Compressor equipment is an important production equipment of the enterprise. Generally speaking, the staff’s management of compressors mainly focuses on the good operation of the equipment, no faults, and the maintenance and repair of the compressor equipment. Many production personnel or related equipment managers only regard the normal operation of the compressor equipment as the basis for judging whether the equipment is intact, and maintenance and repair are only performed after a failure, which causes many problems.
The full life cycle management of compressor equipment can realize the whole process management from equipment demand planning to recycling, fully utilizing the value of equipment, while promoting the continuous innovation and development of enterprise production technology, and improving the level of social construction and development. Therefore, in the compressor equipment management stage, it is necessary to conduct in-depth discussions and thinking based on the full life cycle management theory, strengthen the full life cycle management and control of compressor equipment, formulate scientific and reasonable management and control measures, give full play to the role of the equipment, and strengthen the compressor equipment. Maintenance.
1.Compressor equipment life cycle management concepts, characteristics and goals
Compressor equipment full life management is also called compressor equipment life cycle management, which refers to the management process of the entire life cycle of the compressor from planning and procurement, installation and commissioning, use and maintenance, renovation, outage and scrapping. It is able to cover the compressor equipment life cycle management. Comprehensive management of machines and equipment. In essence, the whole life cycle management of compressor equipment is a new type of technology that can realize the whole process management of the compressor in the early stage, during use and later stage. This can greatly enhance the management effect, help fully understand the usage status of the compressor in each period, and the value created during the production process, thereby maximizing the economic benefits of the equipment. Therefore, making full use of the full life cycle management concept to manage compressors can strengthen management effectiveness and effectively promote compressor production efficiency.
The characteristic of the whole life management of compressor equipment is that the operation and maintenance management of the compressor during use reflects the operation status of the material. Compressor management is inseparable from asset management. The entire life cycle of the compressor, from procurement to maintenance and renovation to scrapping, requires asset management. The focus of asset management in the full life cycle management of compressors is to improve equipment utilization and save corporate costs, thereby realizing relevant value.
The task of compressor full life cycle management is to target production and operation, and through a series of scientific, technological, economic and related organizational measures, the planning and purchase, installation and commissioning, use and maintenance, technical transformation and update of compressors in the production process Manage the entire process of compressor scrapping, scrapping and reuse to achieve the ideal goal of maximizing the comprehensive utilization rate of the compressor in the production process.
2.Difficulties in compressor equipment management
①Many points, long lines and wide coverage
For small and medium-sized enterprises, the centralized use of compressors is more convenient in management, but in large enterprises, such as steel, petrochemical, coal chemical, etc., the use of compressors needs to be arranged according to production characteristics. Each production point is far away from each other, and the processes are different. The types of compressor equipment used will also be different, which will bring great difficulties to the management of compressor equipment. Especially in the process of comprehensive maintenance of relevant compressor equipment organized by the company, since the installation points of the compressor equipment are relatively scattered, most of the time is spent on the road, and the time actually used to carry out equipment maintenance is limited, especially in oil field mining and long-distance oil and gas transmission companies. , such problems are more prominent.
②There are many types of compressor equipment with different uses. Large compressor equipment is difficult to use, and training on staffing technology is not in place.
Energy and chemical companies involve many large-scale equipment such as compressors, with different types, different usage methods, and difficult use and maintenance methods. Therefore, professionals need to undergo professional training and assessment, and obtain relevant qualification certificates. Can carry out operation and maintenance. Due to tight personnel or insufficient relevant training, improper operation of the compressor or inadequate maintenance may cause the equipment to be out of service.
③High data validity requirements and heavy maintenance and repair workload
Many companies have particularly high requirements for usage data of compressor equipment, and large compressor equipment also requires such real-time data tracking. It is not only necessary to ensure the reliable and stable operation of the equipment, but also to provide guarantees for the safety of the equipment and the safety of the staff, and to ensure the true validity of the operating data of the compressor equipment. Therefore, it is necessary to conduct regular maintenance and inspection of the equipment to ensure that the compressor equipment Running well.
3.Compressor equipment full life cycle management
①Equipment Purchase
With the development of enterprises, enterprises need to purchase or modify production processes in new project plans or due to updates to national standards, which will form new equipment purchase plans. At this time, when submitting the compressor equipment purchase list to the material procurement department, the name, specifications, model, technical parameters, etc. of the compressor must be clearly stated. Enterprises can choose multiple suppliers for negotiation or open bidding, and determine the supplier of compressor equipment after a comprehensive evaluation by comparing quotations, equipment technical parameters and various supporting services provided.
