Comprehensive Compilation of Equipment Management Systems (Part 1)

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Table of Contents: Comprehensive Compilation of Equipment Management Systems
I. Basic Technical Management System for Equipment
II. Equipment Maintenance and Repair Management System
III. Equipment Routine Inspection Management System
IV. Equipment Maintenance Management System
V. Pressure Vessel Management System
VI. Lubricants Management System
VII. Management System for Special Equipment
VIII. Equipment Routine Inspection System
IX. Safety Management System for Special Equipment
X. Equipment Sealing Management System
XI. Equipment Anti-corrosion and Insulation Management System
XII. Equipment Installation, Commissioning, and Acceptance System
XIII. Equipment Accident Management System
XIV. Equipment Lubrication Management System
XV. Management of Spare Parts for Equipment
XVI. Management System for Equipment Documentation
XVII. Detailed Rules for Equipment Inspection, Evaluation, and Incentive/Punishment Mechanisms
XVIII. Rotation System for Standby Equipment
XIX. Management System for Electrical and Instrumentation Operators
XX. Management System for Electrical and Instrumentation Personnel and Division of Responsibility Areas
XXI. Management System for Explosion-proof Electrical and Instrumentation Equipment
XXII. Management System for Instruments, Meters, and Automated Equipment
XXIII. Management System for Flammable and Toxic Gas Detection and Alarm Devices
XXIV. Management of On-line Analytical Instruments
XXV. Management of Instrument Power and Gas Supplies
XXVI. Electrical Testing System
XXVII. Routine Inspection System for Substations
XXVIII. Calibration Standards for Measuring Instruments
XXIX. Shift Handover and Management System
XXX. Wiring Standards for Electrical and Instrumentation Equipment
XXXI. Explosion-proof Standards for Explosive Areas
XXXII. Management Methods for Fire Protection and Hazardous Gas Alarm Control Systems
XXXIII. Management Methods for Closed-circuit Monitoring Systems and Intercom Systems
XXXIV. Management of Automatic Control Systems
XXXV. Management of Interlock Protection Systems
XXXVI. Regulations for Interlock Work Orders
XXXVII. Basic Safety Knowledge for Working at Heights
XXXVIII. Standards for Equipment Condition

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I. Basic Technical Management System for Equipment
This system is established to strengthen the technical management of equipment, providing management data, technical information, and criteria for evaluation in order to support effective equipment management. I. The technical foundation management of this equipment mainly includes tasks such as equipment standardization, equipment management quotas, equipment technical archives, and technical drawings and documents related to the equipment. II. Equipment Standards 1. Equipment standards include technical standards and management standards. In all aspects such as the design, manufacturing, installation, use, maintenance, repair, and disposal of equipment, our factory must strictly comply with **standards and industry standards. 2. Equipment technical management standards should be established in accordance with the needs related to the use, operation, maintenance, and manufacturing of equipment, including procedures for equipment operation, equipment maintenance, equipment repair, equipment manufacturing processes, as well as relevant safety and technical regulations. Equipment management standards should establish work procedures based on the tasks involved in equipment management, and set corresponding work standards in accordance with the responsibilities at various levels. When formulating standards, our factory should carefully summarize the practices of its workers and technical staff, combine them with advanced domestic experiences, conduct thorough discussions, and finally submit them to the factory management for approval and implementation. III. Quotas for equipment management 1. The main quotas for equipment management include quotas for the maintenance cycles of equipment, quotas for the duration of maintenance work, quotas for the man-hours required for maintenance, quotas for maintenance costs, quotas for working capital, as well as quotas for the consumption and storage of spare parts and materials. Our factory must maintain the seriousness of quotas, and the establishment and modification of quotas require strict adherence to the relevant approval procedures. 2. Our factory should establish a system for implementing quota standards and conducting strict assessments of those standards. Records of the execution results should be kept, and comprehensive analyses should be conducted regularly. IV. Equipment Technical Records 1. The Equipment Technology and Power Department shall maintain technical records for the main equipment across the entire plant, while the workshops should keep technical records for all the equipment in their respective workshops. The contents of the equipment technical file include: (1) Table of contents (2) Installation and operation manual. Equipment manufacturing certification, pressure vessel quality certificate, equipment commissioning records, etc. (3) Equipment history card. Equipment number, name, main specifications, installation location, commissioning date, names and specifications of auxiliary equipment, operating conditions, records of equipment changes, etc. (4) Equipment structure and spare parts drawings. (5) Cumulative equipment operation time. (6) Records of equipment maintenance, testing, and evaluation. (7) Records of equipment defects and equipment accidents over the years. (8) Equipment rating record. (9) Equipment lubrication records. 