1, the need for equipment maintenance
The sewage station is a 24-hour continuous operation of facilities. In order to ensure the normal operation of the various treatment devices and maintain good treatment results, should be regularly overhauled on a variety of equipment.
2, the principle of equipment maintenance
Equipment maintenance in principle should follow the product specification. Should include cleaning, adjustment and fastening, lubrication and anti-corrosion content. Maintenance work should also be recorded.
3, maintenance work
3, 1 routine maintenance - refers to the operation of the inspection and maintenance.
3, 2 scheduled maintenance - regular downtime inspection and maintenance.
3, 3 parking maintenance - refers to the maintenance of standby units or idle equipment.
3, 4 seasonal maintenance - refers to set into summer, winter, rainy season and other seasonal need for maintenance.
4, equipment maintenance system
4, 1 equipment used for a period of time period, must be carried out small repair, medium repair or overhaul. Equipment manufacturers have clear provisions, should be in accordance with the provisions of the manufacturer to carry out maintenance. If there is no provision, in principle, the following cycle should be scheduled maintenance and overhaul.
4, 1, 1 Roots blower: overhaul 15,000 hours, scheduled maintenance 500 hours
4, 1, 2 submersible sewage machine: overhaul 10,000 hours, scheduled maintenance 500 hours
4, 1, 3 corrosion-resistant centrifugal pumps: overhaul 8,000 hours, scheduled maintenance 500 hours
4, 1, 4 mechanical grille: overhaul 8000 hours, scheduled maintenance 500 hours
4, 1, 5 sludge pumps: overhaul 10,000 hours, scheduled maintenance 500 hours
4, 1, 6 check valves: overhaul 6 years, scheduled maintenance 500 hours
4, 1, 7 manual valves: overhaul 2 years, scheduled maintenance 500 hours
5, daily Maintenance work
5, 1 do a good job in the pump room, unit surface cleaning.
5, 2 should regularly check the water tank, impeller, remove the pump garbage.
5.3 Pay attention to the oil level, oil quality and temperature of the bearings, bearing lubrication should be replaced regularly. Water pump lubricant work 500h for a change, bearing grease work 2000 hours for a change.
5.4 Check whether the fasteners of each component are loose.
5.5 Regularly check and replace the packing.
5, 6 pump operation should pay attention to the packing at the drip is normal, outside the packing allows a small amount of drip but does not allow running water. This can be achieved by adjusting the tightness of the packing gland. Packing pressure plate should not be pressed all the way in. Replacement of packing should measure the pump shaft circumference L, and then put the length of 25mm or so, both ends with hair cut into 45 degrees or so beveled. When putting into the packing cylinder, the two ends should be lapped up and down to prevent water leakage. At the same time, the upper and lower filler joints should be staggered 180 degrees from each other. General packing 1-6, pressure plate into the packing tube nearly 1 / 3 depth can be, pressure plate and pump shaft around the seam should be basically uniform.
Equipment maintenance management system
1, post operators and maintenance personnel should be familiar with the maintenance of mechanical and electrical equipment regulations.
2, should be the structure of the building and a variety of gate valves, guardrails, ladders, pipelines, etc. Regular inspection, maintenance and anti-corrosion treatment, and timely replacement of damaged lighting equipment.
3, should always check and fasten all kinds of equipment connectors, regular replacement of coupling wear parts.
4, a variety of pipeline gate valve should be done regularly open and close the test.
5, should be regularly checked, clean electrical control cabinet, and test its various technical performance.
6, should regularly check the electric gate valve limit switch, manual and electric interlocking device.
7, after each stoppage of the pump, the packing or oil seal seal should be checked and necessary treatment. And fill or replace the packing, lubricating oil and grease as needed.
8, where there is a wire rope device, rope wear is greater than 10% of the original diameter, or one of the strands have been broken, must be replaced.
9, a variety of mechanical equipment in addition to routine maintenance should be done, but also according to the design requirements or manufacturer's requirements for large, medium and small repairs.
