Instrument maintenance service
- Overview of Instrument Maintenance Services
Chemical supervision is an integral part of multiple technical supervisions in power plants. It is an important measure to ensure safe production in power plants and a basic work for scientific management of equipment. Chemical supervision includes three professional supervisions: water, steam, oil and fuel. Doing a good job in chemical supervision is directly related to the safe and economical operation of the main production equipment of power plants, such as boilers, steam turbines, generators, transformers, etc., and occupies an important position in the production of power plants. The main equipment involved in chemical supervision is chemical instruments. The accuracy and reliability of measurement data are of paramount importance in safe production. - With the rapid development of power production and the advancement of science and technology, more and more high-parameter and large-capacity units are put into operation, and the technical requirements for chemical supervision are getting higher and higher. However, chemical instruments are precision measuring instruments. Qualified instruments are in good operating condition, and the measured data are within the allowable error range. They have strict requirements for the environment, installation, sample water, reagents, standard solutions, calibration, and regular maintenance. There are many influencing factors involved, and the requirements are harsh. As a result, the commissioning rate of chemical instruments in many power plants, especially online chemical instruments, is low, and the invested equipment cannot realize its due role and value. Whether it is domestic or imported instruments, they all need professional and periodic maintenance. Analyze the causes, accurately find the root causes of the problems, and solve the problems. This requires experienced professional maintenance personnel to deal with them in a timely manner.
- Based on the above analysis, our company invites experts with many years of experience in chemical supervision as full-time technical consultants, and absorbs professional technicians with many years of rich experience in installation, commissioning, startup and maintenance of chemical instruments as a team. According to the different situations of the current chemical supervision work of new and old power plants, we generate a variety of solutions in a targeted manner to provide you and your factory with professional chemical instrument maintenance, solve practical problems in production, and create value with professionalism and services.
- Purpose of instrument maintenance service
To meet the requirements of chemical instrument input rate and accuracy rate indicators.
All instruments put into operation normally are accurate and reliable.
The consumption of spare parts is controlled within a scientific and reasonable range, which greatly reduces the cost of instrument maintenance and operation.
Scientific management, considerate technical service value-added plan, user satisfaction. - Scope of instrument maintenance service
Chemical instruments used for online supervision in thermal power plants, including chemical furnace sampling analysis instruments, chemical polishing analysis instruments, chemical water analysis instruments,
chemical wastewater analysis instruments, circulating water treatment analysis instruments.
Commonly used instruments in power plant chemical laboratories
. Configuration of laboratory/online instrument chemical reagents and standard solutions.
Hydrogen system analysis instruments for hydrogen stations and generators, desulfurization system analysis instruments.
Flue gas online continuous monitoring system CEMS analysis instruments.
Participate in instrument maintenance and calibration during major and minor repairs of units.
Instrument maintenance service plan
- Instrument maintenance service plan
The formation of the instrument maintenance project plan should be determined according to the specific conditions and specific requirements of each factory.
The main forms are the following three service modes:
Maintenance service technicians on-site service
Scope of work: online instruments + laboratory instruments + preparation of standard solutions and reagents
(I) Online instruments include: water quality and gas analysis instruments for water purification stations, water treatment outside the furnace, furnace, fine treatment, wastewater neutralization tank, main engine, hydrogen production station, desulfurization and other systems
(II) Laboratory instruments include: maintenance calibration and use guidance of water quality analysis instruments, oil analysis instruments, and coal analysis instruments
(III) Configuration of standard solutions and reagents
Scope of application: New power plants with large units and efficient staffing
Comparison: Compared with the recruitment of new personnel in power plants, new personnel need about 3 years of experience in instrument maintenance, even if they study hard. During these three years of exploration, the losses brought to the power plant are huge. Some precision and expensive instruments are damaged due to improper maintenance, and some instruments are incorrectly indicated due to improper maintenance and untimely handling, which makes it impossible for chemical operation to take corresponding measures, resulting in missed opportunities and damage to the unit. The entry of professional instrument maintenance companies and professional maintenance can enhance the views and confidence of chemical specialists and chemical operators on online instruments. When an abnormality occurs, it can be immediately ruled out whether it is an instrument failure, and the problem in the system can be pointed out, guiding chemical operators on how to deal with the root cause of the problem, without delaying time on whether the instrument is faulty, and decisively taking corresponding measures. Usually, it can objectively and impartially provide reasonable economic operation plans and instrument selection suggestions.
