Large-unit management system

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Chapter 1 General Provisions 1. This management system is formulated to strengthen the management of large-scale units, improve their operational performance, and ensure safe, stable, long-term, and efficient production. 2. The large-scale units referred to in this management system are those determined through research based on actual production conditions and certain classification criteria, and are included within the corresponding scope of management. Large-scale units have high power and play an important role in production. The key units that are particularly important in production should be classified as units requiring special care. A large-scale unit is defined as one that meets the following conditions simultaneously: 2.1 The unit’s power is greater than or equal to 500 KW ； 2.2 The unit has an independent lubrication system ； 2.3 Units that play an important role in process production facilities, are complex in structure, and are technology-intensive. 3. To strengthen the management of large-scale units, it is necessary to rely on technological progress, adhering to the principles of \"combining design and manufacturing with operation,\" \"combining maintenance with repairs,\" \"combining repair, renovation, and upgrading,\" and \"combining professional management with overall employee involvement.\" 4. Under the leadership of the executive in charge of the Technology Department, efforts shall be made to strengthen the management of large-scale equipment. The Technology Department serves as the competent authority for such equipment; other relevant departments and units must each fulfill their responsibilities to jointly manage the entire lifecycle of large-scale equipment—from selection, procurement, installation, operation, maintenance and repair, to renewal, retrofitting, and eventual decommissioning. The management responsibilities of various departments and units should be clearly defined, with systems in place for inspection and evaluation. Chapter 2: Management Responsibilities
1. Large-scale units are technically complex and play a crucial role in production. All departments must strengthen the management of such units, establish a comprehensive management network and accountability system for them, fully fulfill their management responsibilities, and continuously improve the operational and management standards of large-scale units. 2. Responsibilities of the Equipment Management Department: 2.1 Responsible for the centralized management of large-scale units, implementing the headquarters’ regulations, procedures, rules, and standards related to such units, and responsible for formulating systems for their management. 2.2 Responsible for or involved in the selection of the unit, design review, manufacturing supervision, installation, commissioning, and acceptance. 2.3 Responsible for organizing technical analyses of the operating conditions of large-scale units, carrying out status monitoring, fault diagnosis, and technical problem-solving for such units, and fully leveraging the role of the equipment technical support team in the Technical Department. 2.4 Organize the top-level maintenance management for large-scale units. 2.5 Organize the establishment of technical management files, reports, and other relevant materials for large-scale unit equipment, prepare summaries of the work related to these units, and conduct regular inspections and evaluations. 2.6 Organize the formulation and review of maintenance procedures for large-scale units; participate in the review of operating procedures ； Organize the preparation of maintenance plans for large-scale units, approve the maintenance plans, and oversee the control of the maintenance process as well as the quality inspection. 2.7 Organize the preparation and review of plans and schemes for the upgrading and renovation of large-scale units, implement them, and ensure proper process control and acceptance procedures. 2.8 Responsible for the technical management of spare parts and components for large-scale units; organizes the preparation and review of spare parts and components plans. 2.9 Responsible for the promotion and application of new technologies, new processes, new materials, and new equipment in large-scale units, with the aim of continuously improving the equipment and technical standards of such units. 2.10 Organize investigation and analysis of major unit accidents and participate in accident handling. 3. Responsibilities of the project’s production, safety, and environmental protection management departments: 3.1 Participate in the selection, modification, and design review of large-scale units. 3.2 Participate in the mechanical operation tests and acceptance of large-scale units, and organize the joint commissioning and performance evaluation of such units. 3.3 Organize the formulation and review of technical documents such as operating procedures, process cards, and accident response plans for large-scale units. 3.4 Responsible for the operation and management of large-scale units, ensuring that they operate under specified technical conditions. 3.5 Participate in the investigation, analysis, and handling of accidents involving large-scale units. 4. Responsibilities of the using units (referring to various workshops) 4.1 Responsible for the operation and maintenance management of large-scale units within their own units, carrying out thorough maintenance on these units, operating them in strict accordance with technical specifications, and ensuring their safe, stable, and long-term operation. 