Why should we regularly maintain equipment in chemical production?

In chemical production, equipment is an indispensable part of production, and it is also a major safety hazard in the production process, due to the poor maintenance of equipment and facilities, or the lack of timely verification of accessories, and over-limit service. The major production safety and equipment accidents abound.

Accident case 1:

March 25, 2010, I plant a repair shop mechanic reactor, the reactor during loosening the bolts with a wrench, because the wrench slipping, the body loses focus, teeth hit the reactor, resulting in the mechanic and a half incisors fracture.

Accident case two:

April 5, 2010, I also plant a workshop mechanic during maintenance ceramic water ring pumps, hydraulic pull code disassemble water pump bearings, the pull-yard foot bolt breaking, screws flying to knock the mechanic The teeth caused the mechanic to knock off one and a half teeth.

Accident Case 3:

July 20, 2011, I plant a workshop mechanic when installing water pump impellers, due to the small clearance between the impeller and pump shaft, using a hammer vigorously tapping process impeller, the fall of the hammer iron splash Out, through the left upper arm of the mechanic, causing the mechanic to be injured, but fortunately sent to the hospital in a timely manner, did not cause major harm.

The above three accidents seem to be all accidental, but in reality they are inevitable. After the accident, we made a more detailed understanding of the following aspects of the responsible person and victim:

1. Does the workshop or department establish a maintenance system for equipment and facilities? Does the maintenance system meet the actual situation in the workshop? Does the maintenance system of equipment and facilities make a detailed and detailed description of the operation process?

2. Are the mechanics operating in accordance with the equipment maintenance system during the operation?

3. Are workers properly wearing protective labor supplies during the operation?

4. Is the maintenance person in charge and the workshop site supervisor effectively supervised the operation process?

5. Is the site supervisor responsible for the overall analysis of the risks faced during the maintenance operations?

According to accident victims at the time, at the time of work, the maintenance manager and the workshop site supervisor both performed maintenance instructions on the site. The workshop also developed a simple system for maintaining facilities and equipment. The operator did not wear work that prevented injuries caused by splashing. Protective Equipment. Management personnel such as maintenance supervisors and workshop site supervisors did not timely detect and stop the mechanics' violation of regulations. Finally, when we asked the parties about whether or not to operate in accordance with the maintenance system of equipment and facilities, the parties replied: We have been doing so, and the maintenance system for equipment and facilities is only for inspection by superiors and external auditors. This answer is greatly beyond my expectation.

Having worked at McDonald's for a period of low-level management, McDonald's even had a very detailed production process for one of the burgers, including the baking of bread, the frying and frying of meatloaf, and the frying and frying of patties. The control of oil and furnace temperature, the proportions of ingredients and ingredients, and even the placement of the tools used to make burgers, the discarding of patties and burgers that have been made, and so on. In other words, a small hamburger from the "live" to "dead" has a compact operation steps, strict control. So what is the big "burger" for equipment in chemical production? Should we also do this? The strict system of Hamburg is just to ensure its quality and safety, allowing customers to enjoy safe, fresh and delicious food. As the equipment in chemical production, the strict operational procedures, inspection and maintenance system is not only to ensure the quality and safety of the products it produces, so simple. Because of the safe operation of the equipment, it not only ensures the production quality and safety, but also reduces the maintenance cost of the equipment due to strict implementation of a series of standardized systems such as operating procedures, inspections and maintenance, and reduces equipment maintenance frequency and equipment. The effective time of safe operation; at the same time, the production cost of the workshop or department is reduced, and the manpower and financial resources invested by the workshop or department in the maintenance of the equipment are reduced; to a certain extent, the occupational health and safety of the maintenance worker is ensured and the production is improved. Efficiency has promoted the production safety of the entire workshop or department and even the whole plant.

After analyzing the three accidents mentioned above, it was found that maintenance personnel did not perform operations in accordance with the maintenance system of equipment and facilities. This was the main cause of personal injury. Maintenance personnel did not properly wear protective equipment and workshop management personnel were not timely. Stopping brutal violations of its operating practices is a secondary cause; at the same time, the safety awareness of workshop maintenance workers is rather weak, and the maintenance system maintained by the workshops or departments is blind and the repair habits that are consistently formed are still consistent. One of the causes of the accident. The procedures and systems for equipment and facilities developed by the workshop or department are not comprehensive and rigorous. They cannot guide the maintenance personnel effectively and cannot effectively control the illegal operation behavior during the maintenance operations. It can thus be seen that the establishment of a series of standardized systems from the “birth” to “death” of the big “Hamburg” equipment and the effective implementation of these systems is imperative. Moreover, the establishment of these systems can also effectively reduce accidental injuries caused by negative emotions such as emotional instability of equipment maintenance operators.

In this case, we should establish standardized management systems in the daily management of equipment and facilities.

