How to perform "three no's" during minor maintenance work of the unit?

Maintenance construction management system

- Maintenance preparation work: In order to improve the quality of maintenance, ensure the progress of maintenance, and complete the maintenance tasks quickly and cost-effectively, the early stage of maintenance construction must be fully done Preparation. For maintenance projects that cannot be completed by oneself, such as equipment overhaul, we should contact the company in advance to complete the maintenance outsourcing work.

1. In order to complete special projects during overhaul, especially some major special projects, arrangements must be made in an early and planned manner, and preparations must be made in terms of materials and processes. Five months before the overhaul, the relevant majors should fill in the overhaul project form and submit it to the department leader for review. The review conclusion will be used as the basis for ordering;

2. Three months before the overhaul, the deputy manager of the Thermal Power Department Organize relevant professional inspections on preparations before overhaul, check the ordering and arrival of equipment, materials and spare parts, design, processing progress and technical and process preparations for major special projects, and implement them one by one to ensure they are achieved as scheduled;

3. 45 days before the overhaul, the maintenance supervisor will review the overhaul project form, fill in the overhaul material application form, and send it to the department leader for review and approval by the vice president in charge before submitting it to the warehousing department for purchasing materials.

2. Preparation of major equipment overhaul construction plan:

1. Main equipment overhaul construction plan shall be prepared by the maintenance technician 30 days before the start of work and submitted to the department manager for review. In the first 20 days, prepare the overhaul control progress and network diagram, coordinate the cooperation between various majors and outsourcing units, propose the overall requirements for the overhaul, and submit them to the department manager and the deputy general manager in charge for approval;

2. Main equipment minor repair construction plan , the maintenance technician will prepare a report 10-15 days before the start of work and report it to the department manager for review, in duplicate, with the department manager and supervisor each keeping one copy;

3. The main equipment overhaul construction plan includes maintenance items ( If the standard items have been ordered, there is no need to list the standard items). Construction progress, necessary technical measures and safety measures, quality standards, regulations on segmented acceptance project levels, specific requirements for seven supervisions, lifting and handling facilities and site layout, labor arrangements and organizational measures, labor, materials, costs, Plans, requests for cooperation from brother units, etc.;

4. Any special project involving equipment changes, such as equipment structure changes or system changes, should handle equipment change procedures according to the equipment change management system;

5. The main equipment overhaul construction plan shall not be changed casually after approval by the deputy general manager in charge. If changes are necessary, approval by the deputy general manager in charge is still required. 3. Technical briefing before construction. After the construction plan is prepared, learning must be organized so that each maintenance team and each maintenance worker must achieve the "Three Clarities" and "Eight Knows": clearly what to repair? Why repair? How to fix it? Eight Knows: Know the items that should be repaired and the equipment defects that should be eliminated; know the maintenance progress, know the materials and tools that should be prepared, know the relevant technical measures, know the quality standards and process methods, know the acceptance system, evaluation standards and acceptance persons , Know the relevant safety measures, know the original measurement records, how to use instruments and measuring tools, and how to read and write technical records. During the maintenance process, the supervisor will be responsible for any quality and safety problems that occur due to unfulfilled tasks. If the tasks are handed over but not implemented in accordance with the instructions, the specific maintenance personnel will be responsible.

4. Construction quality standards: The quality standards, process methods and acceptance regulations shall be implemented in accordance with the maintenance regulations. The professional shall outline the overall quality requirements for large and small equipment repairs before repairs, including the number of consecutive safe days after repairs. Output after repair, technical and economic indicators, major defects that should be eliminated after repair, etc., for inspection and assessment.

5. Inspection of construction preparations 1. Implementation and inspection of preparations for major equipment overhaul.

⑴. One month before the overhaul, the department manager will hold an overhaul preparation meeting to implement the overhaul projects, check the major technical measures, the implementation of the test projects of the entrusted overhaul, testing, and research units, the preparation and arrangement of main materials and spare parts, labor force, and the coordination between relevant departments. ⑵. Before the overhaul, the supervisor shall conduct a comprehensive inspection of the construction preparations of the contracting unit and each team in the department, such as pre-calibration of construction machinery, tools, safety equipment and facilities, measuring tools, measuring instruments, test equipment, etc. For inspection work, technical record forms should be prepared, and spare parts drawings that should be surveyed, mapped, and checked should be determined. If weak links are found, measures should be taken to remedy them quickly and reported to the leader; (3) About one week before the overhaul, the department manager will host various meetings Participate professionally in the overhaul preparation inspection meeting, listen to the report on the preparation work, and make evaluations and instructions on all aspects of the preparation work; (4) Four days before the overhaul, the maintenance supervisor organizes the relevant person in charge of the contracting unit and the personnel of the department to inspect the preparation work Execution status, readiness, and completion of the commencement report. Two days before the overhaul, the vice president in charge approved the official start of construction after deeming that the conditions were met based on the inspection results of all aspects of the preparation work. 2. Preparations for minor repairs of main equipment or overhaul of major auxiliary machines can only be started after being inspected by the maintenance supervisor.

