Industrial Equipment Daily Safety Maintenance Standards Manual

Foreword

This manual aims to standardize industrial equipment daily safety maintenance operations, clarify maintenance responsibilities, and ensure safe, stable, and efficient equipment operation throughout the entire lifecycle, thereby protecting operator personal safety and enterprise production order. The manual content is compiled based on national laws and regulations, industry standards, and practical experience, applicable to equipment management departments and maintenance personnel of various industrial enterprises.

Chapter I: General Provisions

1.1 Purpose and Significance

Industrial equipment is the material foundation of enterprise production, and its safety status directly relates to production efficiency, product quality, and personnel safety. Daily safety maintenance is a key means to prevent equipment failures, eliminate safety hazards, and extend equipment service life, forming an indispensable and important component of enterprise safety production management systems.

1.2 Scope of Application

This manual applies to daily inspection, care, lubrication, cleaning, and minor fault troubleshooting of all in-service industrial production equipment, auxiliary equipment, and special equipment within the enterprise.

1.3 Basic Principles

1. Safety First, Prevention Priority: Always place personnel safety first, reducing equipment failure and safety incident risks through systematic preventive measures.
2. User Responsibility, Maintainer Responsibility: Clearly define safety responsibilities of equipment operators and maintenance personnel, implementing accountability systems.
3. Planned and Standardized: Develop reasonable maintenance plans, strictly follow procedure operations, ensure maintenance quality.
4. Full Participation, Continuous Improvement: Encourage all relevant personnel to participate in equipment maintenance and safety management, continuously summarize experience, optimize maintenance processes.

Chapter II: Maintenance Personnel Responsibilities and Qualification Requirements

2.1 Maintenance Personnel Responsibilities

1. Strictly comply with this manual and relevant equipment safety operation procedures, implement maintenance plans
2. Responsible for equipment daily patrol inspection, periodic care, lubrication, cleaning, and simple fault elimination
3. Accurately record maintenance work content, discovered problems, and handling results
4. Promptly report major equipment hazards, faults, and abnormal conditions, and participate in emergency handling
5. Correctly use and maintain maintenance tools, measuring instruments, and testing devices
6. Participate in equipment safety technical training, enhance personal safety skills and professional quality

2.2 Qualification Requirements

1. Maintenance personnel must undergo professional safety technical training and pass assessment before taking up positions
2. Personnel engaged in special operations (electrical, welding, lifting, etc.) must hold nationally prescribed corresponding special operation qualification certificates
3. Familiar with maintained equipment structure, performance, working principles, and common fault judgment and handling methods
4. Master basic safety protection knowledge and first aid skills

Chapter III: Basic Requirements and General Process for Daily Safety Maintenance

3.1 Pre-Operation Preparation and Safety Confirmation

1. Stop, De-energize, Lockout/Tagout (LOTO): Before maintenance work, ensure equipment has completely stopped running, cut off main power supply and related energy sources (pneumatic, hydraulic), and execute lockout/tagout procedures. Maintenance work while equipment is running is strictly prohibited.
2. Environmental Check: Clear debris from work area, ensure passages are unobstructed, lighting is sufficient, and ventilation is good. Check for flammable, explosive, toxic, or hazardous factors in the work area and take corresponding protective measures.
3. Tools and Materials Preparation: Prepare required tools, measuring instruments, spare parts, lubricants, cleaning agents, and check their integrity and applicability.
4. Personal Protective Equipment (PPE): Correctly wear and use compliant personal protective equipment such as safety helmets, safety shoes, protective goggles, protective gloves, dust masks, etc., based on work content and risk assessment results.
5. Technical Briefing and Plan Confirmation: For complex maintenance work, conduct technical briefing to clarify work content, steps, safety precautions, and emergency measures.