At the same time, considering that compressors are long-term equipment used by enterprises, the selected machines must pass certain actual production and operation tests to prove that they have excellent performance, good maintainability, universal and interchangeable parts, reasonable structure, and short spare parts procurement cycle. , low energy consumption, complete and reliable safety devices, no pollution to the environment (reaching the energy-saving standards stipulated by the state), good economy, and high cost performance.
②Installation, commissioning and acceptance
After the compressor is purchased, due to the uncontrollability of the packing and transportation process, the equipment must be unpacked and accepted, and the packaging condition, integrity, type and quantity of accessories, operating instructions, design information and product quality of the new equipment must be checked. Certification documents, etc. need to be checked one by one. After unpacking and acceptance without any problems, on-site installation and debugging will be carried out. The debugging process includes debugging of single compressor equipment and joint debugging of multiple compressor equipment and related process equipment, and acceptance of their status and functions.
③Use and maintenance
After the compressor is delivered for use, the “three fixed” management of fixed machine, fixed personnel and fixed responsibilities will be implemented. Equipment operation and maintenance personnel should strictly abide by the relevant regulations of the enterprise, do a good job in anti-freezing, anti-condensation, anti-corrosion, heat preservation, leakage plugging, etc. of the equipment, and work with certificates.
During the use of compressors, it is necessary to pay attention to on-site management, strengthen economic management of equipment, reasonably formulate operation and maintenance plans, improve equipment utilization and integrity rates, reduce leakage rates, and implement “special maintenance” on key links in production operations. Carry out relevant maintenance according to the usage characteristics of the compressor, namely daily maintenance, first-level maintenance, second-level maintenance and minor repair, medium repair and major repair. Compressor repair and maintenance must be carried out in strict accordance with the instructions and the equipment maintenance manual specified by the company to achieve safety, high quality, efficiency, environmental protection and economy.
④Compressor equipment update and modification
During the use of compressors, advanced detection, repair, and modification technologies can be used to update equipment in a timely manner to continuously improve equipment performance. Enterprises can carry out equipment renovation and update according to production needs based on actual conditions, based on the principles of advanced technology, efficient production, economical rationality, safety and environmental protection, green energy saving, and production needs. When transforming and updating equipment, we must pay attention to the improvement of quality and performance. According to the actual needs of production, we must consider not only advanced performance and economic benefits, but also safety, energy saving and environmental protection requirements.
The update and transformation of the compressor need to be determined according to its technical requirements and economic benefits. When the compressor encounters the following conditions, it is recommended to update or transform it in time:
(1) The main parts of the compressor are severely worn. After multiple overhauls, the technical performance cannot meet the process requirements, and product quality cannot be guaranteed.
(2) Although the compressor is not seriously worn, it has poor technical condition, low efficiency or poor economic benefits.
(3) The compressor can restore its technical performance after overhaul, but the overhaul cost exceeds 50% of the original purchase value.
⑤Compressor equipment scrapping and reuse
The main focus of the compressor scrapping stage is asset management. During this process, it is necessary to ensure that the equipment has been fully utilized during use. When the equipment has reached its service life, the user department first needs to apply for scrapping, and then a professional engineer will conduct a technical appraisal to determine that the compressor equipment has reached the scrapping conditions. Finally, the asset management department will review the scrapping application for the equipment, and the company will approve it. After scrapping, the equipment will be recorded, written off, recycled and disposed of. The entire process of compressor scrapping and reuse needs to be true and transparent. If necessary, the use of the equipment needs to be verified on site, and reusable accessories must be identified, recycled and reused, so as to maximize the usable value of the equipment.
4. Improve the relevant stages of the full life cycle management of compressor equipment
①Pay attention to the early management of equipment
The early management of compressor equipment is an important part of the full life cycle management, and it is necessary to fully realize the importance of equipment procurement and engineering construction. Purchasing legal, compliant, intact and effective equipment, and installing and debugging it in accordance with laws, regulations, and standards are prerequisites for the safe, stable, and controllable operation of the entire production process. First of all, when carrying out compressor equipment planning and feasibility studies, professional engineers with relevant processes, working conditions, operating environment, automatic control electrical instruments and other related supporting equipment need to intervene in advance to conduct control, so as to finalize the equipment procurement plan; Secondly, before the construction of the project, the enterprise can, based on its own actual situation, form a project construction project team with the personnel who plan to take over the equipment management and the project construction management personnel, so that the personnel who take over the equipment can know the status of the preliminary procedures for the project construction at any time, or they can Strictly control equipment installation and transfer of equipment data. This will play a vital role in the management of the equipment after it is put into use, and also lay a solid foundation for later equipment handover management and technology inheritance.
