Scientific management of main equipment in modern cement production lineDate: 2019-07-10 Views:
With the rapid development of dry-process cement production lines, China's cement equipment has spread all over the world, becoming a beautiful business card in the world cement industry. The main equipment of the cement plant tends to be large, automatic and intelligent. The management, operation and maintenance level of the equipment are relatively lagging behind, which increases the difficulty and cost of equipment management and maintenance. As the competition in the world cement market becomes increasingly fierce, only the guaranteed operation rate of equipment can ensure the stability of the cement production process, reduce production costs and improve the competitiveness of enterprises. This article describes the process of selecting, purchasing, installing, using, repairing and maintaining, replacing parts, and scrapping the main equipment of the cement production line for reference by the industry peers.
1 Fine management of major equipment
1.1 Classification of major equipment
There are many equipments in cement plants. According to the characteristics of cement production and the performance of equipment, the main equipment of cement plant can be divided into crushing equipment (various crushers), pre-homogenization equipment (stacking and reclaiming machine), grinding equipment (vertical mill). , tube mill, roller press), thermal equipment (preheater, rotary kiln, grate cooler, burner, etc.), conveying equipment (plate feeder, belt conveyor, screw conveyor, chain conveyor, lifting Machine, air chute, clinker conveyor, etc.), sorting equipment (cyclone separator, classifier), metering feeding equipment (belt scale, plate scale, solid flow meter, coal powder scale), dust collection equipment (air cooler, bag dust collector, electric dust collector), power equipment (centrifugal fan, Roots blower, air compressor, water pump, waste heat boiler, steam turbine, electric motor, etc.), bulk packaging equipment (bulk machine, packaging) Machines, loading machines), lifting equipment, and electrical automation systems.
According to the importance and influence degree of the above equipment on the production of cement production line, it can be divided into main equipment, main auxiliary equipment and general auxiliary equipment.
Production practice shows that the main equipment and main auxiliary equipment of the production line bear heavy production load due to high equipment operation rate, and the risk of production is affected by equipment failure. According to the different uses of the equipment, the main equipments with higher risk of production due to equipment failure are shown in Table 1.
Table 1 Equipment failure risk list
1.2 Equipment design selection and maintenance planning
The management of equipment in the cement plant has been started since the beginning of the design. Before the new cement production line is determined, it must communicate with the designers of the design institute to inform the designers of the existing ideas and requirements for the use of the equipment. Relevant design and equipment selection, so that the management of electromechanical equipment runs through the whole process of design, system configuration, selection, data deduction, economic and technical analysis, procurement, use, maintenance, and scrapping or updating of electromechanical equipment. The technical file allows the device to have its own ID card. The life cycle process planning is shown in Figure 1.
Figure 1 The life cycle process of the main equipment selection, procurement and manufacturing of the cement plant
The selection and procurement of major equipment involves the production capacity of the system and the entire production line. Therefore, relevant technical experts and design units should be organized before procurement. For equipment and equipment level, production raw material conditions, technical parameters, maintenance requirements, maintenance costs, and after-sales service. Conditions, combined with the system configuration plan technical and economic comparison, system energy consumption indicators, etc. to fully discuss and demonstrate, and finally determine the model specifications of the purchased equipment.
1.3 Operation and use of the equipment
With the increasing size, precision, and automation of equipment, the requirements for the operation and use of equipment are also increasing. The enterprise equipment management personnel shall summarize and organize the random data of the equipment according to the characteristics of the equipment, and compile the corresponding safety operation procedures and equipment fault handling plans.
Before the equipment is used, the enterprise equipment management personnel shall conduct training on the operation and operation of the production operators according to the relevant equipment safety operation rules.
In order to ensure the integrity and operation rate of the equipment, the equipment operator shall operate the equipment in strict accordance with the safe operating procedures, and monitor the temperature, pressure, vibration and other conditions of the equipment during the operation. The abnormal situation shall be recorded and reported in time, according to the corresponding fault. Handle the plan for processing and protect the equipment in time.
Establish a equipment operation assessment system, evaluate the normal operation and fault handling of the operators, and link with the corresponding remuneration, in order to eliminate the hidden dangers of equipment misoperation and ensure the equipment operating integrity rate.
