Cement production line machinery and equipment daily maintenance and repair program

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Cement production line machinery and equipment daily maintenance and repair program

IF you need detailed guide for Kiln Maintenance & other Useful books and excel sheets and notes kindly click here 


IF you need detailed guide for Kiln Maintenance & other Useful books and excel sheets and notes kindly click here 

cement production line machinery and equipment daily maintenance and repair program – cement machinery inspection, cement machinery equipment maintenance work includes: cement production line machinery and equipment daily maintenance (one insurance), cement plant machinery Lubrication of equipment and regular oil and oil change, preventive test of cement equipment, regular adjustment of mechanical equipment of cement plant and second and third grade maintenance of cement equipment, regular inspection of cement machinery, precision inspection, daily maintenance

The correct use and maintenance of machinery and equipment in cement production line is an important part of the equipment management of cement plants . It is a series of maintenance work by the operators and professionals based on the technical data and parameter requirements and maintenance rules of the equipment. It is also the equipment itself. The objective requirements of the sport.

Maintenance and repair work of cement equipment includes: daily maintenance (one guarantee), lubrication of equipment and regular oil change, preventive test, regular adjustment accuracy and second and third level maintenance of equipment. The maintenance and maintenance of the equipment directly affects the operation of the equipment, the quality of the products and the production efficiency of the enterprise.

(1) Inspection of cement equipment

Equipment inspection is an effective means to timely grasp the technical status of equipment, implement equipment condition monitoring and maintenance, and is the basic work of maintenance. It is a heavy burden to maintain the normal operation of equipment by checking and eliminating hidden dangers of equipment and preventing sudden failures and accidents. working.

1, daily inspection (daily inspection)

The daily inspection is the operation of the workers according to the prescribed standards, based on the sense of five senses, to check the technical status of various parts of the equipment, in order to find the trap in time, take countermeasures, and minimize the loss of downtime. For key equipment, each shift or a certain period of time is checked and recorded by the operator according to the equipment check card. During the inspection, the maintenance personnel shall promptly and effectively eliminate the abnormalities recorded by the inspection card to ensure that the equipment is in good working condition.

2, regular inspection

According to the specified inspection cycle, the maintenance personnel will conduct a comprehensive inspection and measurement of the equipment performance and amateur degree. If the problem can be solved at the time, the inspection result will be carefully recorded as the basis for future decision on the equipment maintenance plan.

3, precision check

This is the measurement, analysis and adjustment of the geometric accuracy, machining accuracy and installation level of the equipment. This work is carried out by a full-time inspector as planned. The purpose is to determine the actual scent of the equipment and provide a reference for equipment adjustment, repair, acceptance and scrapping.

Carrying out various inspections on cement machinery and equipment and accurately recording the status information of the equipment can provide reliable basis and maintenance cost for future maintenance.

(2) Daily maintenance

The daily maintenance of cement machinery and equipment can be summarized into eight words – neat, clean, lubricated and safe.

1. Neat: tools, workpieces, and accessories are placed neatly; safety equipment is complete; line piping is safe and complete.

2, clean: clean inside and outside the equipment; all sliding surfaces, screw, rack, gear, handle hand wheel and other oil stains, no damage; all parts do not leak oil, water leakage, iron scrap garbage cleaning.

3, Lubrication: Timing quantitative oil change, oil quality meets the requirements, oil can, oil gun, oil cup is complete; oil standard, oil line, oil scraper keep clean, oil flow is smooth.

4. Safety: Implement the system of fixed person, fixed machine, voucher operation and handover; familiar with the structure of the equipment, obey the rules of operation, rational use, meticulous maintenance, safety and no accidents.

(3) Secondary maintenance

This level of maintenance is based on operational work and maintenance work. The maintenance cycle can be determined according to the working environment and working conditions of the equipment. For example, the gold cutting machine can be set to 400~600 operating hours, and the stopping time and maintenance working time can be calculated according to the 0.5 leaflet per complex factor of the equipment.