6. Other preparatory work before construction: 1. The thermal test should be carried out before the overhaul starts, and all necessary characteristic data should be measured to determine the technical status of the equipment before repair and facilitate the analysis of the maintenance effect; 2 . According to the technical requirements, materials, spare parts and accessories are transported to the site. The quality and performance have passed the acceptance inspection and the warranty certificate is complete; 3. Before starting work, operational analysis should be strengthened. Each professional supervisor should organize equipment owners and full-time technical personnel to conduct an in-depth and detailed equipment inspection. Conduct on-site inspections to review the technical status of equipment as a reference for maintenance.

7. Maintenance stage (process) management. The construction period is a stage where maintenance activities are highly concentrated. 1. Before the maintenance starts, the following work should be done: ⑴. Do a good job in organizing the maintenance personnel, and implement the maintenance projects, labor quotas, and planned construction periods to the team, down to the group and individual; ⑵. Organize the study of safety regulations and maintenance processes Regulations, "Quality Standards" equipment manufacturing drawings, relevant construction drawings, overhaul construction management operation books, etc.; (3) Prepare the maintenance work site, special maintenance machinery, insulation equipment, hoisting machinery, and electric welding machines and put them in place, and conduct necessary inspections. , test (trial transfer), prepare lighting and construction power supply; ⑷, prepare necessary materials, equipment and spare parts for maintenance, and do the final acceptance work to confirm compliance; ⑸, equipment maintenance original record card, acceptance visa, etc. Be ready; ⑹. Clean the site carefully to ensure that there is no garbage, no debris, and no coal powder.

2. Maintenance management during the disassembly stage: (1) Equipment disassembly inspection should be carried out as early as possible, and changes in the technical status of the equipment should be analyzed in a timely manner. The disassembly inspection should be serious, careful and comprehensive, and no items should be missed. If problems are found, they should be Find out the reasons and make original records of disassembly measurements; (2) Hold professional disassembly analysis meetings and formulate repair and adjustment plans.

3. Inspection and management of the repair and adjustment stages: (1) The repair and adjustment stage is an important stage of maintenance quality management. Quality standards should be strictly adhered to for repairs and adjustments, intermediate quality acceptance should be carried out in a timely manner, and necessary Conduct random inspections and complete the acceptance visa procedures in a timely manner; ⑵. Maintenance personnel must adhere to the policy of quality first. When there is a conflict between progress, funding, etc. and quality, quality requirements should be obeyed and strict workmanship should be adhered to; (3) Strictly implement process regulations, repair carefully, and inspect carefully to ensure the quality of maintenance.

4. Maintenance management during the assembly and restoration stage: ∴, strictly prevent tools, workpieces and other debris from being left inside the equipment; ⑵, the assembly and restoration process must be rigorous, especially to prevent quality rework due to sloppy work; ⑶. Do not miss out on assembly and restoration parts, and complete the signs, instructions, signals, numbers, etc.; ⑷. Do a good job of trial rotation and necessary testing of the auxiliary engine section. All majors are required to actively cooperate and fill out the "Trial Transfer Application Form" in a timely manner. Make sure that the work has been completed before countersigning; ⑸. Make necessary preparations for testing, tuning, etc. when starting the whole machine in a timely manner.

5. Technical records should be strengthened to be correct, complete, timely, and clearly written. The situation must be truthfully reflected. The record content should include equipment technical status, system or structure changes, measurement and test data, etc. They are all signed by relevant personnel, and the as-built drawings of the thermal and electrical secondary systems must be completed.

6. Requirements for maintenance work style: Strictly implement maintenance quality standards, conscientiously abide by disassembly and assembly process procedures, and achieve "three noes, three qi, three no chaos, and ten rectifications."

