First, equipment management and staffing
1. Set up equipment management department, staffing to adapt to the needs of the enterprise equipment management and maintenance work, the work of some people are responsible for, and to maintain relative stability.
2. There are plant-level leaders in charge of equipment. The person in charge of equipment management should have a college level of education (or have a technical title of intermediate or above), through job training, practical work experience.
3. Equipment management and equipment management departments and departments related to equipment management functions and responsibilities are clear.
4. Equipment management network at all levels (factory, workshop, team) is sound and normal activities.
5. Equipment maintenance organization is sound.
Second, equipment management regulations
In accordance with national regulations and industry regulations, the development and timely revision of equipment management regulations:
(1). Special equipment [including boilers, pressure vessels (including gas cylinders), pressure piping, lifting machinery, plant-specific motor vehicle management system;
(2). Equipment pre-management (including equipment procurement and bidding management) system;
3. Equipment asset management system;
(4). Equipment use and maintenance system;
(5). Equipment maintenance management system;
6. Equipment spare parts management system and so on.
Three, equipment management procedures and standards to determine
Equipment management and maintenance of a variety of work standards, technical standards, safe operating procedures, maintenance procedures, overhaul procedures, workflow, and technical documents are complete, correct and standardized.
Four, technical and economic data statistics
On time, accurately fill out the equipment management statistical reports and analysis and summary. Equipment management technical and economic indicators should meet the requirements set by the industry or relevant departments. Technical and economic indicators (see appendix for statistical methods) include:
1. Safe operation of equipment:
1. Special equipment inspection rate;
2. Frequency of equipment accidents;
3. Equipment accident downtime rate;
(4). Equipment accident statistics.
2. Equipment technical indicators:
(1). Main equipment intact rate, all equipment intact rate;
(2). Main equipment utilization rate, all equipment utilization rate;
(3). Comprehensive efficiency of equipment;
(4). Leakage rate of dynamic and static sealing points;
(5). Equipment overhaul program completion rate;
(6). Instrumentation "three rates": completion rate, control rate, open meter rate;
(7). Equipment idle rate.
V. Pre-equipment management
1. The equipment management department is responsible for or involved in equipment renewal, technological transformation, new projects, expansion projects, self-made equipment and sporadic equipment purchases of planning and bidding procurement work.
2. Equipment management should be involved in equipment selection, installation, commissioning, completion and acceptance. Key equipment should be involved in its technical and economic analysis and demonstration.
3. Equipment management should be involved in homemade equipment design program research and validation work.
4. Equipment management department is responsible for or involved in the selection of equipment off the work, and put forward on spare parts, lubricants, equipment installation and commissioning and maintenance of technical information and other requirements.
5. Equipment management should be newly commissioned equipment used in the early stages of quality, functionality, efficiency and other deficiencies found in a timely manner to the manufacturing unit feedback, prompting the manufacturing unit to develop and implement corrective measures to ensure that the quality of the equipment, functionality, efficiency standards.
6. Equipment purchases, should grasp the manufacturing, sales unit qualifications and performance status. In the procurement of special equipment, should be in accordance with the "Regulations on the Safety Supervision of Special Equipment" requirements, in the bidding documents clearly stipulate that the bidding unit should have the appropriate level of design qualifications, production qualifications, and products should be provided at the time of shipment of documents and information shall not be purchased illegally produced products.
7. It is strictly prohibited to procure and use process equipment that endangers production safety, which is explicitly eliminated and prohibited by the state.
Sixth, the technical basis of equipment management
1. Equipment technical files are complete and complete. Technical data storage in line with the provisions of the relevant technical file management.
2. Equipment drawings, technical documents, completion information is complete and accurate; special equipment required technical documents, drawings, information should be collected in accordance with the provisions of the "Regulations on the Safety Supervision of Special Equipment" complete.
3. Equipment spare parts catalog is complete, clearly categorized; spare parts with procurement (manufacturing) plan and reserve quota; inventory spare parts clear procedures, complete documentation, accounts, cards, things match; clean storage, spare parts without corrosion damage, good storage.
4. The development of specialized equipment and general equipment, equipment safety regulations, and often on the operators of equipment operation knowledge training, assessment, complete records.
