Equipment repair and maintenance mode of determining
Equipment maintenance can be divided into planned preventive maintenance, from the point of view of ensuring the safe operation of the equipment, it should be emphasized more preventive maintenance. Planned maintenance is based on the law of wear and tear of equipment and the law of equipment failure, the development of equipment maintenance and repair methods. According to the role of maintenance, maintenance can be divided into maintenance, targeted repairs, planned repairs, project repairs, renovation and maintenance, etc., choose to determine the basis of maintenance is mainly based on the degree of wear and tear of equipment and its components, performance, precision deterioration and the possibility of failure.
1.three difficult maintenance system
Equipment maintenance work, according to the workload size and degree of difficulty, is divided into routine maintenance, first-class maintenance and secondary maintenance, the formation of the maintenance system known as the "three-tier maintenance system".
(1) routine maintenance
is the operator must be carried out every shift equipment maintenance work, its content includes: cleaning, refueling, adjustment, replacement of individual parts, check lubrication, noise, safety and damage. Daily maintenance with the daily inspection, is a kind of equipment maintenance does not occupy a separate working hours. (2) the first level of maintenance
It is a form of indirect preventive maintenance based on regular inspection, supplemented by maintenance overhaul. Its main work is: check, clean, adjust the parts of the equipment; check the impeller of the sewage pump, sealing, centrifugal pump impeller, sealing, oiling; checking the distribution cabinet lines, dust, fastening; found that the failure of hidden dangers and anomalies, to be excluded, and exclude the leakage phenomenon, and so on. After the first level of maintenance equipment is required to achieve: clean and bright appearance; no dust; flexible operation, normal operation; safety protection, indicating that the instrumentation is complete and reliable. Maintenance personnel should be the main content of maintenance, maintenance process found and eliminated hidden dangers, abnormalities, test run results, operational performance, as well as the existence of problems to make a record. The first level of maintenance is based on the operator, professional maintenance personnel to cooperate and guide.
(3) the second level of maintenance
is to maintain the technical condition of the equipment is mainly in the form of overhaul, the workload of the second level of maintenance between the repair and repair part of the work, but also to complete a part of the repair, mainly for the wear and tear of vulnerable parts of the equipment and damage to repair or replacement. Secondary maintenance to complete all the work of the first level of maintenance, but also requires all lubrication parts of the cleaning, combined with the oil change cycle to check the lubricant quality, cleaning and oil change. Check the dynamic technical condition of the equipment and the main precision (noise, vibration, temperature rise, surface roughness, etc.), adjust the installation level, replace or repair parts, clean or replace the motor bearings, measure the insulation resistance and so on. After the second level of maintenance, the precision and performance are required to meet the process requirements, no oil leakage, gas leakage, electricity leakage, sound, vibration, pressure, temperature rise and so on in line with the standard. Before and after the second level of maintenance should be carried out before and after the equipment for dynamic and static technical condition determination, and carefully make maintenance records. The second level of maintenance to professional maintenance personnel, operators to participate. (4) the development of three-tier equipment maintenance system
In order to standardize the three-tier maintenance of equipment, should be based on the wear and tear of the parts of the equipment, performance, precision deterioration, as well as the likelihood of failure, etc., the development of the parts of the maintenance cycle, the maintenance of the content and maintenance of the type of schedule, as the basis for the maintenance of the operation of the equipment. Example of equipment maintenance program shown in Table 1, the table "Ο" indicates that the maintenance check. Due to the different cycles of maintenance categories and content is different, in practice, different symbols can be used to indicate different maintenance categories, such as "Ο" indicates routine maintenance, "△" indicates a level of maintenance, "◇" indicates secondary maintenance. " indicates that the second level of maintenance, etc. Table 1 mechanical equipment parts and components maintenance program example
Basic content of equipment maintenance
The basic content of equipment maintenance includes: equipment maintenance, equipment inspection and equipment repair. Details are as follows. First, equipment maintenance
Equipment maintenance is to keep equipment clean, neat, well-lubricated, safe operation, including timely fastening of loose fasteners, adjust the gap between the moving parts. In short, that is, "clean, lubricate, fasten, adjust, anti-corrosion" cross operation method. Practice has proved that the life of the equipment is largely determined by the maintenance of good and bad. Maintenance according to the size of the workload and the degree of difficulty is divided into routine maintenance, primary maintenance, secondary maintenance, tertiary maintenance.
Daily maintenance, also known as routine maintenance. Its main content is: cleaning, lubrication, fastening easy to loose parts, check the integrity of parts, components. This type of maintenance projects and parts are less, most of the external equipment.
The first level of maintenance, the main content is: general tightening, cleaning, lubrication, fastening, but also part of the adjustment. Daily maintenance and the first level of maintenance is generally undertaken by the operator.
Second-level maintenance. The main content includes internal cleaning, lubrication, partial disassembly inspection and adjustment.