1, secondary maintenance content

(1) According to the use of cement machinery and equipment, disassemble, clean and adjust some parts and replace individual wearing parts;

(2) Thoroughly clean the inside and outside of the equipment, go to “Yellow Robe” and dirt;

(3) Inspect and clean the lubricating oil circuit, clean the oil scraper, oil line and oil filter, add lubricating oil as appropriate, and check the oiling condition of the sliding surface;

(4) Appropriate adjustment of the matching surfaces of the moving surfaces of the equipment;

(5) Clean the electrical box (electrician coordination) and electrical equipment to ensure that the line is fixed and safe and secure;

(6) Cleaning equipment accessories and cooling system;

2, maintenance standards

After the secondary maintenance, it can be cleaned inside and outside the equipment, showing the true color; the oil passage is smooth, the oil mark is bright, the oil level is clearly visible; the operation is flexible and the operation is normal. After the maintenance is completed, a special person is responsible for the acceptance, and carefully fill out the maintenance completion record.

Second, equipment repair

Cement machinery and equipment in the process of transportation, due to the wear, corrosion, burning, deformation and other defaults of certain parts, affecting the accuracy, performance and production efficiency of the equipment, correct operation and careful maintenance can reduce damage and extend The service life of the equipment, but the equipment will wear and damage after all, this is an objective law. Therefore, in addition to proper use and maintenance, it is necessary to replace, repair or improve the parts worn by the cement machinery , arrange necessary maintenance plans to restore the accuracy and performance of the equipment, preserve the quality of the certified products and play the equipment. Performance.

(1) Equipment maintenance method

1. Preventive maintenance: In order to prevent deterioration of equipment performance or reduce the probability of equipment failure, maintenance activities are carried out according to pre-specified plans and technical conditions. From the standpoint of preventing “medical”, according to the frequent inspection records or operation of the equipment, there are signs that the quality and production efficiency of the main product are abnormal, and preventive repairs are made before the equipment fails. Preventive maintenance is usually planned according to the actual operation of the equipment.

2, fault repair: unplanned maintenance taken when equipment failure or performance degradation, also known as after-the-fact maintenance.

3. Production maintenance: The maintenance method for improving the production efficiency of cement machinery equipment from the economic benefit , it is treated according to the influence of equipment on production. Unimportant equipment is repaired after the event, and key equipment is used for preventive maintenance.

4. Predictive maintenance: According to the information provided by the state monitoring and diagnostic technology, necessary and appropriate maintenance is performed before the failure occurs, also called condition monitoring and maintenance.

5, in addition to the above several maintenance methods, there are ways to improve maintenance, regular maintenance and no maintenance design.

(2) Significance of preventive maintenance

Preventive maintenance of cement machinery and equipment, prevent accidents, and grasp the wear and tear of the equipment, there are plans to carry out periodic maintenance and repair, is an important guarantee to maintain the normal operation of the equipment and maximize its function.

Planned preventive maintenance is an important part of equipment management work, and is also an integral part of the company’s production, technology, and financial planning. Correct and realistic pre-repair plans can be used to arrange human and material resources and prepare for pre-repair work. Equipment downtime, reduce repair costs, can not only repair equipment on time, but also plan and rhythmically arrange production, to achieve production and maintenance errors.

(ii) Main categories of repairs

1, three-level maintenance (also known as minor repairs)

Minor repairs are regular maintenance work performed by maintenance workers. Partial disassembly, cleaning and repair of the equipment, replacement or repair of severely worn parts, restoring part of the precision of the equipment to meet the process requirements.

The maintenance interval of metal cutting equipment is generally 2500~3000 operating hours. The main contents are:

(1) Replace parts in the equipment that are fast to wear, fast in corrosion, and fast in burning;

(2) Clean some equipment parts and remove the enlarged problems that can be adjusted. Fasten the wedges and screws in the mechanism;

(3) Replace the grease according to the specified period;

(4) Measure and correct the main precision of the equipment and the wear, burning deformation and corrosion of some parts.

2. Targeted repairs (also known as items)

Partial repair of one or several items of equipment under the premise of meeting the process requirements for the structure and use characteristics of the equipment and existing problems. The workload is equivalent to 20% to 70% of equipment overhaul.

