I. Maintenance of production equipment.
1, strengthen the daily inspection management of equipment.
At the beginning of the year, according to the characteristics of scattered equipment and wide coverage, our workshop strengthened the daily inspection work and formulated a strict inspection system. Make the inspection route of inspection equipment, conduct daily inspection by personnel, conduct inspection and supervision by technicians and supervisors, and implement an effective reward and punishment system. In this way, the workshop staff can know the operation of the equipment like the back of their hands. When the equipment is overhauled, you can pay a return visit to the problematic equipment. This can not only save maintenance time, but also solve problems in a targeted manner and ensure maintenance quality. The electromechanical motive of j 103c3# powder exhauster in power workshop is to find abnormal bearing sound during inspection, and to carry out maintenance in time to eliminate hidden dangers. In the water supply and drainage workshop, 450- 1A, 450- 1C, 450- 1d and 450- 1e cooling tower fans found that the motor blades were broken during inspection, so they should be replaced in time to prevent the motor from overheating and burning.
2, focus on technical backbone to solve technical problems.
The plc control system of coal conveying belt in power workshop often has an emergency stop fault, and the control loop has been checked many times without results. In order to solve this problem, the workshop organized technicians to tackle key problems, and finally found out the problem through repeated experiments without coal. It turned out that the starting current of the crusher was too large, which affected the switching power supply of plc and led to the sudden power failure of plc. 1# After the frequency converter of the slag catcher is installed, the dcs can't adjust the speed, and the debugging personnel of the slag catcher manufacturer can't find out the problem. After our workshop learned the situation, we immediately arranged for the workshop technicians to go to the scene to solve the problem. Finally, it is found that several parameters of the inverter are set incorrectly and two external wires are missing. After these problems are solved, the slag scraper runs normally.
Second, the production equipment technical transformation project work.
In order to achieve production efficiency, the company has carried out many transformations on the first-phase production system. In these technical transformations, our workshop fully cooperated with the process to carry out electrical technical design and equipment installation. These technologies have successfully changed the design and installation of electrical components. Details are as follows:
1. Electrical control design and equipment installation of grey water filter pool in sewage treatment station.
2. Electrical device to improve the power of neutralization and submersible pump in desalted water station.
3. Modification of capacitor cabinet in low-voltage distribution room.
4, cooling tower fan motor blade transformation.
5. Renovation of lighting fan system in chlorine bottle room and gas bottle room of water supply and drainage in quality inspection center.
6, oxygen pump two inverter replacement, control circuit transformation.
7. Transformation of station control loop of P1605.
8. Install a new gas station at p 1605.
9. Reconstruction and installation of rainwater collection pump.
Electrical design and installation of 10 and 80 1 piston injection pumps.
1 1, 702, 802 tower lighting transformation.
12, electrical design of boiler secondary recovery water pump.
13. Electrical design and installation of sealing water recovery pump for gasification torch.
14. Electrical design of the lighting fan system of the slag stopper project.
15. Electrical cooperation of filter project.
16, electrical coordination of sulfur recovery project.
17. Electrical design of new fan and lighting for gasification.
Third, the annual overhaul work.
In order to improve the sense of responsibility of each employee and ensure the quality of maintenance, our workshop has implemented the work order responsibility system. Each Zhang Gong sheet records the contents of each job, the person who completed the job, the location of the fault, the completion, the person in charge of safety, etc. And also requires users to accept it. Archive the work order after acceptance, so as to check the quality problems in maintenance and punish the relevant responsible persons. This greatly enhances the responsibility of maintenance personnel and ensures the quality of maintenance. Electrical maintenance, safety is a big problem. Because there is a lot of work involved, in order to avoid sending electricity by mistake during power outage maintenance, our workshop has strict requirements for the team leader before maintenance. Stop sending, should strictly implement the operation ticket system, according to the rules of operation, to ensure the safety of maintenance personnel. After taking the above measures, with the joint efforts of the maintenance personnel in our workshop, the maintenance task was finally successfully completed with good quality and quantity, which made due contributions to the smooth completion of maintenance work. Overhaul * * * completed:
1, oxygen pump current transformer replacement; Replacement of main connector of part 307a; Power outage cleaning and fastening of each distribution room; All minor repairs of 10kv transformer; On-site distribution cabinet maintenance; 37 maintenance items such as motor junction box inspection in the whole plant.