10, overhaul all kinds of machinery and equipment, should be based on the requirements of the equipment, must ensure that its coaxiality, static balance and other technical requirements.
11, shall not repair equipment replacement out of lubricating oil, grease, laboratory wastewater and other debris thrown into the sewage treatment facilities.
12, maintenance of machinery and equipment, shall not be arbitrarily attached to the temporary power line.
13, buildings, structures and other lightning, explosion-proof device testing, maintenance and its cycle should be in line with the provisions of the electricity industry and the fire department.
14, should be regularly inspected and replaced fire facilities and other protective equipment.
Part II: engineering machinery and equipment repair and maintenance systemA division of responsibility
1, after the use of machinery and equipment back, by the Ministry of Materials and Equipment maintenance workshop inspector to fill out the "machinery and equipment warehousing acceptance sheet ", with the use of equipment staff *** with the signature recognition, verification of equipment in addition to normal wear and tear, whether there are assemblies and spare parts, instrumentation, accessories and other defects, in order to distinguish responsibility.
2, from the site back to the mechanical equipment, the maintenance workshop is responsible for repair and maintenance to ensure that the equipment is put into use again when the normal operation.
3, according to the technical condition of the equipment, to determine the repair category and fill out the "construction equipment repair and maintenance records", the normal cost of which is amortized into the project cost. Due to violation of equipment maintenance procedures, abnormal use of mechanical equipment damage caused by the repair costs borne by the user.
4, where the equipment has been put into the site out of the warehouse to use, routine maintenance by the operator is responsible for regular repairs by the use of the unit's equipment and machine repair class is responsible for.
5, after the maintenance of equipment out of the warehouse, by the Ministry of materials and equipment and the use of party *** with the signature of approval, and fill out the "construction equipment, plant and equipment needs", unqualified equipment is not allowed to use out of the warehouse.
6, equipment out of storage, routine maintenance and recurrent repair costs borne by the use of units; in the event of inability to repair and maintenance projects, can be entrusted to the Department of Materials and Equipment maintenance workshop repair, the costs incurred by the use of units responsible for.
Second, the repair category and method
1, overhaul: machinery and equipment overhaul interval is only a reference basis, whether it is necessary to overhaul mainly depends on its technical condition is in line with the overhaul of technical terms to determine. Need to fill out the "construction equipment overhaul plan" for approval by the Ministry of Materials and Equipment.
A, machinery and equipment need to overhaul the technical conditions are as follows:
1) engine
a, a significant decline in power performance (generally reduced by more than 20%)
b, there is a serious phenomenon of oil burning (oil consumption exceeds the quota of more than 1 times)
c, the engine goes after the heat, the cylinder pressure is too low (less than 60% of the standard)
2) the engine is not a good choice for overhauling, but it is a good choice for overhauling, and it is a good choice for overhauling.
2) Mechanical parts
a, the main parts of the transmission mechanism to reach the limit of wear and tear, so that the mechanical equipment in the operation of the swing, noise or impact shaking phenomenon.
b, steering manipulation mechanism wear, excessive clearance, manipulation failure.
c. Gearbox gear shaft wear and tear of serious shift difficulties or often jump gears.
d. The main body of the frame is seriously deformed or cracked.
e. The traveling mechanism is badly worn and cannot work normally.
f, serious wear and tear of the braking mechanism, malfunctioning operation, reduced braking capacity or failure, unable to adjust.
g. The working mechanism is seriously worn, malfunctioning, unable to complete the normal workload or the precision of operation is not up to the requirements.
All of the above, have been unable to use the adjustment and minor repair methods to eliminate, continue to use will lead to serious accidents, only dismantling overhaul, in order to restore the technical performance of machinery and equipment. There are more than two assemblies to be repaired can be regarded as overhaul, there is one assembly to be repaired is regarded as medium repair.
B. Mechanical equipment repair methods: on the car repair method, assembly interchangeable repair method.
C, overhaul acceptance
1) external acceptance inspection: mainly check the perfect mechanical equipment assembly, including lubrication, solid and leakage phenomenon check.
