Standards for shutdown major maintenance work

Thread Content

The goals for the major maintenance shutdown of the facility are: “Four Goods, Six Guarantees, and One Achievement”. “The “four goods” refer to proper shutdown, proper handling, proper maintenance, and proper resumption of operation ； “The “six guarantees” refer to ensuring safety, environmental protection, quality, project progress, schedule adherence, and cost control ； “\"Implementation\" refers to enabling the device to operate for a long period of time after maintenance. I. “Four Good” Work Standards (1) Proper shutdown: 1. Carry out network optimization, clarify the relevant nodes, and execute everything according to the plan ； 2. The plan for shutting down the device is scientific, reasonable, and comprehensive ； 3. The shutdown is organized in an orderly manner, responsibilities are clearly assigned, and everything is carried out strictly in accordance with the plan ； 4. Thorough material recovery during shutdown processes, accurate operations with step-by-step verification, minimizing material loss ； 5. No accidents or incidents occurred during the shutdown period; there was no improper disposal of materials, and it was ensured that no one was injured, no equipment was damaged, and no environmental pollution incidents took place ； 6. Obey the overall situation and strictly follow all company directives. (II) Handle properly: 1. Network optimization, clear node definition ； 2. The device processing plan is scientifically sound and reasonable ； 3. All materials in the device must be emptied as required, with no dead corners and no messy arrangement ； 4. Rational optimization of utility systems to minimize consumption ； 5. The equipment and pipelines have been thoroughly purged, steamed, replaced, and neutralized; the analytical tests have yielded satisfactory results, and the conditions for delivery are met ； 6. Blind plate isolation shall be implemented in full, with strict compliance to the regulations regarding blind plate management ； 7. The power supplies for the equipment shall be completely disconnected as specified ； Nitrogen and flare gas are completely isolated ； Sewers, sewage pits, and floor drains have been sealed off ； 8. Remove all oil stains and flammable materials from the device area ； 9. The equipment area has been properly enclosed in accordance with standards ； 10. The unit meets the requirements for production handover and maintenance at the scheduled time, and the process handover and maintenance inspection is passed in one attempt. (III) Proper maintenance 1. Sound organizational structure, tight organization, and effective command ； 2. The plan is well-formulated; the approval process is strictly followed, with responsibilities assigned to specific individuals ； 3. Optimization of the maintenance progress network, with clear defined nodes ； 4. The completion rate of maintenance projects is 100%. Including: (1) 100% completion rate for the three preventive measures implemented alongside maintenance work, hazard elimination, replacement of worn-out items, treatment of hard-to-reach areas, visualization, and project handover plans ； (2) 100% completion rate for inspection plans for special equipment, safety accessories, and pressure pipelines ； (3) The qualification rate for calibration of control instruments, measuring instruments, and interlocks is 100% ； (4) The pass rate for the calibration (verification) of flammable, toxic, and harmful gas detectors is 100% ； 5. The quality assurance system is effectively operational, with clear and comprehensive acceptance criteria: (1) The quality certification documents for materials entering the factory are complete, the origin of the manufacturers is clearly indicated, and re-inspections are carried out in strict accordance with relevant standards ； (2) First-pass welding qualification rate: 98% ； (3) The one-time qualification rate for the sealing of static equipment is 100% ； 6. A sound safety assurance system is in place, with clear responsibilities, adequate supervision, strict monitoring, and rigorous rewards and penalties; the maintenance process ensures zero accidents, zero injuries, and zero pollution ； 7. The overhaul and process acceptance were passed on the first attempt ； 8. The maintenance records are complete and properly archived as required ； 9. After maintenance, the device achieves zero leakage and meets the standards for being in good condition. (IV) Successful startup
1. The startup plan for the unit is scientifically reasonable and comprehensive ； 2. The project commencement was organized in an orderly manner, with personnel in place and instructions properly implemented ； 3. Thorough replacement during startup, ensuring the plant meets the material introduction requirements from the outset ； 4. The start-up process features smooth temperature and pressure increase, cryogenic cooling, and speed increase without any shocks ； 5. During the operation, there is no material leakage, misplacement, or spillage ； 6. Operate the equipment correctly to achieve zero damage to the equipment ； 7. 100% execution rate of operational instructions, 100% accuracy in the execution of process operation cards ； 8. Instrument automation rate: 100%, primary interlock operation rate: 100% ； 9. The drive was successful, with all technical specifications meeting the standards. II. Work measures for the “Six Guarantees” (1) Ensuring safety: 1. Establish and improve the safety guarantee system, implement a system of full responsibility by the top official in charge of the respective area, strengthen the direct responsibilities of project supervisors, and fulfill the duties related to local management. Strictly implement the principle that \"the person in charge is responsible, the person responsible for the project is responsible, and the person in charge of the area is responsible.