Advantages: Highlight the advantages of professional integration, integrate online and laboratory instruments, and provide guidance and training to chemical operators and laboratory personnel to ensure the overall consistency of analytical data. The configuration of standard solutions and reagents is conducive to further reducing the burden on the staff of the test class, and also ensures that uncontrollable factors cannot be verified during the maintenance and calibration process.
Periodic maintenance and overhaul method + on-site training method (one cycle per quarter or one or two months)
Scope of application: This method is suitable for the factory with chemical instrument personnel, but is not professional in chemical instruments themselves, and requires periodic maintenance and overhaul by instrument maintenance service companies, and provides targeted maintenance and on-site training services according to the instrument maintenance content. - Instrument return to factory repair service
Scope of work: Beijing Times Xinwei Measurement and Control Equipment Co., Ltd. provides customers with installation, commissioning, training, warranty, maintenance and other technical services on a long-term basis. The maintenance service includes the following steps:
(i) Contact our company and inform the model, type and fault of the instrument that needs maintenance.
(ii) Our company will contact relevant professional engineers to understand the situation. If the instrument can be repaired, the maintenance business department will notify the customer of the product that needs maintenance.
(iii) The customer will ship the instrument to our company and transfer it to the technical department for inspection.
(iv) Our company’s technical department will submit the inspection results and estimated repair costs in writing to the maintenance business department and report to the customer.
Scope of application: The following maintenance services can be undertaken:
(i) Imported online chemical instruments
(ii) Laboratories and online analytical instruments in petrochemical, oil refining, metallurgical and other industries
(iii) Automatic control instruments.Specific service content of instrument maintenance.
Establish a complete equipment inventory of analytical instruments and pre-sample measurement and processing devices within the maintenance scope, and establish instrument equipment files.
Formulate complete operating procedures, maintenance and inspection procedures, and calibration procedures
for analytical instruments. According to the instrument configuration and the specific conditions of instruments of different types and principles, formulate a daily maintenance management system.
Regularly issue operating status analysis and quality assessment reports for maintained instruments
. Preparation management and drug formula inventory records of various standard solutions and reagents for laboratory/online instruments.
Fault diagnosis and repair of maintenance instruments, spare parts planning, proposal of measurement system technical transformation plan, formulation and implementation of maintenance plan for major and minor maintenance instruments
Provide technical training and technical consulting services for relevant factory staff in chemical instruments
Provide high-quality and low-cost instrument spare partsProject organization and management measures for instrument maintenance
Daily maintenance of instrument equipment
(i) Cleaning and maintenance of instruments
(ii) Patrol the maintained instruments and equipment once in the morning and evening every day, and fill in the “Operation Log”
(III) Regularly inspect and repair the instrument equipment. The specific time shall be based on the type of instrument or the requirements of the buyer. Instrument calibrationand maintenance at start-up
(I) One hour before the start-up, the maintenance personnel shall arrive at the site to carry out relevant preparations
(II) All instruments shall be powered on and the operation shall be observed
(III) After the start-up, the high-temperature rack shall be drained and manual sampling shall be started until the water sample meets the instrument commissioning requirements
(IV) All water sample pressures and temperatures shall be checked to see if they meet the instrument operation requirements, and any abnormalities shall be handled
(V) The instrument water sample valve shall be opened and the instrument shall enter the operation state
(VI) All instrument pipelines shall be checked again to see if there are any leaks at the reagent connections. If any leaks are found, they shall be handled immediately
(VII) The instrument measurement values ​​shall be checked with the operating personnel, the instrument measurement accuracy shall be checked, and if the online instrument is confirmed to be inaccurate, the instrument shall be calibrated
(VIII) If normal calibration and verification fail, the internal flow path and operation state of the instrument shall be checked to find out the reasons for the instrument itself that caused the verification failure. Carry out maintenance and restore operation in accordance with the “Chemical Instrument Maintenance Regulations”
(IX) The repaired instrument shall be inspected by the buyer’s chemical operation management personnel and signed on the “Maintenance Record” and put into use.Maintenance work during shutdown
(I) The maintenance personnel arrive at the site 1 hour before the shutdown
(II) Check whether the instrument is operating normally
(III) After the shutdown, shut down the instrument and close the sample water valve
(IV) Determine whether to shut down some instruments for maintenance based on the shutdown time
(V) Clean up the work site
(VI) Fill in the work log
(VII) The maintenance personnel confirm that the work is completed on the day and leave the site after acceptance by the operation personnel.Elimination of equipment defects
(I) During the equipment operation and shutdown standby period, the defects of the instruments and equipment undertaken for maintenance shall be eliminated in a timely manner to ensure Equipment is normal and reliable.
