Management Measures for Key Equipment in Chemical Enterprises

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1. Purpose: To strengthen the management of critical and key equipment to ensure their safe and stable operation. 2. Scope of application: Maintenance and management of key equipment in various departments and units of the company. 3. Basis for preparation: \"Production and Equipment Management System\", Chemical Company’s \"Rules for Compiling Internal Control System Documents\", XX Company. 4. Division of responsibilities: 4.1 Mechanical and Power Management Department: 4.1.1 Implement the company’s preventive maintenance system, establish an equipment management approach based on monitoring the operation of equipment, and particularly carry out dynamic process management evaluations for critical equipment. 4.1.2 Based on the working approach for inspecting and evaluating key equipment, formulate management measures to standardize forms and management requirements, thereby achieving institutionalized management. 4.1.3 Responsible for establishing an inspection and evaluation system for key equipment, and conducting monthly evaluations of such equipment by utilizing the production management system and unit status monitoring system, in conjunction with routine inspections. 4.1.4 Responsible for collecting the “Weekly Report on Evaluation of Key Equipment” (hereinafter referred to as the “Weekly Report”) from each production department (workshop); verifying any malfunctions indicated in the inspection data submitted weekly by the production departments (workshops); and providing evaluation comments on their “Weekly Reports”. 4.1.5 Responsible for examining and evaluating the management of key equipment in production departments (workshops). 4.2 Production units and departments
4.2.1 General Manager of the Production Operations Department (Workshop)
a) Responsible for implementing the “Management Measures for Key Equipment”. b) Responsible for checking the data of key equipment collected by various technical supervision units. c) Organize a weekly assessment of the key equipment in the unit or department, and sign approval comments on the weekly assessment form for each piece of equipment. 4.2.2 Deputy General Manager for Equipment of the Production Operations Department (Workshop): a) Organize professional technical supervision within the department, identify key inspection and monitoring data points for critical equipment, determine the division of tasks regarding data collection within the department as well as the management and evaluation of individual pieces of equipment, and establish internal procedures for managing such critical equipment. b) Organize the weekly evaluation of key equipment within the unit/department, review all technical supervision and assessment comments, and sign approval comments on the weekly evaluation worksheet for each piece of equipment. c) Check fault data daily, urge relevant personnel to resolve faults, and establish contingency plans. d) Arrange for equipment failure resolution. 4.2.3 Professional engineers/operators in the production department (workshop): a) Conduct daily inspections of the equipment under their responsibility and collect data from the data sheets. b) Based on data changes, provide evaluation comments by considering the process and equipment conditions, and prepare a “weekly report” to be submitted to departmental supervisors. c) Handle or track equipment defects, and prepare relevant contingency plans. 4.3 Maintenance Units and Departments 4.3.1 Responsible for implementing the \"Management Measures for Key Equipment\" ； 4.3.2 Conduct daily inspections of the managed equipment and collect data from the data sheets ； 4.3.3 Organizing equipment failure handling ； 4.3.4 Handle or track equipment defects, and prepare relevant contingency plans. 5. Content and Requirements 5.1 The content of the “weekly report” includes: data (data points, tag numbers, standard values, daily recorded values), comparison with historical data, equipment evaluation, process evaluation, analysis of significant data, predictions for future monitoring, guidance suggestions, and PLC interface diagrams. The data points mainly include important parameters that affect the safe operation of the equipment (such as load, temperature, pressure, rotational speed, vibration, displacement, conductivity, pH value, etc.). The “daily reports” are prepared separately for high-pressure boilers, gasifiers, converters, urea high-pressure static equipment systems, as well as each individual large-scale unit. 5.2 In addition to the data collected from various online instruments, the data at inspection points should also include information obtained through listening, touching, observing, and smelling, as well as analysis and judgment based on these methods. Data is collected at fixed times and locations every day, with the peak values of the data points being recorded. The weekly evaluations conducted by each unit should not be based solely on the opinions of equipment technicians; rather, a comprehensive analysis and evaluation of the equipment must be carried out by incorporating the suggestions of process technicians. 5.3 The evaluation report shall analyze the trend changes at the monitoring points. For detection points where abnormalities are detected, technical supervisors must copy the interface diagrams and trend graphs for individual points from the DCS, PLC, and unit condition monitoring system, to be used as supporting documents for the evaluation report. 5.4 The Deputy General Manager for Equipment at production units and departments shall, every Wednesday afternoon, organize relevant technical personnel to analyze and summarize the weekly monitoring results of equipment. A “weekly report” is then compiled. On Thursday morning, the evaluation comments (in electronic format) must be submitted to the Mechanical & Power Management Department ； After writing down their recommendations on the evaluation form, the technical supervision team in the Mechanical Power Management Department provides feedback to the relevant leaders of the production units and departments. 5.5 Regarding the monitoring during startup and shutdown periods, each production unit and department must thoroughly analyze any changes in various monitoring data before and after shutdown in their post-shutdown “weekly reports”. These reports should promptly reflect the cumulative operating time of equipment, utilization rates, and major defects. The production operations departments are responsible for collecting all relevant data during the shutdown process. A special assessment meeting should be organized for each emergency stop. 5.6 When any abnormalities are detected in equipment, the responsible person must conduct a thorough inspection and verification, and coordinate with multiple professionals to jointly address the issues. Propose a solution. 5.7 During the period when the equipment is operating under faulty conditions, the person in charge shall provide special supervision over the equipment, organize technical analyses, develop special maintenance plans, and propose technical monitoring measures. 6. Inspection and Assessment 6.1 The Mechanical Power Management Department is responsible for supervision and inspection. 6.2 The Human Resources Department conducts evaluations in accordance with the performance assessment procedures.