2) air running or test load test: mainly test the dynamic performance of machinery and equipment, including starting performance, braking performance and safety performance, etc., to verify whether the mechanical equipment to meet the technical requirements for normal use. Fill in the "trial run of mechanical equipment records.
3) Review after the mechanical test: the main review of the test there is no abnormal phenomenon, at the same time to eliminate the defects and faults found in the test, the necessary adjustments.
4) overhaul acceptance to fill out the "mechanical equipment acceptance records" and "mechanical equipment test run records.
D. Overhaul of equipment to meet the requirements (refers to the equipment in the 7-day guarantee period should be used to meet the requirements).
1) The engine should run normally after warming up, no knocking and other abnormal noises, no cylinder burning and other phenomena, oil pressure and water temperature in accordance with the provisions of the exhaust smoke color is normal, and the power is normal.
2) Clutch engagement is smooth, not swing.
3) Gearboxes, including transmissions, splitters, reducers, differentials, and various drive shafts, etc., no abnormal noise during operation, no overheating of bearings, no oil leakage of various oil seals, no automatic gear skipping, gear loss, and no difficulty in shifting gears.
4) The traveling mechanism is smooth and does not swing.
5) Braking system wear normal, not overheating, stable and reliable performance.
6) The operating mechanism and safety devices are flexible, safe and reliable.
7) The working device is free of serious wear and abnormal sound.
8) No deformation or rupture of the frame.
9) The no-load current and temperature rise of the motor and electrical equipment should meet the requirements.
10) All kinds of meters indicate normal, sensitive and reliable.
E. Guarantee responsibility (seven-day guarantee period)
1) In the guarantee period, if serious equipment failure or damage is caused by repair negligence, it will be repaired by the maintenance workshop of the Ministry of Materials and Equipment without compensation.
2) Other requirements refer to the overhaul requirements.
2, medium repair:
1) the technical conditions of the medium repair: one of the technical conditions in line with the overhaul of machinery and equipment, that is, medium repair.
2) Other requirements refer to the overhaul requirements.
3, minor repair: maintenance repair, mainly to eliminate the use of machinery and equipment in the use of temporary faults and local damage, maintenance of equipment for normal operation.
4, maintenance:
1) a level of maintenance: refers to the recurrent need for lubrication and maintenance of equipment parts of the injection of lubricants (such as calcium-based grease, gear oil, oil, etc.) lubrication unit, lubrication points, lubrication cycle, lubricant type, oil injection method according to the implementation of the equipment manual.
2) the second level of maintenance: adjustment, solid, anti-corruption machinery and equipment, by the equipment officer and the mechanic class is responsible for (simple by the operator to follow the machine is responsible for).
3) tertiary maintenance: take the assembly apart and clean, eliminate faults, by the equipment man mechanic class is responsible for.
Part III: machinery and equipment maintenance system and maintenance principles and requirements 1, 1 to ensure that mechanical equipment is often in a good state of technology, ready to be put into operation at any time, to reduce the failure of downtime days, improve the mechanical integrity rate, utilization, reduce mechanical wear and tear, extend the service life of machinery, reduce machinery operation and maintenance costs to ensure safe production
1, 2 mechanical maintenance must implement the "maintenance and repair, prevention-oriented" principle, to achieve regular maintenance, mandatory, correctly deal with the use, maintenance and repair of the relationship between the use, not allowed to use without maintenance, only repair without maintenance;
1, 3 classes Must be in accordance with the mechanical maintenance procedures, maintenance categories of all types of machinery maintenance work, without undue delay, special circumstances need to be approved by the supervisor of the specialists before deferred maintenance, but generally not more than half of the specified maintenance intervals;
1,4 maintenance of machinery to ensure the quality of the specified items and requirements one by one, shall not be omitted or unprotected. Maintenance items, maintenance quality and maintenance problems found should be recorded and reported to the department of specialists;
1.5 maintenance personnel and maintenance departments should do "three checks and one handover (self-inspection, mutual inspection, full-time inspection and a handover)", and constantly summarize the maintenance experience, improve the quality of maintenance;
1.6 The Asset Management Department regularly supervises and inspects the mechanical maintenance of each unit, regularly or irregularly spot checks the quality of maintenance, and rewards and penalizes the poor.