4.2 Establish and improve equipment technical records, reports, and other relevant documents for large-scale units ； Responsible for preparing technical documents such as operating procedures, process sheets, and emergency response plans for large-scale units. 4.3 Be responsible for carrying out regular analyses of the quality of the oils used by the units, taking appropriate actions based on those analyses, and ensuring that the analysis reports are properly archived. 4.4 Responsible for preparing plans for the maintenance, renewal, and renovation of large-scale units, and submitting them to the relevant authorities ； Responsible for the implementation and acceptance of maintenance, renewal, and renovation of large-scale units. 4.5 Actively carry out condition monitoring and fault diagnosis of large-scale units, identify equipment defects in a timely manner and implement corrective measures to reduce unplanned shutdowns. 4.6 Participate in the investigation, analysis, and handling of accidents involving large-scale units, and formulate accident prevention measures to implement them. 4.7 Participate in the selection of units, design review, supervision of manufacturing, installation, trial operation, and acceptance. 4.8 Be responsible for the technical training and assessment of relevant personnel in the unit, continuously improving the technical capabilities of on-duty personnel in management, operation, and maintenance. Chapter 3: Design and Selection of Large-Scale Units
1. The design unit shall, based on the production process technical requirements put forth by the Technical Department and after conducting design calculations, provide the Technical Department with technical documentation regarding the selection of units, so as to facilitate preliminary design selection, specification determination, and bidding processes with manufacturers. 2. The final selection plan for large-scale units must be approved by the project’s technical department and authorized by the project’s senior management before it can be put into practice. 3. The manufacturer’s preliminary design proposals and drawings must undergo a tripartite design review involving the manufacturer, the design agency, and the construction party before they can be used for manufacturing. 4. The design and selection of large-scale units should comply with the latest versions of relevant technical standards and specifications. Taking into account the flammable and explosive nature of petrochemical processes, units that are reliable in operation, offer great flexibility, have a rational structure, high efficiency, and are easy to maintain should be chosen, in order to meet requirements such as low life-cycle costs, high overall equipment efficiency, and high safety and reliability. 5. Large-scale units must be equipped with comprehensive control systems, interlock protection systems, real-time monitoring instruments, and condition monitoring systems. Chapter 4 Supervision of Unit Manufacturing and Factory Acceptance 1. The selected unit manufacturer must be a company with a good track record, solid reputation, and excellent service. It should possess advanced processing equipment and technical capabilities, as well as relevant international standard certification systems. The units produced by such a manufacturer should exhibit high levels of environmental protection and energy efficiency. 2. The manufacturer must design, manufacture, and test in accordance with the technical agreement. Any modifications must be signed by the technical supervisors from the design, manufacturing, and enterprise sides before they can take effect. 3. During the manufacturing process of large-scale units, the Project Technology Department must dispatch professional technicians or engage qualified supervision personnel to oversee the manufacturing at the factory. The supervision personnel must promptly report any quality issues arising during the manufacturing process to the Technology Department and propose corrective measures. 4. The supervision personnel must oversee the entire manufacturing process of the unit in accordance with the standards and specifications specified in the technical agreement. The supervision personnel have the right to express opinions on behalf of the user, and the manufacturer shall respect such opinions. 5. Before the unit leaves the factory, the company shall conduct acceptance in accordance with the technical agreement and relevant standards. Chapter 5 Installation, Commissioning, and Acceptance of Large-scale Units 1. The unit responsible for the installation of large-scale units must be one with a good track record, excellent reputation, as well as the appropriate qualifications and capabilities for equipment installation. 2. Before the installation of large-scale units and auxiliary equipment, the manufacturer must provide complete technical documentation in accordance with the technical agreement serta relevant technical standards and specifications (which should include at least the factory certification and inspection records, the general assembly drawings of the unit, installation drawings and related diagrams, the packing list and detailed list of components, as well as technical information regarding the unit’s auxiliary equipment). 3. Before the installation of large-scale units, the manufacturer, the project team, and the installation unit must all participate together in the unpacking inspection. 