"Three Nos": refers to "no oil stains, no water, and no ash" during maintenance operations. Three Qi: refers to "the disassembled parts are neatly stacked, the maintenance machines are neatly placed, and the materials and equipment are neatly stacked" at the maintenance site. Three Nos: It means that cables are not pulled randomly at the maintenance site, pipes are not left lying around, and garbage is not thrown away. Ten rectifications: refers to the ten key points in rectifying the maintenance process style. ⑴. The oil system maintenance must not leak oil or vibrate (no obvious vibration phenomenon). ); ⑵. Maintenance of valves ensures that there is no leakage inside and outside, the switch is not sluggish, and the opening indication is consistent with the actual situation; ⑶. Maintenance of electrical switches ensures good contact, correct action, and qualified insulation; ⑷. Arrange pipelines so that they are arranged horizontally and vertically. The support intervals along the slope meet the requirements, and the paint color (thermal insulation) insulation meets the requirements; ⑸. The maintenance of rotating machinery does not leak oil, the vibration meets the standards, and there is no abnormal sound or heating; ⑹ Precision instruments, measuring tools and processed parts must be kept Do not take it indiscriminately, do not use it indiscriminately, and do not place it indiscriminately; 7. When disassembling and assembling flange screws, the disassembly and assembly must be symmetrical, the force distance must be controlled, and the exposed teeth must be consistent; 8. When lifting, do the "three don'ts": the lifting capacity is unclear No lifting, no lifting if the safety factor of the rope is not enough, no lifting if the edges and corners of the objects to be lifted are not wrapped properly; ⑼. Welders will not weld if the material process is unclear, no welding if the joint cleaning does not meet the requirements, and no welding if the test fails; ⑽. The "four essentials" of insulation must be met. The insulation performance must be qualified, the internal and external quality must be good, oil-proof measures must be taken near the bearings, and all insulation iron sheets must be reinstalled.

7. After the overhaul is started, it should be done as soon as possible. Do a good job in the disassembly inspection of the equipment and analyze the changes in the technical condition of the equipment. The disassembly inspection must be serious, careful and comprehensive, and no inspections can be missed. If problems are found, the causes must also be identified. Professional supervisors and full-time technicians must go to the site to find out the details and report After inspection and analysis, a dismantling meeting will be held in a timely manner. The supervisor and full-time technical personnel will review and adjust the maintenance items based on the actual situation of the equipment, implement the maintenance methods, processes and progress, and then report to the leader in charge for approval before dismantling the equipment. For major problems discovered later or during the seven supervisions, the manager of the Thermal Power Department should organize relevant personnel to conduct on-site inspections and determine countermeasures; 8. Scheduling and balancing meetings: ⑴. During the maintenance process, the Thermal Power Department should hold regular scheduling and balancing meetings to keep abreast of the construction quality and progress. , take corresponding measures in a timely manner, organize the process reasonably, and do a good job of balanced dispatching of labor, special types of work, repair and processing, department projects, construction machinery, materials and spare parts supply, etc. The person in charge and technical personnel of the contracting unit and the company's relevant professionals personnel to participate. The meeting should be concise and concise, with the whole body first and then the department. The meeting time is generally no more than two hours; ⑵. The maintenance supervisor should directly control the key items that affect the quality, control progress and the entire project, analyze the completion status day by day, and take necessary measures. Measures to ensure quality and progress are implemented through dispatch meetings at all levels; ⑶. All professional supervisors and full-time technical personnel should conduct in-depth team inspections. During the maintenance period, a meeting with the squad leader or work leader should be held regularly every day to systematically summarize the day's maintenance. situation, solve the balance of specific progress, labor force, and equipment, put forward quality and safety requirements, arrange key projects, check technical records, understand and coordinate the collaborative relationship between the construction unit and the department and between teams, etc.; ⑷. Each maintenance team, team The team leader will preside over the pre-shift and post-shift meetings. The pre-shift meeting will assign tasks for the day, convey instructions from superiors, put forward key requirements and safety precautions, etc. The post-shift meeting will understand and summarize the day's maintenance tasks and safety plans and compare them with the maintenance plan to solve existing problems.

9. Maintenance record work: ⑴. Maintenance record is the technical original data of the status of the equipment before and after maintenance, and the test results of the maintenance. Through the analysis of maintenance, the wear rate and replacement cycle of equipment parts can be obtained, which is conducive to understanding the condition of the equipment. Through analysis and research, defects in structural materials can be discovered, so that improvement measures can be made. The maintenance records can be used as technical files for the equipment ledger. Accumulating data, working hours, and equipment consumption records is the basic data for improving technical management and doing economic accounting. For this reason, maintenance records must be carefully, accurately and comprehensively kept. ⑵. Classification of maintenance records: ①. Administrative records: including clearances, dimensions, technical conditions, maintenance processes, methods, components, test identification results, equipment structure, system changes, etc. before and after repair; ②. Administrative records : Such as tool records, shift handover records, steam drum entry and exit registration, etc.; ③. Economic accounting records: such as records of man-hours, materials, expenses, repairs and waste, savings for use, etc. consumed by each project.