2. After projects such as infrastructure construction, technical measures, and safety measures are put into operation, technical documents such as installation and commissioning records, manuals, inspection certificates, and test records should be included in the equipment’s technical archive. 3. Technical archives must be complete, organized, and standardized, with timely sorting and filling out. V. Equipment Technical Records: The equipment maintenance workshop should maintain complete technical records for all the equipment in the plant. The equipment technical ledger is a comprehensive technical document for all the equipment in the plant, covering the following technical aspects: (1) Summary table of the main technical conditions of the equipment (equipment integrity rate, leakage rate, and major equipment defects). (2) Summary table of main equipment operation status (equipment operation time, downtime). (3) Summary table of equipment maintenance status (major repair projects, actually completed projects, unplanned projects, planned maintenance hours, maintenance costs incurred, etc.). (4) Equipment accident summary table (number of accidents, cumulative downtime, downtime losses, etc.). (5) Summary table of spare parts and material consumption. (6) Summary table of technological innovation achievements for major equipment. 2. The equipment maintenance workshop should assign a dedicated person to be responsible for compiling the technical records of the equipment, as well as for filling in the quarterly reports on equipment operation in accordance with **relevant regulations. VI. Storage of Drawings and Documents 1. The factory’s production department is responsible for storing and providing the drawings for all equipment in the factory. 2. The maintenance workshop is responsible for storing and providing the drawings for spare parts of all equipment in the plant. 3. When equipment is migrated or transferred, its records should be moved along with the equipment; after the equipment is scrapped, those records are kept in the factory’s production department for reference. 4. After the equipment for infrastructure, technical measures, and safety measure projects is put into operation, their as-built drawings are handed over to the factory’s production department for storage. Technical documents such as installation and commissioning records, inspection certificates for manuals, shielding project details, and test records are kept by the maintenance workshop or the workshop where the equipment is located. 5. The maintenance workshop should also keep copies of the relevant drawings for boilers and pressure vessels, as well as maintain records of regular inspections. II. Equipment Maintenance Management System I. Principles of Equipment Repair Production equipment constitutes a major part of a company’s fixed assets and forms the basis of its production capacity. Equipment repair must adhere to the principle of repairing before starting production, with a focus on prevention, as well as equal emphasis on maintenance and scheduled repairs, so as to enable the equipment to serve production more effectively. II. Annual inspection and assessment of the technical condition of equipment 1. In the third quarter of each year, the equipment management department prepares a plan and sets out the requirements for a company-wide inspection of the equipment. This plan is submitted to the equipment production and technology department as well as the chief engineer; once approved, the equipment inspection is carried out throughout the factory, with the equipment management department organizing the actual work. 2. The comprehensive inspection work in each workshop is organized by the section chiefs, who form workshop inspection teams consisting of equipment technicians, team leaders, and maintenance staff to identify the problems existing with the equipment as well as its usage status. The equipment technician fills out the “Equipment Technical Survey Form” to submit requests for equipment that needs repair in the coming year, and submits it along with the survey form to the Production Technology Department. 3. The equipment supervisor is responsible for organizing the establishment of an equipment inspection and assessment team, which consists of equipment managers, technicians, repairmen, machine operators, and electricians, together with equipment technicians and maintenance staff from various work sections, to conduct technical assessments on each piece of equipment that requires major or minor repairs as part of the comprehensive equipment inspection. Identify the major and medium-scale maintenance projects initially, and the technical personnel from the equipment management department’s inspection and assessment team shall fill in the relevant sections of the inspection form. III. Preparation of the plan 1. To ensure that there is sufficient time for the technical preparations prior to maintenance, the annual maintenance plan should be finalized at the latest two months before the year begins. 2. The annual maintenance plan should include: the annual major repair plan (including partial major repairs to key, large-scale, and production-related equipment), as well as plans for intermediate repairs, maintenance, and preventive testing. IV. Approval and Issuance of Maintenance Plans 1. After the annual plans for major and medium-scale equipment repairs are prepared, the medium-scale repair plans are submitted to the Production Technology Department and the Chief Engineer for approval, while major repair plans must be forwarded to the factory manager for approval. Once the plans are approved, the Equipment Management Department forwards them to the relevant departments (production, planning, finance, etc.), as well as to the equipment maintenance units and relevant work teams, for implementation. 