\" The person in charge of the production unit that is shut down for maintenance should organize personnel from the production, technical, equipment, and safety departments, as well as operators, to jointly assess the risks associated with the shutdown and restart processes. Safety measures and emergency plans should be developed, and a risk assessment report should be prepared. After obtaining approval from the relevant department in the factory, training should be provided to the employees, while the construction team should also be briefed on safety procedures ； 2. All on-site personnel involved in inspection and maintenance must be familiar with and strictly abide by the “Ten Unbreakable Safety Rules” and the “Six Prohibitions Against Violations”” ； All personnel engaged in special operations must hold a valid \"Special Operations Operator Certificate\"; otherwise, they are not allowed to carry out such operations ； 3. Before carrying out maintenance work, each unit must provide targeted safety training on maintenance procedures for its employees who will be involved in the work ； Conduct a risk analysis for each construction task, clarify the monitoring requirements, and ensure that monitoring responsibilities are fulfilled ； 4. The contractors responsible for maintenance projects must go through the necessary approval procedures in strict accordance with the requirements regarding qualifications, personnel, and the site itself. Management is carried out based on the principle of \"whoever introduces them is responsible, whoever uses them is responsible, and whoever is in charge of the area is responsible.\" On-site workers must pass a safety education test before they can enter the site, and construction equipment must pass inspections in accordance with regulations before it can be used on site ； 5. On-site inspections shall be carried out in accordance with the safety and technical instructions provided by the entity responsible for the project; a risk assessment of the project’s processes and the construction site shall be conducted, safety and technical measures as well as emergency plans shall be formulated with clear assignments of responsibilities. A risk assessment report for the construction work shall be prepared, and only after it has been approved and the relevant personnel have received training shall work commence ； 6. The contractor must first sign the “Maintenance Safety Contract” and comply with all terms therein. During maintenance and repair operations, the construction organization is responsible for ensuring safety throughout the process, while the contractor is responsible for the safety of its workers ； 7. When shutting down the facility, the plant’s ventilation systems, facilities for handling toxic and harmful substances as well as industrial waste, and flare systems should be deactivated last, to prevent accidents caused by the inability to promptly treat toxic and harmful substances ； 8. All types of equipment must go through handover procedures before being delivered for maintenance ； 9. Main tasks and standards to be carried out before maintenance work on equipment, containers, and pipelines that contain toxic, hazardous, explosive, flammable, or corrosive materials: (1) Appropriate steam purging, hot water washing, neutralization, nitrogen displacement, or air displacement should be performed to ensure that no residual materials remain inside or to meet the specified standards ； (2) The combustible gas concentration shall not exceed 10% (by volume) of the lower explosive limit of the mixture of this medium with air ； (3) The concentration of toxic gases does not exceed **the health standards, with an oxygen content of 19–23.5% (by volume). After passing the analysis, a blind flange should be installed to isolate it from other systems ； (4) The aforementioned equipment, containers, and pipelines that are not subject to maintenance work should also undergo appropriate process treatments to ensure safety during the period of shutdown ； 10. Requirements when it is necessary to open the manholes of equipment after it has passed the process treatment: (1) The internal temperature of the equipment must be below 40°C, and the pressure should be at atmospheric level. After opening the bottom drain valve and confirming that there is no material left inside the equipment, the manholes should be opened sequentially from top to bottom ； (2) When opening the manhole, the nuts should be loosened gradually in a diagonal manner, and measures must be taken to prevent materials from splashing and causing injury, as well as to prevent the bolts on the manhole cover from causing harm ； (3) When cleaning small amounts of residual combustible materials in the container, tools that do not generate sparks must be used; it is strictly prohibited to use iron tools for hitting or knocking ； 11. After the process shutdown procedures for the facility are completed, the production wastewater systems and underground piping systems within the facility area must be sealed tightly. Any oil residues, flammable materials, or hazardous substances on open ditches, shafts, the ground surface, platforms, as well as on the exterior of equipment and pipes (including insulation layers) must be removed completely ； 12. The nitrogen system of the equipment should be managed by a designated person. After use, blind flanges must be installed to isolate the nitrogen system from other systems, preventing any cross-contamination between systems ； 13. Handrails, railings, ladders, platforms, covers, grates, load-bearing components, etc., at the maintenance site should all be inspected and addressed in advance to ensure they are safe and reliable ； 14. Activities such as using fire during maintenance, working in confined spaces, using temporary electricity, and working at heights must be carried out only after relevant permits have been issued, risk assessments have been conducted and safety measures put in place; once everything is found to be satisfactory through analysis, and a supervisor is present, the work can proceed ； 15. Scaffolding and stepping boards used for construction and maintenance work must meet the requirements of the \"Safety Regulations for Refining and Chemical Engineering Construction.