2 maintenance operation implementation and supervision
2, 1 mechanical maintenance adhere to the promotion of "cleaning, lubrication, adjustment, fastening, anti-corrosion" as the main content of the "cross" method of operation, the implementation of routine maintenance and regular maintenance system, strictly according to the operating instructions of the cycle and inspection. According to the instruction manual cycle and check the maintenance program.
2, 2 routine maintenance is before and after the operation of machinery and the process of cleaning and inspection, mainly to check the vital, vulnerable parts (such as mechanical safety devices), coolant, lubricants, fuel, instrumentation and so on. Routine maintenance by the operator to complete their own, and carefully fill out the "mechanical routine maintenance records.
2, 3 level of maintenance: universal cleaning, fastening and lubrication operations, and part of the adjustment operation, maintenance of machinery intact technical condition. The use of unit asset management personnel in accordance with the maintenance plan issued "mechanical equipment maintenance, lubrication notice" down to the operating team, completed by the operator himself, the operating team leader check and supervise.
2, 4 secondary maintenance: including all the contents of the first level of maintenance, inspection, adjustment as the center, to maintain the mechanical assemblies, institutions, parts with good working performance. By the use of unit asset management personnel issued "mechanical equipment maintenance, lubrication notice" down to the operating team, mainly by the operator himself to complete, the operator himself to complete the difficulties, can be entrusted to the repair department, the use of unit asset managers, operating shift supervisor inspection and supervision.
2, 5 other maintenance
2, 5, 1 seasonal maintenance: the main content is to replace the applicable seasonal lubricants, fuel, to take anti-freeze measures, increase anti-freeze facilities. By the use of departmental organization and arrangement, the operation of the shift manager inspection, supervision.
2, 5, 2 go-along period maintenance: new machines and overhaul the completion of the mechanical go-along period must be carried out after the end of the go-along period maintenance, the main content is cleaning, fastening, adjustment and replacement of lubricating oil, by the use of the department to complete the inspection of the asset manager, the Ministry of Asset Management to supervise.
2, 5, 3 transfer maintenance: machinery transfer site before the transfer of maintenance should be carried out, the content of the operation can be based on the technical condition of the machinery maintenance, corrosion can be carried out if necessary. Transfer maintenance by the mechanical transfer unit organization arrangements for the implementation of the project, the project department, the asset manager check, the asset management department supervision.
2,5,4 Parking maintenance: deactivation and sealing of machinery should be maintained, mainly cleaning, anticorrosion, moisture and so on. Inventory of machinery by the Asset Management Department commissioned maintenance, the rest of the machinery by the use of department maintenance.
2, 6 maintenance program should be completed after careful inspection and acceptance, and the preparation of relevant information, so that the records are complete and true.
Part IV: water supply and drainage equipment repair and maintenance systemThe first running check system:
1, the duty officer twice a day in accordance with the circuit route to check the equipment belonging to a, and according to the inspection table to make a good record, the inspection content includes:
(1) the upper and lower pools (1) whether the water level is normal, whether the pool automatic water filling device is normal;
(2) whether the valve switch position is normal, whether the fire valve is in a normal position;
(3) whether the valve pipeline leakage, whether the pressure gauge reading is normal.
2, the duty officer every shift in the pump running field inspection, to understand its working conditions:
(1) pressure gauge readings are normal;
(2) bearing temperature is normal;
(3) the motor junction box with or without heat phenomenon;
(4) the pump unit with or without vibration and abnormal sound;
(5) Coupling packing loosening and tightening, to rule out abnormal water leakage.
The second monthly maintenance:
1, standby system emergency test:
(1) pump room standby supply pumps and fire pumps test run;
(2) basement of the submersible sewage pumps test run;
(3) discharge of dead water pipe water.