2 Status of equipment maintenance management
2.1 Enterprise awareness of equipment management needs to be strengthened
The safe and stable operation of the equipment is the prerequisite for stable and high-yield operation of the cement production line. In many enterprises, in order to complete the production task, the production manager only pays attention to the output, neglects the maintenance and maintenance of the equipment, blindly pursues the operation rate and overload production, which makes the equipment accumulate into a big problem from the glitch, and finally leads to overhaul or even scrap, the cost Take up a large part of the cost. Some devices are not as complex as possible, simple modifications, as long as the effect is also optimized.
2.2 The establishment of equipment management system is not perfect
Many enterprises have not established a complete equipment management system. There are no specific plans and implementation methods for routine maintenance, repair, overhaul, spare parts management, material management, inspection management, lubrication management and accident management of equipment, so that management personnel have no Chapter can follow.
2.3 Equipment operation personnel training is not in place
In many newly-built enterprises, especially in the case of urgent production tasks, the operator's use and safety operation procedures are insufficiently trained, and the performance and technical requirements of the equipment cannot be fully understood and mastered, and the equipment is damaged due to improper operation. Before the new equipment is used, it is necessary to carry out equipment use and safety training for the operator, explain the operation method and precautions of the equipment operation, and simple maintenance methods to reduce the probability of the operator damaging the equipment in use.
2.4 Equipment maintenance is not strictly carried out in accordance with the requirements and relevant standards
The maintenance of the equipment should be carried out in accordance with the standard. If the cause of the failure is not detected, do not blindly try to open it. The inspection must be carried out in strict accordance with the standard procedures.
Professional training for equipment maintenance personnel should be strengthened. In the maintenance process, the barbaric operation is eliminated, and the precision parts of many large cement equipments are slightly deformed, which will affect the normal operation of the equipment. The maintenance of important equipment must be carried out under the guidance of professionals. It should be put an end to the fact that practitioners do not pay attention to operating standards and savagely disassemble precision equipment parts, resulting in reduced performance, life and accuracy of equipment and parts, and affecting production.
3 Equipment operation and maintenance management recommendations
3.1 Develop equipment maintenance plan
Good equipment maintenance is the key to the use of the equipment, ensuring that the equipment has good operating conditions. It should also make maintenance and repair plans for the equipment, carry out regular inspections and repairs, and replace damaged parts of the equipment in time to eliminate hidden dangers.
Equipment maintenance should be standardized and scientific, and must be carried out in strict accordance with the maintenance instructions. There should be corresponding maintenance records, and long-term planning for equipment maintenance should be carried out. Each maintenance and repair should identify and eliminate related faults. The same problem should not be left to the next maintenance and repair. When repairing, special tools or equipment should be used for different equipment for maintenance to prevent damage to the equipment. Parts that are large, relatively tight, and difficult to disassemble should be equipped with or made with special disassembly tools, fixtures, spreaders, etc., to facilitate the lifting and disassembly of equipment and parts.
Equipment management personnel shall establish a complete equipment inspection system, prepare a complete series of inspection forms such as equipment mechanical inspection table, equipment lubrication point inspection table, bearing temperature monitoring table, carefully plan the inspection route, and carefully inspect the inspection personnel. The training, urged its timing, alignment, fixed-point inspections and carefully recorded the inspection form (see Figure 2), found that the problem was reported in a timely manner, to ensure that the inspection is in place, no dead ends, no omissions.
Figure 2 Mill and kiln inspection monitoring table
3.2 Strengthening equipment fault management
Fault management of equipment is the basis for preventing repetitive faults in equipment. For the main equipment, the "Main Equipment Fault Tracking and Management Measures" should be prepared. The fault management of the equipment should be covered from the cause analysis, defect improvement, experience summary horizontal development and standardization. The faults should be analyzed in time for faults exceeding 10 minutes. Find the cause of the failure and prepare a failure analysis report. Develop corresponding countermeasures and measures for faults, eliminate their own defects and expand the analogy horizontally, eliminate the defects of similar equipment, and finally solidify them through standardized procedures to avoid repeated faults.