4. The installation unit must prepare an installation plan for large-scale units in accordance with relevant standards and specifications; the installation can proceed only after it has been reviewed by the project department, the design team, and the supervision unit. The manufacturer shall provide technical guidance and assist in resolving any issues that arise during the installation process. 5. The on-site supervision unit must supervise the entire installation process in accordance with the provisions of the supervision contract and the requirements outlined in the installation plan. 6. After the installation of large-scale units is completed, the installation contractor must provide the project department with complete completion documents as well as electronic versions thereof within the specified time frame. 7. To comprehensively evaluate the mechanical operating performance, process technical performance, and control performance of the unit, large-scale units should undergo trial operation after installation. The project department may, depending on the actual circumstances, establish a corresponding commissioning team, which will prepare the commissioning plan; this plan is then reviewed and approved through joint consideration by units such as those responsible for construction, production, design, and manufacturing. The test run operations shall be carried out by personnel from the company’s production and usage units who are familiar with the test run plan and operating procedures, and who have passed the examination to obtain a work permit. 8. After testing, large-scale units must meet at least the following conditions before they can be accepted: 8.1 They must operate continuously for no less than 72 hours under rated conditions. 8.2 The technical performance meets the design requirements and can fully satisfy production needs. 8.3 The control system and monitoring system are operating well, with all adjustment mechanisms responding quickly, flexibly, and accurately. 8.4 There are complete and accurate test run records. Chapter 6 Unit Operation Management 1. The commissioning of large-scale units must be approved by both the technical department and the production and operation departments before it can proceed. 2. The production and operation departments shall formulate operating procedures for large-scale units, and organize relevant personnel to study them carefully. Operate strictly in accordance with the procedures to ensure that there is no overheating, no overpressure, no overload, no excessive vibration, and no operation at excessive speeds. 3. Operators and maintenance personnel must undergo technical training and pass assessments before they can take up their duties. They should have a thorough understanding of the machinery they operate or maintain, including knowing its structure, principles, performance, and purposes, as well as being able to use it correctly, carry out maintenance, and troubleshoot faults. 4. Strictly implement the patrol inspection system; carefully inspect all parts of the unit according to the patrol routes, contents, and standards, so as to promptly identify any problems and safety hazards. Carefully fill out operation records, defect records, and operation logs. 5. If the operator notices any abnormal operation of the unit, they should immediately investigate the cause. Any issues that can be resolved promptly should be dealt with right away, while those that cannot be resolved immediately must be reported. The entity using the unit should carefully consider appropriate countermeasures to establish a closed-loop management system for fault detection, reporting, and resolution. To ensure the safety of the equipment and personnel, the operating procedures should stipulate that in emergency situations, the operators on duty have the authority to take decisive actions in accordance with these procedures until the machine is stopped immediately, and to report the incident promptly. The cause affecting the normal operation of the unit is unknown; under no circumstances should the unit be started blindly without ruling out any faults. 6. Proper lubrication of the unit is one of the key factors in ensuring its proper operation. It is necessary to establish and strictly enforce a equipment lubrication management system, to properly manage lubricating oil, seal oil, control oil, and related equipment, thereby ensuring that the oil quality, temperature, and pressure are within normal ranges. 7. Ensure regular turning of the standby units as well as periodic maintenance to keep them in good standby condition. 8. Mechanical, instrumentation, and electrical maintenance personnel shall carry out routine maintenance on mechanical equipment, control instruments, interlock protection systems, and electrical equipment in accordance with relevant regulations, so as to continuously improve the equipment integrity rate, instrument control rate, and accuracy of relay protection operations; the utilization rate of interlocks should reach 100%. 9. The user unit shall ensure that the unit operates under conditions permitted by the design; it must prevent abnormal operating conditions such as surging, choking, and reverse flow in the centrifugal compressor. Under normal circumstances, anti-surge and other facilities should be set to automatic mode. When the operating conditions of the unit change, or when there are significant alterations to the flow path of the unit, a professional technical entity should be commissioned to calculate and determine the new operating conditions, and to revise the operating curve accordingly. 