Why do Factories need to Inspect and Repair Repeatedly？
Every August, factories across the country enter the annual centralized Inspect and Repair period. This special period, known as the ‘Inspect and Repair Month’, often raises questions from the outside world: since the factory is usually engaged in equipment maintenance and upkeep, why is there a special shutdown for Inspect and Repair? Isn’t this a waste of valuable production time?
In fact, this centralized Inspect and Repair system precisely reflects the high importance that the chemical industry attaches to safety production.
Unlike ordinary manufacturing factories, the production system of factories has distinct characteristics: firstly, chemical production often involves hazardous process conditions such as high temperature and pressure, flammability and explosiveness, toxicity and harm;
Secondly, production equipment operates in a state of strong corrosion and high load for a long time; Furthermore, there is a close linkage between various production units, and any minor malfunction in any link may trigger a chain reaction.
--The Six Importance of Inspect and Repair--
1、 Ensure safe production and prevent major accidents from occurring
Factory production involves flammable, explosive, and toxic chemicals (such as methanol and chlorine) as well as high-temperature and high-pressure equipment (such as reaction vessels and steam pipelines). Equipment aging, corrosion, or improper operation can easily lead to serious accidents such as leaks, explosions, and poisoning. Regular Inspect and Repair can promptly detect and eliminate potential safety hazards (such as pipeline cracks, safety valve failures, and equipment seal damage), which can prevent accidents from occurring at the source.
2、 Extend the service life of equipment and reduce the cost of equipment replacement
The investment in factory equipment such as reactors, pumps, and valves is large (a single reactor can cost millions of yuan), and long-term operation can lead to problems such as wear, corrosion, and scaling. Regular Inspect and Repair (such as disassembly and cleaning, replacement of worn parts, and repair of corroded areas) can delay equipment aging and extend the service life of each device.
3、 Improve production efficiency and reduce downtime losses
Equipment failures are the main reason for factory shutdowns (according to search results 8, equipment failures account for 5% -10% of the total production time). Regular Inspect and Repair can optimize equipment performance (such as cleaning scale, adjusting parameters, replacing aging parts), reduce downtime due to malfunctions, and improve equipment stability.
4 、 Improve item top quality and minimize flaw rate
The decrease in devices performance in manufacturing facilities (such as inaccurate temperature level control of response vessels and unstable pump circulation) can bring about an increase in product contaminations and Inspect and Repair (such as low quality fertilizer pureness and Inspect and Repair active ingredients). Normal maintenance (such as adjusting instruments, repairing activator blending gadgets, and replacing seals) can make certain that the equipment is in optimum working problem and improve item consistency.
5 、 Control environmental pollution and abide by environmental protection demands
Factory equipment leak (such as pipe corrosion and shutoff failure) can cause too much chemical exhausts (such as COD and ammonia nitrogen surpassing the criterion), contaminating water bodies, environment, and soil. Routine Inspect and Repair can immediately determine potential leak hazards (such as inspecting pipe welds and changing aging valves), successfully control devices emissions, and comply with nationwide ecological laws (such as the Environmental Management Regulation and the Chemical Industry Contaminant Discharge Standards).
6 、 Reduce overall production expenses and enhance financial efficiency.
Although routine Inspect and Repair require a certain price investment (such as labor, spare components, downtime losses), it can minimize long-lasting prices:
1. Minimize upkeep costs: Prompt repair service minor faults (such as pump shaft wear) to stay clear of developing into significant faults (such as pump body tear) and decrease maintenance prices;.
2. Minimize downtime losses: Change sudden downtime with prepared Maintenance to minimize order losses triggered by downtime (for instance, a chemical plant plans to close down Inspect and Repair for 1 day, resulting in a loss of around 500000 yuan, which is much lower than the 1.5 million yuan loss of 3 days of sudden downtime due to breakdowns);.
3. Expand tools life expectancy: Lower equipment replacement regularity and lower tools purchase expenses (for instance, expanding the service life of a reactor from 10 years to 15 years can conserve around 2 million yuan in purchase prices).
Factory Inspect and Repair is a key measure to prevent problems before they occur. Its importance runs through the entire process of safety production, equipment management, production efficiency, product quality, environmental protection, and cost control. It is the core guarantee for chemical plants to achieve stable operation and sustainable development.
As everyone has said, “Inspect and Repair of chemical plants is an important component of production safety, and even a slight mistake can lead to accidents. Therefore, it must be carried out regularly and in a standardized manner. ”
Shandong Zhishang Bio Co., Ltd
Zhishang Bio, a subsidiary of Zhishang Chemical Co., Ltd., was established in 2016 and is a new type of chemical enterprise that integrates research and development, production, and sales. Zhishang Chemical always adheres to the concept of “integrity management, strict quality control, customer first”.
Through continuous efforts, significant breakthroughs have been made in industries such as pharmaceutical intermediates, pesticide intermediates, food additives, and cosmetic raw materials. The domestic trade team sells well throughout the country, while the foreign trade team is exported to more than 30 countries and regions including the United States, Russia, Spain, Brazil, and enjoys a global reputation.
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About Zhishang Bio About Us
Zhishang Bio Co., Ltd. is located in the High tech Zone of Jinan City, with its research and development base located in the Yinfeng Biomedical Industry Park. The company integrates research and development, production, and operation, focusing on the field of fine chemical industry. We insist on creating value for customers and growing together with them!
In the next 10 years or even longer, Zhishang Bio will strive to provide professional and thoughtful services to at least 1 million customers, striving to become the first choice for customers to purchase chemicals, and committed to becoming the world’s most trusted chemical supplier.
Zhishang Bio strives to build an internationally renowned brand trusted by customers, with the spirit of “one meter wide and ten thousand meters deep”, continuously focusing on product research and development, serving customers, continuously improving the supply chain service system, building a professional chemical supply service team, and achieving long-term cooperation and win-win results with customers.