\" With the exception of wooden scaffolding that can be used in equipment containing fragile materials such as ceramics or fiberglass, all other scaffolding must be steel-based. After installation, they must pass inspection and obtain a permit before they can be put into use ； 16. Lifting machinery and electrical/welding tools must be in good condition, and must have passed inspection and been fitted with appropriate labels before they can be brought onto the site ； The acetylene cylinder used for gas welding must be placed upright and secured to prevent it from tipping over ； A tempering device should be installed at the outlet of the pressure relief valve. The distance between acetylene cylinders, oxygen cylinders, and open flames should be no less than 10 meters; the distance between acetylene cylinders and oxygen cylinders should be more than 5 meters. They must not be placed near heat sources or electrical equipment, and exposure to direct sunlight should be avoided ； 17. When using high-pressure washers or high-pressure water guns to clean equipment, a work permit is required; operators must pass safety and technical training examinations, and the safety operating procedures for the equipment must be strictly followed during use ； 18. During maintenance, safety facilities such as walkways, guardrails, scaffolding, and walkboards must be properly protected. If temporary changes are necessary, warning signs, barriers, and red lighting at night must be installed, along with dedicated personnel to oversee the area ； 19. When conducting hydrostatic tests on containers, pipes, equipment, etc., two pressure gauges with the same range and calibrated must be installed in easily observable locations. All fasteners must be securely tightened. Under normal circumstances, compressed gas shall not be used as a test medium. In special cases where compressed gas is used as a test medium, prior approval from the responsible supervisor at the testing facility is required. Unrelated personnel are not allowed to stay at the test site ； 20. Construction work shall not use production equipment, pipelines, utility poles, as well as buildings and structures as anchor points for steel wire ropes to bear loads; in special cases, approval from the management of the relevant unit is required ； 21. Hazardous areas within maintenance construction sites, such as wells, pits, electrical equipment, and points where gases or liquids are discharged, as well as sites where special types of work are carried out, should be marked with hazard warning signs; red lights should be used at night ； 22. During the maintenance process, the company’s change management system is strictly followed to prevent changes to projects without corresponding designs, plans, or strategies; arbitrary modifications to construction plans are also prohibited, as is any casual alteration of equipment and facilities ； 23. After the maintenance and construction work is completed, the contractor shall promptly clean up the site to ensure that all tools and materials are removed and the area is left clean. Both the maintenance and production teams should follow strict handover procedures, and maintenance tasks must pass quality inspection. After confirming that the hot work at the construction site has been completed, that the safety equipment has been returned to its proper position and passed inspection, the unit responsible for maintenance shall organize a comprehensive inspection and acceptance of the device’s maintenance work. Only when all conditions are met can the stage of preparation for production commencement be entered. 2024 Training Course on Continuous Process Development, Pilot Plant Scale-Up, and Industrialization (II): Environmental Protection 1. Identifying environmental factors in shutdown procedures, maintenance activities, and restart plans for facilities, and formulating corresponding plans for the disposal of waste materials and risk control measures ； 2. The wastewater generated during parking operations and maintenance work must be monitored, and an emission plan must be determined based on the monitoring results ； All waste gases that can be sent to the flare system should be sent there, in order to reduce uncontrolled emissions at the site ； Solid waste that can be recycled is recycled, while that cannot be recycled is sent to industrial landfills for disposal. Achieve orderly, compliant, and controlled emission of pollutants ； 3. During shutdowns for maintenance, seal the rainwater drainage system promptly to prevent materials and pollutants from entering it ； 4. For high-noise operations such as device purging and target shooting, sound-damping measures should be taken, and the relevant procedures must be handled by reporting to the company’s environmental protection department in advance ； 5. During major maintenance, the management of radioactive level gauges and flaw detection operations is proper, ensuring that radiation safety is under control. Strictly follow the procedures for radiation work and keep proper records, while implementing measures such as notification, isolation, warning, and supervision ； 6. Ensure controlled emissions from flares, protect wastewater treatment plants from disruption, achieve zero environmental pollution incidents, and carry out maintenance in a green, clean, and civilized manner. (III) Ensuring Quality 1. In accordance with the requirements for managing major maintenance projects, each maintenance unit and construction unit must establish corresponding quality management leadership teams and develop a comprehensive quality assurance system. For each project, there should be a dedicated person responsible for quality control, with clear responsibilities assigned to specific individuals ； 2. Develop