10. When the unit undergoes major operations, relevant professional technicians should be present to supervise. 11. Advanced monitoring instruments and methods should be actively adopted to carry out effective condition monitoring and fault diagnosis of large-scale units, thereby improving the level of predictive management of their operating conditions. Chapter 7 Operating Conditions 1. At the operating posts of large-scale units, there shall be 1.1 Operating procedures for the units. 1.2 The acceleration curves, performance curves, and system flow diagrams necessary for unit operation. 1.3 Values of various performance indicators during the normal operation of the unit. 2. To ensure the proper startup and safe operation of large-scale units, the following conditions must be met before the units are put into operation: 2.1 The mechanical and electrical components of the main unit or auxiliary equipment have been verified to meet the requirements. 2.2 The monitoring instruments, automatic control devices, safety protection systems, interlock alarms, and other facilities of the 2.2-unit plant must be fully equipped, and their reliable operation must have been verified. 2.3 The oil used in all parts of the unit (including auxiliary equipment) must meet the standards. 2.4 The process production conditions meet the operational requirements for unit startup. 2.5 In the event of significant changes in the operating conditions of the 2.5-unit unit, a senior management official from the plant or a responsible person from the relevant department should be present during the first start-up. 2.6 The various operational limit values for the 2.6-unit plant shall be established based on the data specified in the manufacturer’s accompanying instructions (if it is necessary to adjust certain values due to actual conditions, approval from the plant’s management and the relevant higher-level authorities is required; meanwhile, the relevant departments such as those responsible for machinery, electricity, and instrumentation must be informed so that they can carry out the necessary adjustments and make the required changes to the technical documents). 2.7 Carry out all the preparatory work necessary before starting up the unit. Chapter 8: Daily Management of Large-scale Units 1. The Technical Department is responsible for establishing a \"premium maintenance\" team for large-scale units. This team is headed by the project supervisor, with participation from the supervisors of relevant departments and units, as well as various technical professionals and maintenance staff. This team is tasked with overseeing the operation, maintenance, repair, and technical improvements of these large-scale units. 2. The daily management of the “special care” team is the responsibility of the Technical Department, with technical personnel from various fields such as machinery, electricity, instrumentation, management, and operation participating. 3. Each large-scale unit should have its own specialized maintenance plan. The premium maintenance plan should include the organizational structure and members of the premium maintenance leadership team, and a comprehensive premium maintenance team comprising representatives from mechanical, electrical, instrumentation, control, and operation fields should be established, with clear and specific responsibilities defined for personnel at all levels ； There are specific inspection routes, inspection contents, and frequency for personnel at all levels, along with prescribed inspection records; an inspection assignment system is implemented. 4. A special maintenance meeting should be held at least once a month, with the senior management and the head of the technical department in attendance. Various professionals shall report on the operating status of the large-scale equipment during that month, analyze and address any issues that arise during operation, propose preventive measures and corrective actions, and keep records of these meetings. 5. The Technology Department shall formulate assessment rules for large-scale units, organize inspections and assessments of such units once a month, enforce rewards and penalties in accordance with the assessment rules, and keep records of the assessments. 6. Keep detailed records of unit operation and records of shutdowns due to failures. Including various operating parameters, the course of failures (accidents), cause analysis, emergency repair plans, as well as corrective and preventive measures ； In the event of a failure, immediate repairs should be organized, and it is the responsibility to report the details of the failure (incident) to the technical department promptly. Chapter 9 Inspection of Large Units 1. The inspection of large units mainly includes: inspections by the Technical Department, inspections in the workshop, and inspections by the Maintenance Department. 2. For large units, 24-hour inspections must be conducted, including on holidays and at night. 3. For inspections of large-scale units, it is necessary to establish fixed personnel, timing, routes, inspection contents, and locations. There must be defined inspection routes, inspection times, and inspection contents, with dedicated personnel carrying out inspections on a regular basis. 4. During the inspection process, the inspectors must conduct thorough checks in accordance with the designated inspection routes, areas, and tasks. Any issues identified should be addressed promptly or reported to the relevant departments and personnel. 