2. 1 10kv regional equipment preventive test to protect the whole group calibration; 10kv equipment protection whole group calibration preventive test; There are 20 test items, such as grounding resistance test, DC system and communication system inspection.
Four, workshop maintenance, maintenance personnel training.
Our workshop has formulated a detailed employee on-the-job training system with corresponding assessment rules. Workshops often organize squad leaders and technicians to conduct spot checks on on-the-job training, and organize relevant technicians to give lectures to improve the theoretical and technical level of employees. Organize a team to simulate the operation of the motor control circuit, and the workshop technicians will artificially create faults for employees to find and improve the actual operation level.
Five, workshop equipment account management.
According to the requirements of the company and mobile management, our workshop has made detailed statistics on the electrical equipment of the whole company, as follows:
1, spare parts reserve quota statistics.
2. Cable factory fixed assets statistics, improve the fixed assets accounting.
3, XXX years overhaul plan, material plan.
4. Statistics of dynamic and static sealing points.
5. Equipment management account is perfect.
6. Elevator management system.
7, motor delivery repair system.
Six, there are still many problems in the management and maintenance of workshop equipment:
1, each workshop does not arrange designated personnel to handle the maintenance license. According to the regulations, the person in charge of maintenance should apply for a maintenance license, but for various reasons, it is often the chemical operator who handles the ticket.
2. At the end of maintenance, the maintenance supervisor did not hold a maintenance license when sending electricity. Because the ticket is handled by chemical operators, the maintenance license is usually lost when the shift is changed.
3. Workshop equipment management account needs to be further refined. The workshop will gradually improve and refine the equipment management account according to the requirements of mobile management.
4. There are still hidden dangers in site temporary line management. For example, temporary wires, such as lighting and electric welding machines, which need to be installed during on-site maintenance, are often removed without informing the electrical personnel after maintenance, and the electrical personnel do not know whether the on-site maintenance is over, so that the temporary wires are always charged at the site, forming hidden dangers.
Chapter 2: Summary of factory maintenance. The cadres and workers in the air separation workshop attach great importance to this maintenance. During the whole overhaul process, the air separation workshop adhered to the principle of safety first, strengthened the safety management during overhaul, improved the safety management level and the safety awareness of all employees, and created a good safety overhaul atmosphere. In the process of maintenance, maintenance personnel can conscientiously implement various safety management measures, standardize the safe operation at the maintenance site, and effectively ensure the safe and smooth completion of maintenance. During the maintenance period, the workshop strengthened the on-site safety inspection and monitoring of key maintenance projects, and supervised the maintenance projects to strictly abide by the requirements of various safety management systems and maintenance procedures. The safety work during maintenance is summarized as follows:
First, the safety preparation before maintenance.
1. Establish an organization and implement responsibilities step by step.
Before maintenance, the workshop set up a safety organization for equipment maintenance, and at the same time, it is required to implement the safety responsibility of each maintenance project step by step. In the maintenance project, it is necessary to clarify the main person in charge, the person in charge of safety and the on-site guardian, carefully decompose the safety responsibilities, and implement them step by step to form the maintenance responsibility system of "safety responsibility first". In order to make the safety work more fully prepared, the workshop safety management personnel go to the site to confirm one by one according to the maintenance items, and strictly formulate detailed and specific safety measures according to the specific conditions of each maintenance item, and take corresponding safety precautions. Focus on key maintenance projects and high-risk maintenance projects, and implement key supervision and monitoring.
