Principles for formulating major maintenance plans at CNPC

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Principles for formulating maintenance plans at CNPC: Immersive reading in a novel reader; scientifically determining maintenance plans and the volume of work required; strictly controlling the scope of maintenance; firmly avoiding inefficient or unnecessary maintenance activities; and eliminating any ad-hoc or arbitrary projects. Referring to the template for maintenance plans of major production facilities, all aspects of plan preparation, including the selection of maintenance items, the determination of solutions, and the scheduling of maintenance activities, must adhere to the following basic principles. 01 Principles for long-term operation of units: All production units, utility systems, and auxiliary systems in the plant must meet the requirement of high-quality operation with maintenance every four or five years; unit shutdowns due to defects or quality issues in the units or equipment are not permitted. The equipment has the issue of not being able to operate safely and stably until the next maintenance cycle, so it has been included in the maintenance plan. 02 Principle of “Mandatory repairs must be carried out; there is nothing better than performing these repairs properly” (1) Eliminating potential hazards and defects: Based on the equipment condition information gathered from daily inspections, regular checks, condition monitoring, and repair records, as well as the results of annual equipment inspections and tests, equipment whose technical condition has deteriorated or that has defects is addressed ； The equipment and facilities identified during the inspection of concealed items have issues such as non-compliance and failure to meet standards ； Based on the 36 requirements for hazard identification, and taking into account the specific characteristics of the enterprise as well as lessons learned from accidents involving similar equipment, the scope and content of hazard identification should be expanded. Issues such as potential hazards or defects in equipment and facilities that require repair must be included in the maintenance plan. (2) Restoring equipment performance: In accordance with the contents and requirements outlined in the equipment maintenance manuals, industry standards for inspection and repair, as well as technical guidelines issued by higher-level professional management departments, when the equipment has reached or is about to reach its scheduled maintenance cycle, regular inspection and maintenance are necessary ； Depending on the operating conditions of the plant’s processes, these factors can easily affect the performance of the equipment and facilities. Any equipment that requires maintenance after shutting down over the years should be included in the maintenance plan. (3) Equipment whose service life has expired in accordance with the preventive maintenance strategy – that is, equipment that needs to be replaced due to the expiration of its service life – should be included in the maintenance plan. (4) Strengthen predictive maintenance by emphasizing assessments prior to maintenance; through the use of condition monitoring methods as well as reliability and risk analysis techniques, improve the predictive maintenance of equipment on a daily basis, and reasonably control the degree of equipment disassembly during major maintenance tasks. (5) Other items that can be repaired during the operation of the equipment and carry relatively low construction safety risks shall, in principle, not be included in the shutdown maintenance plan. 03 Compliance Principle (1) As stipulated by policies and regulations, in accordance with the requirements set by relevant national and local authorities regarding safety, environmental protection, and energy conservation, any devices or equipment that do not meet these standards in terms of safety protection, environmental compliance, or energy efficiency must be included in the maintenance plan. (2) Statutory inspection requirements: In accordance with **relevant laws and regulations, the inspection and calibration items for special equipment, their safety accessories, measuring instruments, and electrical instruments and equipment shall be included in the maintenance and inspection plan. 04 Principles of Integrated Management (1) Equipment maintenance should be integrated with the company’s major technical upgrades, the elimination of safety and environmental hazards, and the improvement of product quality to meet relevant standards. All maintenance projects as well as investment projects carried out during maintenance periods should be managed in an integrated manner, ensuring unified approval processes, coordinated planning, consistent implementation, standardized funding arrangements, and uniform supervision and evaluation. (2) Special tasks such as catalyst replacement in the unit should be planned in conjunction with the unit’s maintenance cycle, and carried out whenever possible during the maintenance period. (3) During the maintenance period, funds required for all planned maintenance tasks and investment-related projects (repair costs, capital expenditures and safety production expenses, surplus funds, etc.) shall be arranged in a coordinated manner and secured before the maintenance begins; the implementation of any project for which the necessary funds have not been secured is prohibited. 05 Principles for the demonstration and review of technical upgrades: (1) For items included in the maintenance plan, those involving significant changes in the plant’s main production processes, technologies, products, or equipment structure must go through the corresponding demonstration and review procedures ； For major production units such as catalytic cracking and ethylene cracking, approval from the Refining, Petrochemicals, and New Materials Company must be obtained before implementation. (2) Investment projects shall go through the procedures for reviewing and approving feasibility study reports and preliminary designs in accordance with relevant regulations. (3) It is strictly prohibited to use repair costs for technical transformation projects. It is strictly prohibited to break down a large technical renovation project into several small maintenance projects. 06 Principle of cost-effectiveness: (1) Strictly control and manage repair costs, and assess in a practical and scientific manner the funds required for maintenance projects, in order to avoid unnecessary repairs and unreasonable expenditures. (2) The promotion of the adoption of \"four new\" technologies should be guided by the principles of advancement, maturity, reliability, applicability, and cost-effectiveness; the use of immature or untested technologies is strictly prohibited. (3) Regarding whether a project should be included in the maintenance plan, it is recommended to use a risk & consequence analysis matrix for determination. (4) Enterprises should determine the risk level of a maintenance project based on the likelihood of its failure and the severity of the potential consequences of that failure. Items identified as red zones should be included in the maintenance plan.