Modern cement machinery equipment maintenance and management equipment is one of the three elements of productivity. It is the material management of equipment for social production. It has a decisive influence on the economic and technical indicators such as the quantity, quality and cost of enterprise products. Therefore, it must be strict. In accordance with the operating rules of the equipment, the correct use of the equipment, careful maintenance, scientific maintenance, and efforts to improve the equipment integrity rate, the establishment of the following equipment maintenance system: 
First, the operator and maintenance (inspection) repair personnel should be the master Attitude, do the right use, meticulous maintenance, maintain the equipment with a serious attitude and scientific methods, adhere to the maintenance and overhaul, and strictly implement the post responsibility system based on the principle of maintaining the expansion, implement the equipment package mechanism, and ensure the equipment in use. intact 
Second, the operator of the equipment used by job training and learning technology, “four know, three will be” (to understand the structure and understand performance, understand the purpose; full use, will be maintenance, will be troubleshooting), and Enjoy “three rights”, namely: the right to stop the use of self-operated equipment by others; no precautions have been taken Without the approval of the subject-object division overload devices, have the right to stop using the equipment is found not functioning properly, not extended maintenance, safety device does not meet the requirements should be reported immediately, if not dealt with immediately and take corresponding measures, the right to stop the use of 
three operating Personnel must do the following major tasks: 
(1) Proper use of cement machinery and equipment, strict observance of operating procedures, careful preparation before starting, repeated inspections during start-up, proper handling after parking, good adjustment during operation, and conscientious implementation of operational indicators Excessive temperature, overpressure, overspeed, and overload operation are not allowed.
(2) Carefully maintain and strictly implement the patrol inspection system, use the “five-word operation method” (listening, wiping, smelling, watching, and comparing), holding the “three-piece treasure” (boarder, stethoscope, rag) and regularly checking the route. Carefully inspect the equipment, find problems, solve them in time, eliminate hidden dangers, and clean, lubricate, tighten, adjust and anti-corrode equipment (ie, “cross-operation method” to keep parts, accessories and tools intact. 
(3) Master equipment failure. Prevention, judgment and emergency treatment measures, keeping the safety protection device intact and easy to use 
(4) The cement machinery equipment is planned to operate, and it is regularly switched to cooperate with the maintenance personnel to carry out maintenance work of the equipment, so that it is always in good condition and can be started at any time. For spare equipment, it is necessary to regularly drive the car, do a good job of antifreeze, anti-condensation, etc. 
(5) Carefully fill in the equipment operation record, defect record, and operation diary 
(6) often keep the equipment and environment clean and hygienic, so that the ditch bottoms, the shaft see the light, to see the true nature of equipment, glass doors and windows net 
Fourth, improve equipment lubrication strict implementation of petrochemical equipment lubrication management system, adhere to the “five Set “,” “three-level filtration” (five fixed: fixed point, timing, qualitative, quantitative, fixed person; three-stage filtration: from the oil vat to the post oil storage barrel, the post oil storage barrel to the oil pot, the oil pot to Refueling point) Regularly clean and change oil parts and fuel tanks

3, the machine overhaul

This is the most expensive way to repair. Complete overhaul equipment, repair the reference parts, replace or repair all damaged parts, comprehensively remove defects, restore the original accuracy, performance, efficiency, meet the factory standards or meet the requirements of the process requirements.

When overhauling cement machinery and equipment, it should be combined with technical transformation to improve the accuracy and performance of the original equipment.

In addition to the above types of maintenance, there are regular cleaning and oil change, pre-repair inspection and maintenance methods such as power running equipment and preventive testing, seasonal technical maintenance to ensure the normal operation of different types of equipment.

4. Acceptance criteria

The acceptance criteria of overhaul can be divided into three categories: acceptance accuracy, relevant accuracy, and irrelevant accuracy. The acceptance accuracy is the accuracy of the restored part in the repair, and must meet the factory standard; the relevant accuracy is not lower than the pre-repair accuracy; Accuracy is not checked.

In modern industrial enterprises, equipment reflects the degree of modernization and scientific and technological level of enterprises, and occupies an increasingly important position in the production and management process of enterprises. The quality, output, production cost, delivery time, energy consumption and human-machine environment of enterprise products And so on play an extremely important role. With the rapid development of science and technology, the production technology and equipment of the enterprise are constantly updated, and the automation and continuity of product production are getting higher and higher. Therefore, equipment has occupied a pivotal position in the survival and development of the enterprise and the ability to compete in the market.

The maintenance and repair work of cement machinery equipment is closely related to the production, operation and efficiency of enterprises. Whether it is a large-scale enterprise or a small or medium-sized enterprise, it should not be ignored. It should attract the attention of leaders and management departments at all levels, especially the current enterprise equipment. The ground update, high precision, high efficiency, and increasing automation equipment show the importance of equipment maintenance and repair work.


IF you need detailed guide for Kiln Maintenance & other Useful books and excel sheets and notes kindly click here 


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