2, a comprehensive check of water supply and drainage and fire water pipeline whether the main valves in the normal position, rotate the valve is usually not moving.
3, clean the pump room, remove the pump and motor surface dust.
Third quarterly maintenance:
1, the main valve screw cleaning and refueling.
2, remove underground sewage, well debris, so that the drainage pump works smoothly.
3, each pump motor terminals solid, testing motor.
4, test each pump control box working condition, replace the bad indicator and abnormal accessories.
Article IV Annual Maintenance:
1, the life and fire pumps:
(1) check the sealing ring wear and tear, measure and record the movement gap, if necessary, replacement or repair;
(2) replacement of sealing packings;
(3) check the corrosion of all the bearings, replace the Bearing oil;
(4) proofreading curve, make a record;
(5) check the coupling hinge and shaft wear;
(6) check the corrosion of the pump lobe pump casing, the pump casing and the seat of the rust and paint;
(7) check whether the pressure gauge is normal;
(8) motor to do the annual maintenance;
(9) check the working performance of the pump. ) Check the working performance of the pump.
2, sewage submersible pumps:
(1) dismantle the pump cover to measure and check the end face gap and make a record, if necessary, repair;
(2) check the integrity of the axial sealing device and the sealing performance;
(3) check the corrosion of the pump lobe pump casing, the pump casing to remove the rust and paint;
(4) check the hose. Intact condition;
(5) the motor to do annual overhaul maintenance;
(6) check the working performance of the pump.
3, pipe system:
(1) the entire pipe system to do a comprehensive inspection, to determine the reliability of the pipe system to continue to operate;
(2) check all the pipelines and valves of the rust protection is intact, if necessary, to do the big maintenance of the paint;
(3) the replacement of corroded and aging seals and can not continue to use the pipe.
Part V: property area water supply and drainage equipment maintenance regulations1, purpose
Timely processing of water supply and drainage equipment (facilities) faults, maintenance of equipment, to ensure that the performance of the equipment is always in a good running or standby state.
2, the scope of application
The property area of the living water pumps, fire pumps, spray pumps, booster pumps, sewage pumps, air-conditioning pumps, related valves, piping and other water supply and drainage equipment (facilities) repair and maintenance.
3, duties
3, 1 engineering administrator is responsible for the development of maintenance work plan, maintenance work guidance, inspection and supervision and outsourcing repair contact work.
3, 2 management director is responsible for approving the maintenance work plan.
3, 2 plumbers are responsible for the maintenance of water supply and drainage equipment (facilities).
4 work procedures
4, 1 water supply and drainage equipment repair and maintenance work program
4, 1, 1 maintenance team is responsible for the maintenance of water supply and drainage equipment (facilities).
4, 1, 2 engineering administrator in December each year to develop the next year's "equipment annual repair and maintenance program", and according to the operation of the development of medium repair, overhaul plan.
4, 1, 3 maintenance group according to the "equipment annual maintenance plan" requirements of the maintenance of equipment, and maintenance will be recorded in the "Facility Maintenance Sheet" and summarized in the "Facility / Equipment Maintenance Records".
4, 1, 4 water supply and drainage equipment failure is generally not more than 8 hours, if the failure of important parts of the failure can not be resolved within 8 hours, the cause of the failure, the solution, the solution time should be reported in writing to the management office.
4,1,5 Where the night occurs, does not affect the user's life, work, will not produce serious consequences of water supply and drainage equipment (facilities) failure, can be maintained by the morning shift plumber.
4,1,6 engineering manager to provide work guidance and inspection supervision.
4,1,7 need to stop the water for repair and maintenance, do a good job of prior notice and explanation.
4, 2 water supply and drainage equipment (facilities) failure to deal with general working procedures
4, 2, 1 water supply pump failure, the duty plumber should be immediately activated standby pumps, and then immediately notify the management office to organize timely maintenance of relevant personnel.