(ii) Defect elimination time is based on the manufacturer’s regulations. Spare parts andconsumables are proposed and purchased.
(i) The person in charge of the instrument maintenance project is responsible for timely proposing a demand plan for spare parts and consumables for Party A to review and confirm. The purchase is approved by the relevant departments of the manufacturer. The reporting time and frequency of the procurement plan can be negotiated and formulated with the buyer.
(ii) The demand plan is detailed and thoughtful, meets the needs of on-site instrument equipment maintenance work and is scientific and reasonable. It does not affect the normal and good operation status of the instrument and does not increase the factory’s inventory pressure. Instrument components that can be restored to use through repair are restored to use as much as possible, and costs are not increased without reason, so as to minimize the buyer’s operating costs.Improvement suggestions for maintenance work and instrument equipment transformation plans are proposed
(i) Provide instrument maintenance reports and calibration reports to the management department designated by the relevant departments of the factory on a monthly basis. The reports analyze the working status, technical parameter indicators and material consumption of the instruments, summarize the instrument maintenance work, and put forward improvement opinions and transformation suggestions for existing problems of the instruments and equipment.
(ii) Provide accuracy and commissioning rate reports to the relevant departments of the factory on a monthly basis.Instrument maintenance service guarantee
Because the company has been committed to the development, production and maintenance of chemical instruments for power plants, the technical service personnel have a deep understanding and cognitive ability of domestic and imported chemical instruments in terms of technology, fully master the analysis technology of most chemical instrument manufacturers, and have the comprehensive ability to ensure the use, maintenance and troubleshooting of various chemical instruments in power plants. The technical service personnel have all undergone production process training in the company’s production workshop, and have been trained and improved on-site during the after-sales service of the instruments. They have profound experience and qualifications in technical difficulties and difficult faults in chemical instruments.
The technical service personnel employed by our company all have a university degree (electronics, electrical automation, mechanical manufacturing, etc.), rich professional knowledge, familiar with the working principle, structure, operation mode and operation process of related instrumentation equipment; have more than 2 years of work experience in related instrumentation technical support, have rich field operation experience, are familiar with the various causes of chemical instrument errors, can clearly determine the causes through diagnosis, and propose corresponding solutions; work conscientiously and prudently, and have a strong sense of responsibility.
Our company’s technical service personnel have all undergone production process training in the company’s production workshop, so they are familiar with the basic working principle and structure of chemical instruments, have a systematic understanding of the detection amplification, analog-to-digital conversion, data processing and output of the single-chip microcomputer system, and can repair chemical instruments. According to the instructions, they can install and debug various new chemical instruments. Familiar with the process flow of chemical majors, the operation mode and working principle of related equipment, familiar with the characteristics and working principle of related calibration instruments and can use them correctly, familiar with the causes of various errors in chemical instruments, correctly analyze and judge the causes of errors in various chemical instruments, and propose elimination measures.
After the sale of instruments, our company is involved in instrument installation, commissioning and maintenance. Therefore, our technical service personnel are trained and improved in the on-site after-sales service process and have rich experience in installing, commissioning and repairing chemical instruments.
Because our company has signed multiple instrument maintenance projects, we have summarized a relatively complete management system in the instrument maintenance work. All maintenance personnel have received professional training and have on-site service experience. The company’s after-sales service department uniformly arranges maintenance personnel, establishes a project team, and appoints a project supervisor to lead the maintenance team. The project team is managed independently on a daily basis, but the company’s after-sales service department conducts monthly supervision and assessment to ensure the quality of the buyer’s maintenance work.