Tertiary maintenance. Mainly on the main part of the equipment dismantling inspection and adjustment work, if necessary, to reach the prescribed wear limit of the parts to be replaced. In addition, the wear and tear of the main parts to measure, identify and record. Secondary maintenance, tertiary maintenance in the operation of workers to participate in, generally by full-time maintenance and repair workers.
In all types of maintenance, routine maintenance is the basis. Maintenance categories and content, to be specified for different equipment, not only to take into account the production process, structural complexity, scale and size of the equipment and other specific circumstances and features, while taking into account the long-term formation of maintenance habits within different industrial enterprises.
Two, equipment inspection
Equipment inspection, refers to the operation of the equipment, working accuracy, wear and tear or corrosion degree of measurement and calibration. Through the inspection to fully grasp the technical condition of machinery and equipment and wear and tear, timely identification and elimination of hidden equipment, purposefully do the preparatory work before repair, in order to improve the quality of repair, shorten the repair time.
Check the time interval is divided into daily inspection and regular inspection. Daily inspection by the equipment operator, with the daily maintenance combined, the purpose is to find abnormal technical conditions in a timely manner, to carry out the necessary maintenance work. Regular inspection is in accordance with the plan, under the participation of the operator, regularly by full-time maintenance workers. The purpose is to comprehensively and accurately grasp the actual situation of wear and tear of parts through inspection, in order to determine whether there is a need to carry out repairs.
Check by technical function, can be divided into function check and precision check. Functional inspection refers to the function of the equipment to check and determine, such as whether the oil leakage, water leakage, air leakage, dustproof sealing how, parts of high temperature, high speed, high pressure performance, etc.. Accuracy inspection refers to the actual processing accuracy of the equipment to check and determine the accuracy of the equipment in order to determine the degree of accuracy, acceptance, repair and update the equipment to provide a basis. Third, equipment repair
Equipment repair, refers to repair due to routine or abnormal causes of equipment damage and precision degradation. Through the repair and replacement of wear and tear, aging, corrosion of parts and components, can make the equipment performance is restored. Repair and maintenance of equipment is a different aspect of equipment maintenance, the two due to the difference between the content of the work and the role of the two can not replace each other, the two should be done at the same time, in order to cooperate with each other, complement each other.
1, the type of equipment repair. According to the size of the scope of repair, repair intervals, repair costs, equipment repair can be divided into small repairs, repairs and major repairs in three categories.
(1) small repairs. Small repairs usually only need to repair and replace part of the wear and tear faster and the use of the period equal to or less than the repair interval parts, adjust the local structure of the equipment to ensure that the equipment can operate normally to the planned repair time. Minor repairs are characterized by a high number of repairs, a small workload, a short repair time, and the cost of repairs is included in the cost of the property. Minor repairs are generally performed by full-time maintenance workers at the project.
(2) repair. Repair is part of the equipment disassembled, repair or replacement of some of the main parts and reference parts, or repair of the use of the period is equal to or less than the repair interval parts; at the same time to check the entire mechanical system, fasten all the parts, to eliminate the expansion of the gap, correct the equipment benchmarks to ensure that machinery and equipment can be restored and to meet the due standard and technical requirements. Repair is characterized by: more repairs, the workload is not very large, each repair time is shorter, repair costs are included in the maintenance fund costs. Most of the items in the repair by the project's full-time maintenance workers in the equipment site, the individual requirements of the project can be undertaken by professional outside the unit, after the repair should be organized to check the acceptance and for repair and repair unit handover procedures.
(3) major repair. Major repair refers to the replacement, restoration of its major components, restore the original accuracy of the equipment, performance and productivity and comprehensive repair. Overhaul is characterized by: fewer repairs, heavy workload, each repair time is longer, repair costs paid by the overhaul maintenance fund. Equipment overhaul, quality management and equipment management departments should be organized to use and repair units with the relevant personnel **** inspection and acceptance, after passing the repair unit and repair units for handover procedures. 2, the method of equipment repair
Commonly used equipment repair methods are mainly the following:
(1) standard repair method, also known as the mandatory repair method, refers to the service life of the equipment parts, the preparation of a specific repair plan in advance, specify the date of repair of the equipment, the category and content. Equipment operation to the specified period, regardless of its technical condition, whether good or bad, the task is light or heavy, must be in accordance with the provisions of the scope of operations and requirements for repair. This method is conducive to the repair of the preparatory work, effectively ensure the normal operation of the equipment, but sometimes cause excessive repair, increased repair costs.
(2) regular repair method, refers to the service life of the parts, production type, workpiece conditions and the relevant quota information, in advance, set out a fixed sequence of various types of planned repairs, planned repair intervals and their repair workload. Before the repair is usually based on the state of the equipment to determine the content of the repair. This method is conducive to good preparation for repair, is conducive to the use of advanced repair technology, reduce repair costs. (3) repair method after the inspection, is based on the wear and tear of equipment parts and components information, in advance, only the number of inspections and time, and each time the specific period of repair, type and content are determined by the results of the inspection. This method is simple and easy to implement, but due to poor repair planning, inspection may be due to the equipment condition of the subjective judgment error caused by excessive wear and tear of parts or failure.