A brief introduction to the preparation and implementation of major and medium repair plans for cement plant equipment

Yin Yugang

(Shaanxi Fuping Ecological Cement Co., Ltd.)

Introduction

The purpose of equipment overhaul is to carry out planned and periodic physical and technical compensation for equipment that has technical defects due to severe wear, corrosion, fatigue deformation and other reasons of equipment reference parts during long-term use, and has lost most of its main accuracy and performance, resulting in reduced equipment usage efficiency, so that it can meet or be close to the original design standards.

For cement plants, effective major and intermediate equipment overhauls (hereafter referred to as overhauls) can reduce or prevent equipment incidents, improve equipment operating rates and production efficiency, and reduce production costs. Overhaul plans should be based on actual equipment usage and the production schedule. Major overhauls are generally scheduled at the beginning of the year and kept within 20 days; intermediate overhauls are generally scheduled in the second half of the year and kept within 10 days. A preparatory meeting should be held 3 months before each annual major overhaul to compile, discuss, optimize and integrate maintenance projects across disciplines, including mechanical, electrical (including automation instruments), process engineering and construction machinery. Procurement plans for materials and spare parts with long delivery lead times should be submitted in advance.

One month before the kiln is shut down, the overhaul project will be re-examined and confirmed, adjustments will be made according to the actual situation, and the preparations for the overhaul will be inspected.

01 Preparation of overhaul plan

1.1 Basis for preparation of overhaul plan

1, equipment technical status information accumulated during daily inspections and periodic inspections of equipment;

2, equipment annual technical status survey data and equipment testing results (for example: oil product testing analysis, vibration analysis of large fans and host equipment bearings, motor online testing analysis, kiln barrel temperature monitoring results analysis, etc.);

3, equipment maintenance file information and equipment repair complexity coefficient;

4, technical transformation projects that need to be implemented during the overhaul period;

5, equipment maintenance cycle and next year’s production plan tasks and variety requirements;

6, safety and environmental protection requirements. According to national standards or relevant regulations, safety protection requirements for equipment and excessive emissions of gases, liquids, dust, etc.

1.2 Overhaul plan preparation content and requirements

1, the overhaul plan includes: preparation instructions, overhaul organization structure, overhaul work requirements, overhaul process management, quality acceptance and commissioning requirements, overhaul plan schedule, safety assurance plan, etc.;

2, the expected goals of the overhaul plan, mainly include the recovery degree of various technical parameters of the equipment, the reliability coefficient of each host equipment, actual values such as coal consumption, power consumption, station-hour output, continuous operation time, and the expected requirements to reach the target value after the overhaul;

3. In the preparation of the plan, it is necessary to determine the key maintenance items that are urgently needed for production and affect product quality, and single key equipment on the production line as the main line of maintenance work. The entire overhaul work should focus on the main line;

4. When preparing the overhaul plan, all aspects of resources must be fully considered, including: manpower, materials, tools, construction machinery, outsourced construction, etc.;

5. When preparing the overhaul plan, attention should be paid to the coordination and connection between different maintenance projects, and cross-operation projects should be reasonably arranged to avoid mutual interference and conflict;

6. When preparing an overhaul plan, it is necessary to prepare an overhaul project cost budget and estimate the costs of all aspects related to the overhaul, including spare parts, materials, labor, outsourcing, tools and construction machinery rental, etc.

02 Preparation for overhaul plan

2.1 Preparation for key maintenance projects

Maintenance specifications should be prepared for key maintenance items. The workload of key maintenance projects is large, the construction is difficult, and the composition of construction personnel is complex. These projects determine the overall progress of the entire overhaul and must be fully prepared in advance. Sufficient time must be left to inspect the equipment and order spare parts. If outsourcing is required, qualified contractors must be organized to bid.

2.2 personnel preparation

Based on the scope of the overhaul work and the skills of the required personnel, it is necessary to decide whether the enterprise will perform the maintenance itself or outsource the maintenance projects, organize the personnel and teams involved in the overhaul work, balance the personnel allocation of each project and profession, and ensure the construction progress and maintenance quality.

2.3 Preparation of spare parts and materials

According to the contents of the overhaul plan, formulate a plan for required materials and accessories, compare the inventory list, determine the items that need to be purchased additionally, and contact the supplier to confirm the arrival time. Especially for important spare parts with long delivery times, the lead time of arrival must be guaranteed. Relevant technical personnel must be organized in a timely manner to inspect and accept each batch of arriving materials and spare parts.

2.4 Tools and machinery preparation

Tools (such as jacks, chain hoists, torque wrenches, etc.), safety tools (seat belts, rope ladders, etc.), instruments, etc. required for overhaul must be inspected and maintained in advance and verified to be qualified. For equipment that you plan to rent, such as cranes, bricklaying machines, etc., you must contact us in advance to make arrangements.

2.5 technical requirements

Prepare corresponding equipment instructions, technical drawings, technical specifications and requirements for each maintenance project.

2.6 Preparation for logistics support

Participate in the shift arrangement of maintenance personnel, including rest, meals, bathing, transportation to and from get off work, transportation vehicles, medical kits and emergency first aid measures, etc.

03 Implementation of overhaul plan

1, overhaul must be carried out according to the division of labor and responsibilities of the personnel of the established organizational structure. The person in charge of the maintenance is fully responsible for the maintenance and is responsible for integrating all maintenance plans including mechanical, electrical, process, etc., and must communicate and understand major matters (such as shutdown and start-up dates, equipment maintenance time, work sequence, etc.) with the maintenance project leader and the outsourcing units participating in the maintenance in a timely and accurate manner to ensure smooth flow of information and orderly progress of work arrangements during the maintenance period.

2. The person in charge of each maintenance project should conduct pre-construction task clarification and safety technical training for the personnel participating in the maintenance, so that each personnel participating in the maintenance clearly understands the content of their work during the maintenance period, and ensures clear tasks and responsibilities.