4, 2, 2 sewage pump failure, first check the cause of the failure, such as control circuit failure, check and eliminate; if the pump failure, then repair the pump.
4, 2, 3 water supply network failure, leakage affecting the normal water supply, the duty plumber should immediately close the upper end of the valve, timely notification of the management office to organize the relevant personnel repair, and do a good job of explaining the affected users.
4, 2, 4 sewage wells, rainwater wells, etc. due to clogging caused by poor drainage, flooding, etc., immediately notify the maintenance personnel by phone to dredge.
4, 3 water supply and drainage equipment (facilities) inspection and maintenance table
No. inspection and maintenance items maintenance content (including the use of materials) cycle
01 pump unit and accessories clean appearance scrubbing, decontamination month pressure gauge indicator shows abnormal, check and replace unscheduled motor main circuit, control loop testing, inspection, fastening half a year pump shaft end seals, such as leakage exceeds the standard, replace the Mechanical seals irregular motor bearings, pump bearings refilling
02 pipeline appearance such as leakage, leakage repair; such as rust, rust removal, brush rust paint and top coat irregular valve appearance valve stem leakage, compression bolts; such as rust, rust, rust removal, brush rust paint and top coat irregular
5 work
5, 1 living water pumps, Air conditioning cooling pump, air conditioning chilled water pump every six months for comprehensive maintenance.
5, 2 fire pumps and sprinkler pumps, lifting pumps every three months for a trial run, running time of 1 minute, once a year for comprehensive maintenance.
5, 3 sewage pumps once a year for comprehensive maintenance.
5, 4 each pump maintenance should be connected with the pump body within 5 meters of the valves, pressure gauges, piping and other maintenance with the pump at the same time.
5, 5 pump body maintenance
5, 5, 1 checked pump body should be free of damage, complete nameplate, water flow direction indication clear and clear, neat appearance, paint intact.
5.5.2 Check and replenish the lubricating grease, if the oil is discolored or impurities, it should be replaced.
5,5,3 check the pump shaft end sealing, if there is leakage beyond 10 drops / min, should be disassembled to check the mechanical seal, found serious wear or cracking should be prepared to replace the mechanical seal.
5,5,4 coupling bolts and rubber washers should be replaced if damaged.
5, 5, 5 tighten the seat screws and do rust treatment.
5, 5, 6 living water pumps and air conditioning pumps due to frequent operation, should be disassembled every year coupling bearings at both ends for cleaning or replacement.
5, 6 pump motor maintenance
5, 6, 1 appearance check should be neat, complete nameplate, ground wire is well connected.
5, 6, 2 dismantle the motor junction box wire connection piece, with 500 Ⅴ megohm meter shake test motor winding phase and phase, relative to the ground insulation resistance value should not be less than 0, 5 megohm.
5, 6, 3 motor junction box within the three-phase wires and connecting pieces should be firm and tight, no aging phenomenon.
5, 7 related valves, piping and accessories maintenance:
5, 7, 1 each valve switch should be flexible and reliable, no leakage inside and outside.
5, 7, 2 check valve action should be flexible, no leakage inside and outside the valve body.
5, 7, 3 pressure gauge indication is accurate, dial clear.
5, 7, 4 piping and accessories appearance neat and beautiful, no cracks, paint should be intact without peeling.
5, 8 control cabinet maintenance
5, 8, 1 disconnect the control cabinet from the main power supply, check the switch, start, stop button action should be flexible and reliable.
5, 8, 2 check the cabinet air switch, contactor, relay and other electrical appliances are intact, tighten the electrical contact wire head and terminal screws.
5,8,3 Clean the dust inside and outside the control cabinet.
5, 8, 4 close the main power supply, check whether the power indication is normal.
5, 8, 5 maintenance is completed according to the specified requirements to start the pump, observe the ammeter, the indicator indicator is normal.
5, 8, 6 observe the pump running smoothly, no obvious vibration and noise, the pressure gauge is normal, the control cabinet of the electrical appliances without bad noise.