construction technical plans or maintenance operation procedures for each inspection and repair task, and it is not permitted to modify these plans or deviate from them during implementation ； Any changes to the construction plan must be approved in writing by the person who originally approved the plan ； 3. The quality of maintenance materials is managed at three levels, with clear responsibilities established; the principle of \"whoever purchases is responsible, whoever receives is responsible, and whoever uses is responsible\" is strictly followed to ensure strict control over the quality of materials, spare parts, and equipment throughout their procurement, re-inspection, arrival at the facility, and use: (1) It is necessary to carefully check the relevant information on the quality certification documents of raw materials upon their arrival, verifying the manufacturer, production batch number, specifications, model, quantity, material type, geometric dimensions, and appearance ； (2) For chromium-molybdenum steel, nickel-containing low-temperature steel, and molybdenum-containing austenitic stainless steel, verification tests on the main alloying elements shall be carried out using spectral analysis or other methods as specified in the standards, with proper recording and labeling to be done ； (3) Valves must undergo pressure testing of the valve body and sealing surface testing in accordance with the specifications, one by one. Valves that pass these tests should be marked, and a record of the pressure testing should be kept. Low-temperature valves shall be accompanied by a certificate of successful low-temperature sealing test issued by the manufacturer ； (4) The threads of the fasteners must be intact, free from defects such as scratches or burrs, and the machining precision must meet the requirements of the product standards ； (5) The wound gasket must not be loose or warped, and its surface must be free from defects such as scars, gaps, irregularities, and rust spots that could affect its sealing performance ； The machining dimensions, precision, and surface roughness of the metal ring gaskets and lens gaskets must meet the specified requirements; their surfaces shall be free from defects such as cracks, burrs, grooves, radial scratches, and rust ； (6) The auxiliary materials provided by the contractor, such as welding materials and their accessories, adhesives, etc., must have their quality carefully controlled during procurement, and should be used in accordance with relevant standards and specifications ； (7) All materials must undergo verification re-inspection in accordance with construction specifications. 4. Strict material management at the site is required; materials must be managed through classification and proper labeling to prevent their mixed or incorrect use ； 5. Strict quality control during the construction process: (1) Personnel engaged in special construction tasks must hold valid certificates to work; welders, scaffolders, and crane operators must pass the qualification reviews and skill tests conducted by the construction company. Construction machinery must pass the evaluations and inspections carried out by the construction company, while electrical equipment and electricians must pass the assessments conducted by the Electrical and Instrumentation Department or the Power Plant. The facility manager conducts an on-site review of the qualifications of the aforementioned personnel and the condition of the equipment ； (2) Conduct inspections at the designated shutdown points in accordance with the construction sequence, ensuring strict verification at each step ； (3) Hidden items must be inspected and approved by the construction party’s technical and quality supervisor as well as the project manager in charge of the installation before they are covered up, with proper records to be kept ； (4) After the completion of each project, it must pass the inspection by the technical and quality supervisor of the constructor as well as the project manager in charge of the installation, with proper records to be kept ； (5) All pressure-bearing welds shall be subject to non-destructive testing in accordance with standards, and the welder’s code shall be indicated ； (6) All static sealing points must be labeled with the name of the person who carried out the installation work, to ensure zero leakage after maintenance ； (7) The pressure testing of equipment and pipelines shall be carried out strictly in accordance with the relevant regulations; the test records must be filled out accurately, and they shall be verified by the person responsible for the technical quality of the installation ； (8) During the construction process, the contractor must ensure that the equipment and pipelines are clean, with no debris allowed to remain ； (9) The valves replaced on-site must undergo a 100% pressure test ； (10) The gaskets and bolts used on site must be installed in accordance with the specifications of the original equipment; no changes should be made arbitrarily. For flange bolts under pressure of over 6.4 MPa and bolts with a diameter larger than M27, torque wrenches or hydraulic/pneumatic tools must be used; hammering is prohibited ； (11) The installation and restoration of pipe supports and hangers comply with the requirements of the design and specifications ； (12) The insulation layer shall be constructed in accordance with the specifications, ensuring uniform thickness, tight joints, proper fastening, and appropriate tightness, so as to guarantee good insulation performance ； (13) Thorough rust removal must be carried out in accordance with the specification requirements before anti-corrosion work begins, and the next stage of work can proceed only after the installation has been approved ； (14) For electrical and instrumentation work, it is necessary to ensure that connections are secure and have good contact; each connection must be checked carefully, and tests must be carried out in strict