5. National and local technical supervision departments issued by the relevant laws and regulations of special equipment, regulations and provisions of the complete, and often on the equipment management personnel and operators to carry out publicity, and its operators should have the relevant technical supervision departments issued by the operation of the certificate, the license on duty.
6. Special equipment should be subject to technical supervision departments of the safety monitoring, registration, and according to the provisions of the regular testing, preventive testing and online inspection, and timely elimination of hidden problems, to ensure that the special equipment used in the test period of validity.
7. Special equipment should be managed by special people, according to the "Regulations on the Safety Supervision of Special Equipment," the provisions of the establishment of special files, the development of special safety regulations, and in accordance with the relevant provisions of the national and provincial regular maintenance, maintenance and online inspection, make a good record, to ensure that its normal operation.
8. The equipment safety valves, explosion-proof mold (piece), safety interlocking devices should be set up and have a person to manage the account, often online inspection, regular calibration. Inspection, calibration records should be archived.
9. Equipment accidents should be in line with the cause of the accident analysis is not clear not to let go; accident prevention measures are not implemented not to let go; the person responsible for the accident has not been dealt with not to let go; the majority of cadres and workers have not been educated not to let go of the principle of compliance with the "Reporting and Investigation of Manufacturing Safety Accidents and Disposal Ordinance" or "Regulations on the Supervision of the Safety of Special Equipment" of the relevant provisions of the treatment.
VII, equipment modernization management
1. Equipment ledgers, files, spare parts, equipment status, lubrication management, technical and economic indicators, reports, information and preparation of overhaul plans using computer-aided management.
2. Strengthen the construction of equipment inspection system, the use of equipment condition monitoring and fault diagnosis technology, and the gradual implementation of preventive maintenance based on condition maintenance.
3. Strengthen information management, timely understanding of the state of equipment in the same industry, the use of new materials, new processes, new technologies in equipment manufacturing, renovation and maintenance, and improve the output of equipment and devices.
4. Adopt scientific and advanced methods to monitor the status of various lubricants (including hydraulic oil) or the use of on-site rapid analysis methods, to grasp the oil quality, as a basis for good lubrication program.
Eight, the economic management of equipment
1. The whole process of equipment management should pay attention to economic efficiency. Acquisition of new equipment and equipment major transformation should be carried out technical and economic analysis and demonstration.
2. According to the provisions of the full amount of depreciation, depreciation is mainly used for the renewal and transformation of enterprise equipment.
3. In the preparation of the equipment maintenance program should be prepared at the same time the equipment maintenance cost budget plan. Repair costs after accounting for the implementation of the production costs.
4. The financial department of the enterprise should be in conjunction with the equipment management department of the equipment overhaul cost assessment and statistical management, and overhaul cost review, analysis.
5. To carry out the analysis of the operating efficiency of the equipment, and the economic accounting of kinetic energy, improve the operating efficiency of the equipment, reduce the level of energy consumption, and do a good job of kinetic energy control and energy saving.
6. Equipment scrapping, transfer according to the relevant provisions, equipment transfer transfer should be in accordance with the relevant provisions of the asset transfer procedures.
7. Equipment asset classification, numbering in line with industry standards, equipment ledger, the original data is complete and correct, accounts, things match.
8. Equipment and assets put into use acceptance, transfer, removal, deactivation, transformation, renewal, scrapping in line with the provisions of the system, complete documentation.
9. Equipment technical transformation should be in accordance with the provisions of the equipment value-added procedures.
10. The establishment of idle equipment ledger, idle equipment to do a good job of reporting, transfer work.
9, equipment use and maintenance, maintenance
1. Operators should be qualified by the training and assessment, issued by the post operating certificate before the license to work.
2. Operators should master the "four understand (understand the structure, understand the principle, understand the performance, understand the use)", "three will (will be used, will be maintained, will troubleshooting)", the implementation of the job responsibility system, the operation of the equipment for more than one person, the implementation of the head of the class The system is responsible for the equipment operated by many people, the implementation of the shift leader.
3. Operators should strictly implement the equipment safety regulations, equipment operating parameters to comply with the specified indicators (temperature, pressure, flow, current, etc.), shall not be over-temperature, over-pressure, overloaded operation, the operation record is clear, complete and true.