⑶. The person in charge of the work is responsible for the maintenance records of the work, ensuring that they are correct and used as technical data for acceptance; ⑷. The squad leader and team technicians are responsible for the review of the maintenance records of the whole class. They should arrange retesting of important technical data and review the work. The general data measured by the person in charge should also be sampled and retested to further improve the quality of the data. The team technician is responsible for the retesting, sorting, and registration of various maintenance records within the class; ⑸. The various types of maintenance records that have been sorted should be divided into sections. The day before acceptance, it must be submitted to the person in charge of acceptance for review. The cover cylinder must be submitted for review twenty-four hours before. The original records must be left in the class. Some copies must be made in triplicate based on the opinions of the person in charge of acceptance as an attachment to the acceptance visa; ⑹, Technical records are kept by the supervisor, summarized and sorted by professional and full-time technical personnel, and the rough ones are removed and the fine ones are written into the overhaul summary attachment. Administrative records are kept by the maintenance team themselves, and relevant economic accounting records are kept at two intervals; ⑺. Professional form record cards should be used for various types of maintenance records, which should be clean and complete. The record content should comply with the requirements of the form and should not be altered or messed up in the record book. Painting; 9. Maintenance records are one of the main contents of shift handover; 10. Technical personnel should regularly or irregularly check the correctness and completeness of various maintenance records, and analyze the data at any time to detect abnormalities and handle them in a timely manner.

10. Maintenance personnel must adhere to the principle of "quality first", adhere to a strict workmanship style, strictly implement process procedures, carefully inspect, carefully measure, carefully repair and debug, and ensure the quality of maintenance. The process must serve the next process. If the quality of the previous process is not up to standard, the next process should be rejected to ensure quality;

11. Technical supervision projects must be carried out seriously, and professionals must support each other and work together in unity , providing convenient and timely sampling for analysis or testing. For equipment defects or problems discovered during the supervision project, technical supervisors must promptly report to the leadership to make judgments on the equipment status and put forward requirements and suggestions;

12. Electrical safety must be conscientiously implemented throughout the entire maintenance process Work procedures to prevent personal and equipment accidents. During the disassembly and installation stages, tools and other debris must be strictly prevented from falling inside the equipment. If they accidentally fall into the equipment, report to the workshop leader in time to take measures.

13. Strengthen on-site parts management: ⑴. Small parts removed during maintenance, such as screws, pins, etc., should be stored in special boxes according to type and specification. Some should be labeled to prevent incorrect installation; ⑵. The removed parts should be counted, wiped clean, and stacked neatly. If the quantity is found to be inconsistent, the reasons must be identified; ⑶ For precision parts such as gears and bearings , bearings, speed-regulating structures, etc. should be covered with white cloth and placed in boxes if possible; ⑷. Removed large parts should be neatly stored in pre-designated locations; ⑸. When new parts need to be added, they should be added through The squad leader should find out the reason for the supplement and verify that the specifications and materials of the new parts are consistent with the original parts; ⑹. Old parts that are replaced or removed should generally be disposed of in a timely manner. Extra large parts, such as primary air elbows and burners , large valves will be processed regularly after the maintenance is completed; ⑺. Equipment, pipelines, etc. that need to be opened during maintenance must be blocked with special blocking boards or wooden plugs. Some open parts must be covered and tied with white cloth, and taped Seal it to prevent debris from falling in.

14. Tool management at the maintenance site: ∴. Before finishing work every day or at the end of a certain work, tools should be counted; ⑵. Public tools such as electric drills, portable grinding wheels, portable light transformers, blowtorches, ladders, and sledgehammers etc., should be designated for safekeeping. When borrowing, registration procedures must be completed and returned immediately after use; (3) When entering the interior of the container to work, the tools brought in should be registered in time and checked after the work is completed. If they are found to be missing and cannot be checked, When it is cleared, it should be reported immediately to the squad leader to discuss and deal with it.

15. During maintenance, we must strengthen civilized production, clean up debris in a timely manner, keep parts neatly placed, keep the site clean, and work hard to eliminate "seven leaks";

16. End of maintenance Excess equipment must be removed and the site must be cleared of materials after work is completed.