Equipment Detection and Implementation Management

Fu Ning Peak Paper Co., Ltd. is one of the 100 large-scale papermaking enterprises in the country and mainly produces high-grade coated white paperboard. "Peak" brand coated white paperboard is a famous brand product in Hebei Province and has won the National Excellent Award; the equipment management has won the provincial B grade. Over the years, the company has paid close attention to equipment management and improved the economic efficiency of the company. In particular, in recent years, through the use of equipment detection methods, it has implemented forward-looking management to prevent problems, effectively reduced equipment failures and accidents, ensured the healthy operation of equipment, and enabled companies to develop steadily in the fierce market competition. .
Fault diagnosis technology of equipment is a technology to understand and master the state of the equipment in use, determine whether it is normal or not, identify faults and causes early, and can forecast the development trend of faults. It can achieve early detection, early treatment, prevent sudden failures and accidents caused by downtime, reduce parking time, so as to achieve the highest utilization rate of equipment, the lowest maintenance costs. Our knowledge of this technology stems from the detection of a steamer tank in a workshop. At that time, it was found that the rivets at the end plates of the both ends of the shaft head were leaking. The result of the emergency shutdown inspection was that there was wear on the internal side plate rivets. In order to obtain a more accurate diagnosis, the original equipment manufacturer technicians were further tested. The wall thickness of the tank was measured at multiple points using an ultrasonic thickness gauge. It was found that the original wall thickness was 16 mm, and the wall thickness of individual parts was reduced to a minimum due to wear. 5.5mm.
Because this tank is a pressure vessel equipment, the normal working pressure is 0.8MPa, and the current wall thickness can no longer meet the requirements for design and use. Therefore, the timely disposal of the waste is stopped and the detection is timely, preventing the occurrence of a major equipment accident. This shows that condition monitoring is an important guarantee for the normal operation of equipment.
In order to do a good job of this work, the company first improved the awareness of all employees on the use of equipment testing methods, organized equipment management personnel, maintenance personnel to learn equipment testing expertise; selected personnel to participate in the "equipment diagnosis technology and maintenance technology" training, the basic system of learning know how.
Secondly, according to the characteristics of the paper industry equipment, ultrasonic thickness gauges, surface roughness gauges, cloth hardness testers, rubber hardness testers, bearing fault detectors, fault sounding instruments, and infrared surface temperature detectors suitable for company use were selected. Arrange personnel to manage and use, and organize personnel to the instrument manufacturer to learn the operating principle and test experience of the instrument, so that the specialist can further master the knowledge learned and apply it to the actual work.
The third is to establish a testing system, and to implement a combination of regular inspections and irregular sampling tests and routine inspections, using different methods for testing by equipment and site by site. At the same time, regular comprehensive inspection systems are developed for large-scale equipment such as boilers, dryers, and various storage tanks; the surface temperature is monitored with a surface thermometer, and the internal structural changes or wear are analyzed according to the temperature changes. The surface roughness tester is used. The accuracy of the working surface is detected; the thickness and wear of the container are measured with a thickness gauge. Through the inspection of the key parts affecting product quality, such as the thickness, hardness, roughness and roll surface accuracy of the press roll, iron roll, stone roll, etc., it is possible to predict in advance, detect problems in advance, and effectively prevent equipment. The fault occurred.
In March 2002, 30 drying cylinders of No. 4 paper machine in No. 2 workshop were inspected, and it was found that the surface temperature of 7 cylinders was lower than the normal operating temperature. During the dismantling inspection using the process downtime, it was found that some of the drained siphon pipes in the dryer had been worn out and repaired in a timely manner to ensure the equipment output, increased thermal efficiency, and solved the problem of uneven paper drying, local warpage, and other paper diseases. The product's output and quality.
In February 2001, the 20-ton boiling furnace blower motor was inspected with a bearing fault diagnostic device. It was found that the bearing had abnormalities, and the bearing was inspected after shutdown. If it was not replaced in time, the motor would be burned out. This item reduces the loss by 3,000 yuan.
In Apr. 2002, the company's new 50,000-ton production line was equipped with φ1500 electroplating drying cylinders. When it was on site for acceptance before the manufacturer's delivery, the surface roughness tester was used to check the chrome plating accuracy of the dryer cylinders and found that 3 of them had Surface defects, which are manufacturing quality problems, have prevented the company from losing nearly 100,000 yuan in economic losses.
At present, condition monitoring has become the main method used by the company to guide production and improve product yield and quality in equipment management. By adopting equipment condition monitoring and strengthening foresight management, the company’s equipment management level has been continuously improved. The equipment failure downtime rate has dropped from 2% to 0.98%, and the main production equipment in good condition has increased from 95% to 98%. The maintenance costs have also dropped significantly, and the old equipment has played a greater efficiency, enabling companies to survive and develop in the market competition of their aging equipment and strong competitors.