equipment
(1) Four definite tasks
(1) designated personnel. According to the system of appointment, the operators of precise, large and sparse equipment should choose those with strong sense of responsibility, high technical level and rich practical experience in this type of work, and keep relative stability for as long as possible.
(2) Certified maintenance personnel. Enterprises with more refined, large and sparse equipment may organize professional maintenance or repair teams of refined, large and sparse equipment in accordance with the conditions of the enterprise, which are specially responsible for the inspection, accuracy adjustment, maintenance and repair of refined, large and sparse equipment.
(3) Establish operating procedures. Precision, large and sparse equipment should be separated to compile operating rules one by one, display them and strictly implement them.
(4) Fixed spare parts. According to the role of various fine, large and rare equipment in the production of enterprises and the source of spare parts, the reserve quota is determined, and priority is given to the solution.
(2) Requirements for the Use and Maintenance of Precision Equipment
(1) Equipment must be installed in strict accordance with the specifications;
(2) Enterprises that have special requirements for the environment (constant temperature, constant humidity, shock-proof and dust-proof) should take corresponding measures to ensure the accuracy and performance of the equipment:
(3) In the daily maintenance of the equipment, it is forbidden to disassemble the parts and components, stop immediately when abnormal conditions are found, and run with illness.
(4) Strictly implement the cutting specifications stipulated in the equipment specifications, and only allow the finishing of parts for direct use. Processing allowance should be as small as possible. When processing castings, the surface of the blank should be sandblasted or painted beforehand.
(5) Non-working hours should be covered with protective cover, long breaks, regular wiping, lubrication and empty operation;
(6) Appendices and special tools shall be shelved on special shelves, kept clean, prevented from grinding and may not be lent out.
IV. Requirements for the Use and Maintenance of Power Equipment
Power equipment is the key equipment of enterprises. There are high temperature, high pressure, flammable, toxic and other risk factors in operation, which are the key parts to ensure safe production. In order to supply the necessary kinetic energy for production safely, continuously and steadily, special requirements should be laid on the use and maintenance of power equipment.
(1) Operating personnel must be trained beforehand and passed the examination;
(2) Complete technical data, safety operation technical regulations and operation records must be provided;
(3) Operating personnel shall conduct itinerant inspection at any time during their duty period, and shall not leave their posts at will;
(4) When abnormal conditions occur in the course of operation, the staff on duty should deal with them urgently according to the operating rules and report to their superiors in time.
(5) Ensure the sensitivity and accuracy of all kinds of indicators and safety devices, and check them regularly. The spare equipment is complete and reliable.
(6) Power equipment shall not operate with illness, and any malfunction must be eliminated in time.
(7) Regular preventive tests and seasonal examinations;
(8) Safety education is often given to the staff on duty, and the safety and security system is strictly enforced.
V. Regional Maintenance of Equipment
Regional maintenance of equipment is also known as maintenance work contract mechanism. Maintenance workers are responsible for the maintenance of equipment in a certain production area. They are responsible for daily maintenance, itinerant inspection, regular maintenance, planned repair and troubleshooting with production operators. They are also responsible for completing the assessment indicators of equipment intact rate and failure outage rate in the management area. Regional maintenance responsibility system is a good form of strengthening equipment maintenance to serve production, mobilizing the enthusiasm of maintenance workers and making them take the initiative to care about equipment maintenance and maintenance.
The main organizational form of equipment professional maintenance is regional maintenance group. The Regional Maintenance Group is fully responsible for the maintenance and emergency repair of equipment in the production area. Its tasks are:
(1) To be responsible for the maintenance and repair of equipment in the region, to ensure the completion of equipment intact rate, failure outage rate and other indicators;
(2) Carefully implement the system of regular spot inspection and regional tour inspection of equipment, guide and urge operators to do well in routine maintenance and regular maintenance;
(3) Participate in equipment condition survey, accuracy check, adjustment, leak control, fault analysis and condition monitoring under the guidance of workshop mechanics.
The advantages of pure water equipment maintenance organization form are: high mobility when emergency repair is completed, which can shorten the break time of equipment repair, and the duty fitter can complete various preventive operations and participate in planned repair when no one calls.
The division of equipment maintenance area should take into account such factors as distribution of production equipment, equipment condition, technical complexity, production needs and technical level of repair fitters. Workshop equipment can be divided into several areas according to the above factors, and regional maintenance groups can also be divided according to the type of equipment. The equipment of the production line should be divided into maintenance areas according to the line. The Regional Maintenance Team shall prepare periodic inspection and precision inspection plans, and stipulate the regular inspection time for the equipment in each shift. In order to ensure that these jobs do not affect production, the planned inspection of equipment should be arranged on non-working days of the plant, while the routine inspection of each shift should be arranged on the noon break of the production workers.
VI. Measures to Improve Equipment Maintenance Level
In order to improve the level of equipment maintenance, the maintenance work should basically be standardized, technological and institutionalized.
Standardization is to make the maintenance content unified, which parts should be cleaned, which parts should be adjusted and which devices should be inspected, which should be considered and stipulated in accordance with the objective law of each enterprise.
Processing is to formulate various maintenance process rules according to different equipment and maintain them according to the rules. Institutionalization is to stipulate different maintenance cycles and time according to different working conditions of different equipment, and strictly implement them. For regular maintenance work, the man-hour quota and material consumption quota should be formulated and assessed according to the quota. Equipment maintenance should be assessed in conjunction with the economic contracting responsibility system of enterprises. At the same time, enterprises should also mobilize the masses to carry out the maintenance work of equipment combined with special groups, carry out self-inspection, mutual inspection and carry out major equipment inspection.
Author: Hangzhou Water Shield Technology Co., Ltd.
Website: http://www.zjhzsd.com/
Key words: pharmaceutical pure water equipment, chemical industry water equipment, food water equipment
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