5. Inspectors must accurately record the actual operating values of various parameters in accordance with the requirements specified in the inspection records. . 6. No items may be left blank in the inspection records, and the handwriting must be clear and neat. 7. The inspection record book is kept by the production staff. 8. Inspection responsibilities: Chapter 10 Lubrication Management of Large Machinery Units 1. Responsibilities of the Technical Department for lubrication management 1.1 Overall responsibility for the mechanical lubrication of large machinery units. Responsible for organizing the formulation and implementation of lubrication management regulations for large-scale units, assigning lubrication management responsibilities at all levels, and supervising the enforcement of various rules and regulations. 1.2 Organize the preparation of lubrication charts and cards for various units, including: distribution maps of lubrication points, names of lubrication points, methods of oil filling, names and grades of oils, amount of oil to be added or replaced each time, intervals for oil filling and replacement, as well as consumption quotas. 1.3 Responsible for approving the use and substitution of lubricants, and organizing research to resolve issues existing in lubrication work. 2. Responsibilities of the Technology Department regarding storage and lubrication management
2.1 There should be sufficient reserves of lubricating oil to ensure that the units can be refueled at any time or that all the oil in the tanks can be replaced. 2.2 Newly purchased lubricating oil must be accompanied by a certificate of conformity from the manufacturer and an oil analysis report; it can only be stored in inventory after being confirmed as qualified ； 2.3 If oil is stored for more than six months, a quality analysis must be conducted again; it can be used further only if it passes the test. 2.4 When delivering the oil, a copy of the quality test report confirming that the oil meets standards should be provided to the user unit for reinspection ； 2.5 The analysis test reports for each batch of oil products must be retained for one year before they can be destroyed. 3. Responsibilities for lubrication management in the production workshop
3.1 The production workshop must prepare specific lubrication instruction charts based on the actual conditions of the major equipment. These charts must clearly specify: lubrication points, type of lubricating oil, quantity of oil to be added, and timing of lubrication ； Sampling and testing time for circulating lubricating oil ； At the same time, there must be dedicated record forms for careful documentation. 3.2 Responsible for confirming the delivery of lubricating oil by the oil supply department. Acceptance is granted only after confirming that all testing items are complete and that all indicators meet the specified requirements; the test report is then archived for future reference. The spare oil supplied must be regularly inspected and tested to ensure that its quality remains satisfactory at all times. 3.3 Strictly implement the lubrication management regulations of the “three filtrations and five fixations” (filtration during warehousing, filtration during dispensing, filtration during oil refilling; fixed personnel, fixed locations, fixed quality, fixed quantity, and fixed timing). 4. Lubrication responsibilities of operators 4.1 Operators must follow strictly the oiling methods, oil grades, timing, locations, and amounts specified in the lubrication schedule for large-scale machinery; no changes should be made arbitrarily. 4.2 Before starting up each large-scale unit, the regulations regarding lubricant circulation and filtration must be strictly followed ； During refueling, the filter screen must be secured, free from damage, and should be cleaned or replaced regularly ； It is necessary to keep careful records every time fuel is added or the oil is changed. 4.3 Conduct inspections and make records of all lubrication points along the inspection route. 4.4 Lubrication equipment should be kept clean and in good condition. Chapter 11: Management of Technical Archives For large-scale units, complete technical archives must be established, and dedicated personnel should be responsible for managing these archives, ensuring that records are kept up to date and archived in a timely manner. Mainly includes: 1. Installation and operating instructions, product manufacturing certificates or quality certificates, drawings, and related technical documents. 2. Installation record. 3. Equipment maintenance records. It is necessary to record in detail the time of each maintenance operation (including minor repairs) on the equipment, the main maintainer, the reason for the maintenance, the maintenance process, the parts replaced, as well as the time when the unit was restarted and the conclusions drawn from the maintenance. 4. Operating procedures including unit startup, operation, shutdown, etc. 5. Equipment lubrication records. 6. Equipment operation records. Records various performance parameters and operating conditions during the unit’s operation. 7. Equipment inspection records. 8. Equipment failure (accident) records. Record in detail the course of each fault (incident) that occurs, the cause analysis, the emergency repair process, and the corrective and preventive measures taken after the incident. 9. Records of major technical modifications to equipment. 10. Accessories catalog.