accordance with relevant regulations and standards ； (15) Civilized construction is required during maintenance work, and no damage shall be caused to other equipment and facilities ； 6. Upon completion of the equipment maintenance work, the contractor must hand over the individual pieces of equipment to the person in charge of the project and go through the handover procedures ； In accordance with the specifications, tests, inspections, and calibrations of individual equipment are required to be carried out strictly ； 7. After the maintenance work is completed, the construction unit shall prepare completion documents in accordance with CNPC’s project completion acceptance standards, while the equipment management personnel in the workshop shall record any issues that arose during the maintenance process as well as the measures taken, and file this information in the equipment maintenance records. (IV) Project Assurance 1. Assign project leaders for each item in accordance with the project plan issued by the company, clarify responsibilities, and ensure that the projects are carried out as planned during the maintenance period ； 2. Strictly comply with the company’s regulations regarding inspection, maintenance projects, and related costs; it is not allowed to omit any items, leave anything out, or change the content of the projects. If it is indeed necessary to add or modify project elements, such changes must be approved in accordance with the company’s relevant rules ； 3. During the major maintenance period, if various factors prevent the projects from being carried out as planned, approval from the Major Maintenance Command must be obtained, and this must be recorded in the relevant documents. For legacy and unfinished projects, a plan for rectification should be prepared; for potential equipment hazards, preventive measures and response strategies must be established. (5) Ensuring progress: 1. Thoroughly carry out the preliminary technical preparations; when the branch factory provides instructions to the construction team, it is necessary to address safety, quality, and progress at the same time. The construction unit must carry out thorough coordination, prepare practical construction organization plans and procedures, employ advanced construction techniques and methods, assign highly qualified workers, and improve the efficiency of on-site construction work ； 2. Strictly adhere to the schedule outlined in the major maintenance construction plan. By comparing this with the actual progress of on-site maintenance work, any delays in construction must be promptly analyzed to identify their causes. Appropriate measures should be taken to adjust the schedule based on the degree of deviation, so as to correct such deviations and ensure that the project is carried out in accordance with the planned schedule ； 3. Ensure timely implementation of the usage schedule for large machinery during maintenance periods; when using them alternately, make proper plans and ensure adequate coordination ； 4. Strengthen the control of various tasks on the critical paths, conduct comprehensive analyses, concentrate available resources on the key tasks, and prioritize support in terms of management and resources for the processes on these critical paths to ensure the achievement of the overall maintenance deadline ； 5. Strengthen coordination and supervision among different specialties and job types, determine the handover dates for adjacent process stages, emphasize the importance of meeting deadlines, and ensure that the project progress is not delayed at any particular stage; by controlling the quality and timing of each process, the overall schedule for the major maintenance work can be ensured ； 6. Strengthen the management and allocation of inspection, maintenance, and construction teams. When signing contracts with contractors, the start date of work must be clearly specified; the plan must be followed strictly, with ongoing monitoring to allow for timely adjustments to the project schedule and to address any shortages in construction resources ； 7. Ensure the timely arrival of supplies, coordinate the procedures for their inbound and outbound handling, arrange for the necessary planning and funding, so that maintenance supplies can be delivered to the construction site as soon as possible ； 8. Prepare the formation and allocation of a reserve team for major overhauls to deal with any unexpected incidents. (VI) Insurance premiums: 1. Strictly comply with the company’s regulations regarding inspection, maintenance projects and related costs. During the implementation of these projects, any deviations between the actual costs incurred and the planned costs must be reported in a timely manner, and projects that exceed their budgeted costs must be approved in accordance with the established procedures ； 2. Establish a system for verifying and confirming the physical workload during project implementation, assigning responsibilities to specific individuals; those who sign off are responsible for the project’s physical workload ； 3. Strict control should be exercised over on-site changes to planned projects; any additions or reductions to construction projects, as well as changes to the project scope, must be approved by the Major Overhaul Command before they can be carried out ； 4. Strengthen on-site quality control to prevent cost increases resulting from quality rework ； 5. Organize project construction reasonably, optimize the construction organization design and plans, balance project resources, and avoid waste of personnel, equipment, and materials ； 6. Accelerate the settlement process, strictly adhere to company policies, and complete settlements in a timely manner within the specified time frames. III. Overall goal of “one achievement”: To achieve long-term stable operation of the device after maintenance, ensuring that no unplanned shutdowns occur due to issues related to the quality of the maintenance work.