GB/Z 44604-2024Analyser systems maintenance management (English PDF)

1.1 Purpose

This document is intended to help understand the principles and methods of analytical instrument maintenance.

It provides guidance on the organization, resources and systems required to set performance goals, improve reliability strategies and evaluate effectiveness methods.

Only when the corresponding measurement methods are established for key indicators can the online analytical instruments be managed effectively.

The purposes of online analytical instruments application in industry are as follows.

---Safety and environmental protection. This type of analytical instrument is used to control and monitor safety and environmental protection systems. Its key evaluation parameter is online time.

This is inherently easier to measure than the contribution of analytical instruments to profits, but is similar to process analytical instruments used to maximize profits.

Likewise, its contribution will depend on its ability to perform its functional requirements on demand.

---Asset protection and profit maximization. This type of online analytical instrument can have a direct impact on process control, which directly affects asset protection Such analytical instruments can be used to analyze the product quality (such as corrosion, catalyst contamination) or to optimize the operation of the process (such as energy efficiency).

The key evaluation parameters are the loss of equipment damage or the direct impact on the overall profit of the process unit.

The effect (such as reduction of process losses or increase of profits) will take about 18 months to be judged, which is difficult to measure.

The contribution of a system will depend on its ability to perform its functional requirements on demand.

This document focuses on the costs and benefits of traditional analytical instrument maintenance organizations. Due to the complexity of modern analytical instruments, the need for an organization to maintain Therefore, it is not necessary to include their expenses in the overall maintenance cost. Very important.

1.2 Main issues to be addressed

Considering online analytical instrument systems and their maintenance, the following questions help determine problems in the maintenance strategy.

---What is the normal operating time of each key analytical instrument? Is the normal operating time measured and recorded? Is it clearly Do you know the value provided by each analytical instrument and determine which ones are critical? Do you regularly review the operation status of analytical instruments? Authors (users), and re-examine the priorities of analytical instruments?

---What value does analytical instrumentation provide in process performance improvement? [i.e., increased yield, improved quality, or improved production or process cycle time] improvement, process safety (such as linkage), environmental importance, etc.] Is this information easily accessible? Does it meet the needs of operators? Request? Is it updated regularly?

---What is the "utilization rate" of each key analytical instrument? If an analytical instrument is used in a control loop, the data of the analytical instrument What is the proportion of manual analysis time that affects quality? Is the automatic operation of the analytical instrument in the control loop continuously recorded?

Do you regularly visit the operators of analytical instruments to understand the reliability of the analytical instrument data?

---Does each analytical instrument have a regular preventive maintenance program, including regular calibration? Is the calibration/verification procedure Are statistical process control (SPC) concepts included?

---What are the upper/lower limits and variation (or noise) of the analytical instrument? Is the documentation of the procedure complete? Is it routinely maintained under normal circumstances?

---Are there trained personnel (capable of performing all required procedures and troubleshooting most faults) responsible for the operation of the analytical instruments?

Do these personnel understand the process? Do they understand the laboratory measurement data in relation to the analytical instrument results?

---Do trained maintenance personnel have the opportunity to obtain a higher level of technical support to solve problems that arise during the process and more complex Are you having a complex analytical instrument problem? Are you in touch with the (manufacturer) or supplier of the analytical instrument? A higher level technical support person