3.2 Safety Operation Points During Work

1. Operate according to procedures: Strictly follow equipment maintenance instructions or established maintenance procedures, do not arbitrarily change operation methods or omit necessary steps.
2. Component inspection and cleaning: Conduct detailed inspection of equipment components including fastener tightness, abnormal wear, cracks, deformation, pipeline leakage, and wire damage or aging. Clean equipment exterior surfaces and critical parts, removing oil stains, dust, and debris.
3. Lubrication: According to equipment lubrication chart requirements, regularly add or replace qualified lubricants at each lubrication point, ensuring appropriate quantities and unobstructed oil passages. Note that different grades of lubricants must not be mixed.
4. Adjustment and tightening: Precisely adjust components requiring adjustment (belt tension, clearances, pressure, etc.); tighten loose fasteners but avoid over-tightening causing damage.
5. Prohibited behaviors: Non-work-related operations during maintenance are strictly prohibited; arbitrarily removing or bypassing safety protection devices is strictly prohibited; directly touching rotating parts or high-temperature surfaces with hands is strictly prohibited.
6. Abnormal condition handling: If abnormal sounds, vibrations, odors, or temperature rises are found during work, immediately stop operations, identify causes, and properly handle before continuing.

3.3 Post-Work Site Restoration and Confirmation

1. Clean site: Correctly reinstall disassembled components, clean oil stains, waste materials, tools, and debris from the work site, maintain clean environment.
2. Return tools and materials: Sort and organize used tools, remaining materials, and waste items, store or dispose according to regulations.
3. Restore safety devices: Ensure all safety protection devices are correctly installed and fully functional.
4. Unlock and trial run: Only after confirming all maintenance work is complete and personnel have evacuated dangerous areas, remove lockout/tagout according to prescribed procedures and conduct equipment trial operation. During trial operation, closely observe equipment running status and confirm no abnormalities before putting into normal operation.
5. Records and handover: Carefully complete equipment maintenance records including maintenance date, content, discovered problems, handling results, replaced spare part models and quantities. Report unresolved issues to superiors and conduct proper handover.

Chapter IV: Specialized Safety Maintenance for Common Industrial Equipment

4.1 Mechanical Equipment (Transmission and Rotation Types)

• Gear Transmission: Check gear meshing condition for broken teeth or surface spalling; check gearbox oil level and quality; check bearing temperature, vibration, and abnormal noise.
• Belt/Chain Drive: Check belt/chain tension appropriateness, cracks, wear, and aging; check pulley/sprocket alignment; clean and lubricate regularly (chains).
• Hydraulic and Pneumatic Systems: Check tank oil level and quality, filter cleanliness; check hydraulic pumps, cylinders, pneumatic components for leakage; check pressure gauge readings and safety valve reliability.
• Stamping and Shearing Equipment: Focus on checking safety protection devices (photoelectric protection, two-hand start devices, guards); check clutch and brake performance; regularly inspect die wear and fastening.

4.2 Electrical Equipment

• Electric Motors: Check motor temperature, sound, and vibration during operation; check motor junction box and cable connections; clean motor housing and ventilation covers; check bearing lubrication.
• Distribution and Control Cabinets: Clean internal dust regularly; check circuit breakers, contactors, relays for burning, adhesion, or abnormal noise; check terminal connections for looseness or overheating; check grounding system reliability.
• Wires and Cables: Check cables for damage, aging, or overheating; verify proper routing without crushing or dragging risks.

Chapter V: Emergency Response and First Aid

5.1 Emergency Response Principles

1. Immediate stop and power off: When accident occurs, the first task is to cut equipment power and energy sources
2. Personnel priority: Ensure injured personnel receive timely assistance, quickly evacuate danger zones
3. Report and alert: Immediately report to site supervisor or emergency command center, call emergency or fire services if necessary
4. Control situation: While ensuring safety, take measures to prevent accident expansion such as fire extinguishing or cutting leak sources
5. Protect scene: Without affecting rescue, protect the accident scene for subsequent investigation

5.2 Basic First Aid Knowledge

Maintenance personnel should master basic first aid skills including CPR, bleeding control, bandaging, fracture stabilization, and burn treatment. Enterprises should regularly organize first aid training and drills.

Chapter VI: Training and Qualification Management

Enterprises should establish equipment maintenance safety training systems covering this manual and related safety rules and regulations, equipment structure and principles, maintenance operation procedures, hazard identification and risk control, correct PPE use, LOTO procedures, and emergency response and first aid skills. Training frequency should meet regulatory requirements and enterprise actual needs to ensure employees maintain sustained competence.