Definition of equipment spot check

In order to maintain the original performance of production equipment, through the five senses (sight, hearing, smell, taste and touch) or simple tools and instruments, the process of preventive and careful inspection of designated parts (points) on the equipment is carried out according to the preset period and method, so that the hidden dangers and defects of the equipment can be found, prevented and treated early. This kind of equipment inspection is called spot inspection.

"Five Fixed" Contents of Equipment Spot Inspection Work

(1) Fixed point-Set the location, items and contents of the inspection;

(2) Determine the method-fixed-point inspection method, whether to use five senses or tools and instruments;

(3) calibration-establishing maintenance standards;

(4) regularly set the inspection cycle;

(5) Personnel-Determine who will perform routine inspection items.

Classification and division of labor of spot checks

(1) Routine inspection on a periodic basis:

(a) Daily spot check-conducted by post operators or post maintenance workers.

(b) Short-term spot checks-conducted by full-time spot checks.

(c) Long-period spot check-proposed by full-time spot check personnel and entrusted to the maintenance department for implementation.

(d) Precision spot check-proposed by full-time spot check personnel and entrusted to the technical department or maintenance department for implementation.

(e) Focus spot check-when the equipment is in doubt, take it apart for inspection or precision spot check.

(2) According to the division of labor:

(a) Operation inspection-conducted by post operators.

(b) Professional spot check-conducted by professional spot check and maintenance personnel.

(3) According to the method of spot check.

(a) disintegration inspection.

(b) routine inspections will not be dismantled.

Main contents of daily inspection work

(1) Equipment inspection-five senses (sight, hearing, smell, taste and touch) inspection;

(2) Minor repairs-repair and replacement of small parts;

(3) Fastening and adjustment-fastening and adjustment of springs, belts, bolts, brakes and stoppers;

(4) Cleaning-cleaning of tunnels, ditches, working tables and equipment without disassembly;

(5) Grease supply-oiling of the oil supply device and oiling of the oil supply part;

(1) drainage-drainage of steam drum and gas storage tank;

(2) Use records-record the contents of spot checks and inspection results.

Contents of regular spot checks

(1) Regular inspection of equipment without disassembly;

(2) Equipment disintegration inspection;

(3) Deterioration trend test;

(4) Equipment accuracy test;

(5) Check and adjust the accuracy of the system;

(6) Regularly analyze, replace and add the components of oil tank grease;

(7) Replacement of other parts and repair of damaged parts.

Inspection business and responsibilities of full-time inspectors

(1) Formulate basic data such as routine inspection standard, grease supply standard, part code, standard working hour quota, etc.

(2) Prepare various plans and performance records.

(3) Earnestly carry out the spot check operation as planned, guide the spot check maintenance business for the post operators or operators, and have the right to supervise and inspect. If there is any problem, find out the situation and deal with it in time.

(4) Prepare the maintenance project schedule and list the monthly maintenance project plan.

(5) According to the inspection results and maintenance needs, prepare the cost budget plan and use it.

(6) According to the expected use plan and maintenance plan of spare parts, prepare the maintenance material demand plan and material requisition.

(7) Collect equipment status information, conduct trend management and quantitative analysis, and master the deterioration degree of parts.

(8) Participate in accident analysis and handling, and put forward suggestions for repairing, preventing and improving equipment performance.

(3) Provide maintenance records, analyze the performance of related faults, maintenance and expenses, and put forward countermeasures and suggestions for improving equipment.

(10) Participate in the precision spot check.

Four links of spot check management

(1) Formulate the routine inspection standard and routine inspection plan (P).

(2) Carry out the spot check maintenance project (d) according to the plan and standards.

(3) Check the implementation results and conduct performance analysis (c).

(4) Make measures on the basis of performance inspection and analysis, and improve (a) independently.

Definition of precision spot check

Use precision instruments to conduct a comprehensive test and investigation of the equipment, or apply diagnostic technology without disassembly, that is, use special instruments, tools or special methods to measure the physical quantities such as vibration, wear, stress, temperature rise, current and voltage of the equipment, and quantitatively determine the technical status and deterioration trend of the equipment through the analysis and comparison of the measured data, so as to judge the necessity of its repair and adjustment.

Definition of deterioration trend management

In order to master the degree of deterioration tendency and the changing trend of loss of target equipment, it is necessary to observe its fault parameters, measure the deterioration amount regularly, manage the quantitative data of equipment deterioration, analyze the causes and parts of deterioration, so as to control the deterioration tendency of target equipment, predict its service life and carry out maintenance most economically.

Implementation steps of deterioration trend management

(1) Determine the project-that is, select the target equipment that tends to be managed and manage the project;

(2) Making a plan-designing and compiling a trend management chart;

(3) Implementation and recording-recording measurement data and drawing trend management curve;

(4) Analysis and countermeasures-make statistical analysis, find out the deterioration law, predict the replacement and repair cycle, and put forward improvement countermeasures.

Ten elements of routine inspection (routine inspection content)

(1) pressure; (2) temperature; (3) flow; (4) leakage; (5) the status of fat feeding; (6) Different voices; (7) vibration; (8) Cracking (breakage); (9) wear and tear; (10) Relax.

Factors that determine the inspection period.

(1) Equipment operating rate;

(2) Equipment use conditions;

(3) Environmental conditions (temperature, humidity, dust, etc. );

(4) Lubrication condition;

(5) the degree of influence on production;

(6) Using the actual performance value;

(7) Manufacturer's recommended value.

Main detection methods of precision spot inspection

(1) NDT-used to detect defects and cracks of parts;

(2) Measurement of vibration and noise-mainly used for periodic measurement of unbalance, shaft misalignment and bearing wear of high-speed rotating machinery;

(3) Ferrography and spectral analysis-used to measure and analyze the quantity, size and shape of metal powder in lubricating oil regularly;

(4) Oil sample analysis-used to analyze the deterioration degree of lubricating oil, hydraulic oil and transformer oil;

(5) Stress, torque and torsional vibration testing-used for transmission shafts, pressure vessels, crane beams, etc.

(6) Surface non-disintegration detection-For the parts that cannot be detected by general tools, special technology and special instruments are used for detection;

(7) Relay protection and fault safety test-used for periodic protection test of transformers, motors, switches and cables;

(8) Switch test-contact resistance test of ——SF6 and other switches;

(9) Electrical system test-including SCR leakage test, transmission protection test, transmission system contact pulse and characteristic test, etc.