( 1 ) Equipment technology basic management system

1 It mainly involves a number of national technical standards such as equipment, a series of information such as the internal structure of the equipment, materials, wearing parts, spare parts, etc.

2 Qualification certificates, production licenses, safety instructions, manufacturing certifications, quality inspection certificates, and equipment commissioning records of the equipment;

3 The "ID card" of the equipment includes the equipment's serial number, name, main specifications, date of commissioning / use, name and specification of ancillary facilities, operating conditions, etc.

( 2 ) Equipment maintenance system

1 It should be responsible for the maintenance of the equipment and be responsible for each equipment, every spare part or tool.

2 Ensure that the maintenance personnel of the equipment should do “four understandings” and “three meetings” for the equipments being maintained and maintained;

3 Confirm the maintenance content of the equipment, carry out regular maintenance according to workshop production characteristics and equipment operation conditions, and determine the frequency of maintenance;

4 The tools and accessories required for the maintenance of the equipment shall also be correspondingly required.

( 3 ) Formulate safety technical operation rules for equipment

It mainly includes the switching sequence of the relevant valves on the equipment and the risk of abnormal conditions of the equipment.

( 4 ) Equipment plan maintenance management system

1 According to the actual maintenance interval of the workshop or department and the problems discovered and existed in the daily inspection and professional inspection of the equipment, formulate large, medium and minor repair plans for the equipment;

2 For the large and medium repairs of equipment, corresponding plans and emergency measures for abnormal situations shall be formulated. The plan shall include the contents to be inspected for maintenance, quality requirements after inspection, inspection progress, special tools, materials and preparation required. Accessories and so on;

3 Check the qualified equipment for inspection and maintenance shall strictly handle the handover with the production site management personnel;

4 The complete maintenance record of large and medium-sized equipment shall be kept.

( 5 ) Sealing Management System of Equipment

1 Sealing not only includes dynamic seals, such as compressor shafts, W pump shafts, and stirring of various reaction vessels, but also includes static seals, such as flanges on equipment pipelines, unions, orifices connecting meters, etc.;

2 should specify the location of the major leakage points of the equipment, and be aware of it;

3 The equipment that has been properly and statically sealed shall have the inspection standards and the method used to conduct pressure test leaks to ensure the integrity of the seal;

4 Establish the dynamic and static sealing files of the equipment and test leak test records.

( 6 ) Equipment Lubrication Management System

1 According to the requirements of the equipment, corresponding lubrication technology should be adopted, and the lubrication of the equipment should be checked regularly;

2Specify the specifications and models of the lubricants that should be used in the process of equipment lubrication, and the methods used to refill the lubricants;

3 Determine the daily regular lubrication points of the equipment, determine the frequency of refueling lubrication and the amount of oil to be filled each time.

( 7 ) Equipment anti-corrosion management system

1 to formulate equipment anti-corrosion plan, establish equipment anti-corrosion files and ledgers;

2 According to the medium and industrial atmospheric corrosion equipment in the production process, anti-corrosion measures shall be formulated according to the primary and secondary times of the equipment and the medium involved;

3 For equipment that has been used for anti-corrosion, it should be considered that it does not affect the safety, environmental protection and product quality.

( 8 ) Equipment inspection and rating management system

1 Periodically check the equipment used in the workshop or department, and confirm the frequency of checking the rating;

2 For defects, hidden troubles, and unsafe factors found in the inspection and rating of equipment, effective measures shall be taken to timely rectify, and set up the equipment review and rating hidden trouble rectification account;

3 The equipment's inspection rating should not only include the equipment itself, but also include the pipelines, flanges, instrument orifices connected to the equipment, and even equipment foundations, foundations, brackets, insulation, anti-corrosion and antifreeze.

4 According to the equipment's inspection rating, the unqualified equipment shall be scrapped, cleaned, idled, etc., and the equipment shall be scrapped and the washing machine shall be placed in idle storage.

( 9 ) Equipment accident management system

The main causes of equipment accidents are:

1 The design of the equipment itself is irrational;

2 illegal operation, illegal command;

3 poor maintenance;

4 overhaul technical solutions are not appropriate;

5 Barbarian maintenance operations;

6 overhaul or take up service;

7 safety accessories, instrument failures and other aspects.

Accidents caused by equipment should be strictly in accordance with the principle of "Four not missed", identify the cause of the accident, put forward preventive measures, formulate rectification programs, and ensure that no similar accidents occur in the equipment.

Therefore, in our day-to-day management of equipment, we should strengthen the construction of equipment standardization system, improve our safety management of equipment, ensure safe operation of equipment, thereby ensuring production safety, and ultimately achieve minimum investment and maximize efficiency. While establishing a standardized equipment management system, we must resolutely implement it. Otherwise, even the best system will eventually be a dead letter, and it is difficult to form a good equipment safety culture.

The information in this article comes from the Internet and was reorganized and edited by China Rescue Equipment Network.