②Strengthen basic equipment information management
Strengthening the basic information management of compressors is also a very important part of the full life cycle management of equipment. It is the basis for carrying out compressor equipment management and information management. It plays a vital role in understanding the operation of enterprise-related equipment and improving the equipment management system. important role. Strengthening the basic information management of compressor equipment requires starting from the following two aspects.
(1) Improve the equipment management system
Enterprises need to develop a complete set of complete life cycle management systems for compressor equipment. From the early stage of equipment procurement, installation and commissioning, to post-use maintenance and repair, to scrapping and reuse, a series of policies need to be formulated at each stage. Management measures can make the use of compressors more scientific and standardized, improve equipment management levels, improve equipment utilization and integrity rates, and fully utilize the available value of equipment. When using compressors, it is necessary to fully adhere to the important principle of focusing on maintenance and supplementing repairs, strengthen the inspection and daily maintenance of relevant staff during the use and operation stages of the compressor, and at the same time fully clarify the maintenance responsibilities of the equipment. Strictly implement the “three certain” management and use standardized and rigorous systems to ensure the safe and efficient operation of equipment, so that the equipment can create richer value and benefits for the enterprise during the process of being put into use.
(2) Establish equipment technical files
When a compressor is put into use, it is necessary to establish equipment technical files one by one. File management can ensure the standardization and scientificization of equipment management. It is also a crucial part of implementing the full life cycle management concept. In practice, the technical files of the compressor are important archival materials formed during the purchase, use, maintenance and transformation of the equipment. They include original materials such as instructions and drawings provided by the manufacturer, and also include the equipment during the put-in-use stage. Production operation, maintenance and repair and other technical information. On the basis of establishing and improving relevant files, the user unit also needs to establish and improve basic information such as compressor stand-alone cards, related components such as dynamic sealing point cards and static sealing point cards, lubrication diagrams, sealing point diagrams, equipment ledgers, and stand-alone equipment files. Save them together to establish and improve technical files. By continuously improving the basic information of compressor management, it can provide a reliable basis for its management planning, decision-making and improvement work.
③Build an equipment information management platform
The management level of each enterprise is different, resulting in uneven management levels of archive management, basic information management, production operation and daily maintenance of compressor equipment. Many of them still rely on manual management, making management difficult. . Information management of compressor equipment can realize real-time dynamic management and save manpower and material resources to a large extent. The compressor full life cycle management platform needs to include data sharing and support from many platforms such as related equipment preliminary material procurement, asset management, equipment operation and maintenance. From the beginning of front-end business to the end of scrapping, comprehensive management of the entire process of equipment needs to integrate equipment acceptance, ledger management, file management and knowledge base, defect management, accident and failure management, safety accessory management, equipment lubrication management, dynamic and static sealing management, Inspection and inspection management, report management, spare parts management and many other functions can provide timely and comprehensive control of equipment conditions. Enterprises need to focus on production safety and use relevant equipment ledgers as basic data to conduct information management of the use of compressors at each stage, carry out structural design according to modern management working models, and implement comprehensive management of the entire process of compressor equipment. Reduce costs and increase efficiency, and improve the safety management level of equipment.
The effective management of compressors is directly related to the safe operation, production and operation, product management, production costs, market competition, etc. of the company. Together with the management of other production equipment, it has become the basis of the company’s production and operation management and has an important impact on the long-term development of the company. Since the full life cycle management of compressor equipment involves many links and complex processes, reasonable system planning must be carried out in advance and a complete management model must be established. At the same time, the construction of an information platform is also extremely necessary, which can greatly improve the convenience and accuracy of equipment management.
In addition, improve the level of information sharing to ensure that relevant departments of enterprise equipment management can share data. With the further development of technologies such as the Internet of Things and big data, the full life cycle management of compressor equipment will be further developed, which is important for ensuring the safety and controllability of equipment, improving usage levels, maximizing corporate operating benefits and saving costs. of great significance.
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Post time: May-20-2024