With the development of emerging state monitoring and fault diagnosis technologies, intelligent analysis of equipment faults can be realized, and hidden fault locations and problems of equipment can be judged in time to perform equipment state predictive maintenance. The main equipments such as vertical mill reducer, high temperature blower, raw material mill circulating fan, kiln exhaust fan, kiln head exhaust fan, coal mill reducer, cement mill reducer and roller press reducer have complex and continuous structure. Long operating time, large load fluctuations, high equipment cost, etc. Although these key equipments can be surface-monitored for equipment operation by strengthening the inspection frequency, it is difficult to directly and effectively monitor the internal components, and once the faulty equipment is generated Downtime will directly affect the operation of the entire production line, causing large losses. Therefore, such host equipment can be connected to the equipment vibration monitoring and spectrum analysis technology to visually monitor the operation of its internal components, so that the internal fault location and the cause of the fault can be accurately and timely predicted. Effectively reduce downtime maintenance time, which is beneficial to improve the operation rate of equipment and even the entire production line.
3.3 Strengthen the lubrication management of equipment
The lubrication management of the equipment runs through the life cycle of the equipment and is an important system engineering of the cement plant, including the lubrication management and technical management of the equipment. The lubrication management of the main equipment for the production line should cover the following aspects:
(1) Improve the lubrication management system and clarify the duties of lubrication management technicians.
(2) Improve equipment lubrication technical files, compile relevant equipment oil consumption quotas and annual and quarterly oil plans, prepare equipment lubrication technical requirements and instructions, charts and lubrication record cards (see Table 2), combine equipment oil conditions and overhaul Plan to prepare equipment cleaning and oil change plans.
Table 2 Equipment lubrication checklist
(3) Strengthen the technical inspection of equipment lubrication, so that the oil can be adjusted, fixed, quantitative, regular, and fixed (five fixed). The oil is filtered from the storage to the filling equipment, and the oil quality is tested regularly. And iron spectrum, spectral analysis, waste oil recycling.
(4) Regularly organize training for lubrication personnel. For cement plant lubricants, large replacement raw material vertical mill, cement mill, coal mill reducer and other equipment, the first fueling operation within one year, the oil quality sampling can be tested every six months. After one year of operation, the oil quality test frequency should be increased to quarterly sampling test, and the corresponding oil replacement cycle should be determined based on the oil quality test results.
3.4 Strengthening the optimization of spare parts for equipment
Scientific and reasonable spare parts inventory is conducive to the good operation of the equipment. Excessive spare parts inventory will occupy more funds of the enterprise, and the inventory quantity is too small, which will affect the normal operation of equipment and production. Therefore, the optimal management of spare parts, the classification of spare parts according to the risk of component failure, the trend of consumption, the degree of production impact, the development of spare parts procurement plan, and the reasonable determination of the safety stock of spare parts can effectively reduce the funds used for spare parts procurement and increase the inventory turnover rate. Enterprises reduce costs.
4 Establish a standardized equipment traceability equipment database
Establish a complete database of equipment installation, operation, maintenance, spare parts, parts and maintenance operations. Once the equipment fails, you can timely access the equipment database query equipment and the model specifications and inventory of the faulty parts. Replace and troubleshoot equipment components in the shortest time. All changed data is carefully and accurately recorded during the life of the device and can be queried, including documents, images, maintenance personnel, number and model of updated accessories, and more. And the data is analyzed regularly, the operating cost of the equipment is controllable, and the first-hand information is provided for the decision-making of the leader.
Equipment maintenance and repair personnel should work in accordance with relevant regulations, carefully fill out the equipment maintenance card, accurately describe the equipment fault characterization, treatment measures and effects. After the repair is completed, the maintenance card delivery management personnel will score the maintenance process, and the score is directly linked to the maintenance personnel's salary. . Adjust the enthusiasm of maintenance equipment maintenance personnel, so that equipment maintenance and repair can be implemented.
The efficient and stable operation of electromechanical equipment is an important guarantee for the stable production and high production of modern cement production lines. As the manager of the enterprise, it should abandon the extensive management mode, attach importance to and strengthen the management of the whole life cycle of the equipment, and effectively establish effective traceability from the operation monitoring, fault prediction, inspection, lubrication, maintenance and maintenance of the equipment. The management system timely tracks the emerging and reliable equipment monitoring technologies in the industry and establishes complete rules and regulations. The equipment management and maintenance personnel are regularly trained in relevant professional skills and new technologies to make the equipment management level of the cement plant increasingly refined and modernized, and to adapt to the updated development of the equipment, to provide guarantee for the stable production and high yield of the cement production line