2. Formulate various systems to provide system guarantee for safety maintenance.
Before the overhaul, the workshop held two mobilization meetings for the overhaul, at which the safety work during the overhaul was emphasized, and each overhaul project was decomposed one by one, and each overhaul project was set up with a safety guardian and an overhaul inspector, realizing closed-loop management. In order to ensure the safety and smooth progress of the whole overhaul process, the safety and environmental protection department of the company formulated and issued the Safety Management Regulations during Overhaul according to the actual situation, the inflammable, explosive, toxic and harmful characteristics of chemical production and the frequent experience of safety and environmental accidents in the overhaul process of chemical equipment, so as to ensure the safety of personnel. The safety of equipment and property, avoiding safety accidents during maintenance shutdown, put forward clear requirements for all links of maintenance, effectively strengthening all links.
3. Strengthen safety education and training to improve the safety quality of construction workers.
With the maintenance work in full swing, maintenance personnel and workshop personnel * * * enter the maintenance site together, as well as outsourced maintenance personnel. The situation of foreign maintenance personnel is complicated, with weak safety awareness and lack of safety concept. In order to ensure the operation safety during maintenance and prevent the occurrence of safety accidents, it is particularly important to do a good job in safety education and training for all maintenance personnel. The workshop overcame the limitation of educational venue conditions and adopted flexible education and training according to local conditions. In the process of education, the contents of safety management regulations during maintenance are emphasized, and the precautions for high-risk operations such as hot work, confined space operation and aerial work are emphatically explained.
Second, the safety management in maintenance.
1, strictly perform the examination and approval procedures for various tickets.
The confined space operation shall be checked and confirmed by the workshop safety officer before issuing the confined space operation certificate. Before hot work, the safety officer should go to the site to check whether the safety measures are qualified, and then issue a hot work permit. In this overhaul, * * * carried out 17 times of secondary hot work; 7 confined space operations; Working at high altitude for 6 times; "Three stresses and one implementation" activity record 2 1 time; Each assignment strictly implements the content of the "three stresses and one implementation" activity. All kinds of operation tickets have gone through the examination and approval procedures according to regulations, and all safety measures have been implemented, which provides a guarantee for safe maintenance.
2. Strengthen the safety inspection at the maintenance site.
During the maintenance period, the workshop overcame the difficulties of less personnel, large equipment, more work and heavy tasks, and focused on checking the implementation of safety protection measures for dangerous operations during the maintenance period; Check the implementation of safety management regulations during the maintenance of various maintenance projects on the construction site; Check the wearing conditions of labor protection articles of on-site maintenance personnel; Check the approval of various work permits; Keep abreast of the safety trends in maintenance and construction operations, discover and eliminate hidden dangers of accidents at the maintenance operation site in time, correct illegal operations in time, and prevent safety accidents.
3. Highlight key points and strengthen the monitoring of high-risk operations.
In many maintenance projects, the disassembly, reassembly and hoisting of liquid nitrogen pump have the characteristics of great maintenance difficulty, limited operation space and many dangerous factors. The workshop organized the workshop safety officer, process director and maintenance director to hold a special meeting on the spot to discuss the possible safety accidents during the operation, and required all departments to formulate corresponding safety protection measures and strictly implement the maintenance plan. The safety and environmental protection department of the company also sent special personnel to guide the work, ensuring the safety of key maintenance projects.
Third, the existing problems.
During this overhaul, the main problems exposed are:
1, the safety awareness of outsourced construction personnel is weak, the safety helmet is not standardized, the labor protection is untidy, there are potential safety hazards in the scaffolding for aerial work, the safety belt for suspended work is not tied with auxiliary ropes, and the safety guardian is not conscientious. Workshop safety personnel shall find and correct in time, and at the same time educate the person in charge and construction personnel of these projects.
2. Habitual violations occur from time to time in maintenance work, and the safety awareness of all staff needs to be further strengthened.
3. Every time the designated safety guardian is maintained, it is not serious enough.
The above security issues need to be improved in the next step of security management. We must always put safety first, strictly control safety, strengthen on-site supervision, and put safety precautions in place. Otherwise, any small matter is an unstable factor and will lead to accidents.
The safe and smooth completion of this overhaul is the result of the joint efforts of workshop leaders and all inspectors. In this overhaul, the safety management has made gratifying achievements and accumulated experience for the safety management of the device operation in the future. In the future, we will continue to tap the potential and explore bravely to make safety management work in by going up one flight of stairs.