4. Operators should adhere to the daily maintenance and regular maintenance of equipment, and participate in equipment inspection. Equipment maintenance should achieve neat, clean, lubricated, safe standards, in line with the requirements of clean and civilized production.
5. The key and main production equipment should be designated people, machines and duties; the implementation of the shift handover record system, the correct use of equipment maintenance.
6. Equipment maintenance personnel to implement regional maintenance responsibility system, regular inspection, maintenance, inspection and maintenance records are clear, complete and true.
7. The equipment safety valves, explosion-proof mold (piece), safety interlocking devices should be frequently maintained, online inspection, regular calibration, inspection, calibration records, records are true and complete.
8. Spare equipment to establish a regular trial system.
9. Idle equipment should be required to carry out regular maintenance.
Ten, equipment overhaul, renovation and renewal
1. Equipment overhaul plan preparation is based on the adjustment procedures. Equipment large and medium repair plan into the enterprise production plan at the same time issued by the enterprise equipment management department to organize the implementation of the completion of the schedule and summary and assessment; equipment repair or fault repair without affecting the production of the premise, by the workshop's own arrangements, inspections, summaries and assessments; outside the repair of equipment in accordance with the provisions of the implementation of the enterprise.
2. Equipment major and medium repair should be under the task book, including technical preparation before repair, production preparation, safety precautions, working hours, spare parts to be replaced, materials and repair costs and so on.
3. Special equipment overhaul, overhaul units to provide the appropriate level of maintenance qualification certificate and special operator qualification certificate in order to carry out overhaul. In the overhaul mission statement must be clearly put forward on the overhaul unit and special operators qualification level requirements.
4. Special equipment overhaul must be carried out at the same time with the regular testing of the equipment. Detection work must be undertaken by a unit with the appropriate qualifications, overhaul the task book must be clearly specified on the qualification requirements of the testing unit. For the test rated unqualified, must be discontinued and replaced.
5. After the completion of the overhaul project, according to the quality standards set out in the equipment overhaul program for acceptance, and for acceptance of technical information and equipment handover procedures.
6. In-use equipment for technological transformation or renewal to have approval procedures, transformation and renewal of the technical program by the equipment management department to organize the relevant departments to demonstrate that the company's main leadership after the signing of a clear responsibility for the implementation of the department.
7. After the completion of the technical transformation or renewal of equipment to handle the completion and acceptance procedures, asset value-added procedures and equipment being updated for the end of the procedures.
Xi, good equipment site management
1. Workshop equipment management objectives are decomposed into groups, clear objectives, clear indicators, and regular assessment and evaluation.
2. Workshops have various types of equipment ledger, the workshop equipment safety, technology, economic indicators and maintenance of statistical information and original records, according to the requirements of the enterprise hierarchical management, to do a good job in the management of information, reports.
3 production site operation room equipment site management system (shift handover system, inspection system, lubrication management system and equipment maintenance system, etc.), and can seriously implement.
4. Regularly carry out equipment integrity and civilized production inspection, inspection and assessment methods and incentives and penalties, equipment production site is clean, civilized, equipment maintenance sites have obvious regional signs and safety signs.
5. Do a good job of daily maintenance of equipment, no obvious "running, bubbling, dripping, leaking" phenomenon.
6. On-site equipment operating parameters in line with the specified indicators, a variety of original operating records and shift handover records are complete, fill in the serious, true, standardized.
7. Equipped with full-time (part-time) lubrication management personnel and lubrication workers, the full implementation of equipment lubrication "five" (fixed person, fixed point, fixed time, fixed quality, fixed quantity) work, lubrication station, lubrication points to implement the oil quality testing, oil change on time, equipment lubrication records are complete, lubrication is in good condition.
8. All kinds of pipelines, valves, pipe fittings bracket is stable, pipeline arrangement, color coding in line with industry regulations, anticorrosion, heat preservation, insulation is good, there is no obvious "running, bubbling, dripping, leaking" phenomenon. Temporary connection, piping with approval procedures, pipeline changes have modified records.
9. No more than permissible vibration of the equipment in operation, noise, equipment foundations and pipe racks are stable, no loose ground bolts.
10. Special equipment operators are licensed to work, the certificate is neat, effective and properly stored.