2. For workshop repairs, if they are capable of carrying out medium-level repairs and level 2 maintenance, the tasks will be assigned to the workshops. If the workshops can only handle level 2 maintenance but not medium-level repairs, then those medium-level repair tasks will be undertaken by the mechanical repair workshop; for repair projects that require cooperation between the production workshop and the mechanical repair workshop, the tasks will be assigned to both workshops respectively. 3. The preventive testing plan is issued by the equipment management department and carried out by the power maintenance and equipment repair units. V. Technical preparations for equipment repair 1. Preliminary inspection: Conducted about three months before the major repair, or it can be carried out simultaneously with the previous level-2 maintenance before the major repair, with the equipment department responsible for scheduling it. The pre-inspection items for chief technicians, major repair fitters, and section equipment technicians include: (1) Inspection of the main accuracy and performance of the equipment. (2) Identify the cause of the equipment failure in order to determine the repair tasks. (3) Maintenance of the electrical components. (4). Based on the equipment’s wear condition and data analysis, remove and disassemble the necessary components to understand the internal structure, determine which parts need to be replaced or repaired, in order to prepare a list of defects. (5) Prepare the necessary drawings, and check the existing repair manuals and relevant materials. (6). Study repair plans and manufacturing processes for key components. 2. Re-inspection: Conducted during major overhauls and disassembly, it involves the lead technician, the process engineer from the repair facility, the maintenance fitter, and the equipment technician from the operating department, in order to verify and supplement the preliminary inspection. 3. Preparation of the repair technical plan: After the preliminary inspection and assessment, the lead technician prepares a “repair technical plan”. The main bases for this plan are the equipment’s historical record (including previous major and minor repairs, damage caused by accidents, and any modifications made), various records of the equipment’s technical condition prior to repair, as well as the plans regarding the organizational aspects of the repair process. Three copies of the repair technical preparation document shall be prepared; after being signed jointly, they shall be submitted to the operating workshop, the repair workshop, and the equipment manager for archiving respectively. VI. Acceptance and Handover 1. After major, medium-scale repairs or maintenance of the equipment, the equipment management department organizes the chief technical officers in charge of the equipment, the persons in charge of the equipment at the respective workstations, inspectors, chief fitters, and operators to carry out the acceptance process. Upon completion of the acceptance, the chief technical officer fills out an acceptance form for the completed equipment repairs; this form is made in four copies, one copy to be sent to the production equipment management department, one to the workstation where the equipment is used, one to the finance department, and one to the enterprise management planning and infrastructure department. 2. After acceptance, the planner shall collect and organize the relevant repair documents (including the equipment submission form for repair, the technical preparation document for major repairs, a list of defective parts, records of precision inspections, records of technical performance tests, and the notification of completion of equipment repair), and submit them to the equipment manager and the company’s archives for storage. 3. Within three months of acceptance and operation, if faults occur due to poor repair quality, the original repairer shall be responsible for carrying out further repairs and assume corresponding liability. 4. Handover of repaired equipment: After the inspection of the equipment that has been overhauled in the maintenance workshop is completed, the equipment officer from the workshop that sent the equipment for repair fills out the “Equipment Handover Form” (in three copies), one copy for the equipment management department, one copy for the maintenance workshop, and one copy for the workshop that sent the equipment. VII. Inspection and Assessment: This system is managed and inspected by the department in charge of equipment, assessed by the Production Technology Department, and supervised by the Enterprise Management and Planning and Infrastructure Department as well as the Finance Department. III. Equipment Routine Inspection Management System 1. General Provisions This system specifies the management structure and tasks related to equipment routine inspections ； This system applies to the management of production equipment on the company’s production lines ； II. Management Organization 1. Based on the actual requirements of regular equipment inspections in our company, a three-level management network is established, with frontline staff as the foundation, section technicians playing a key role, and the equipment management department responsible for overseeing these inspections. 2. Production equipment is the responsibility of the operators at each post, and the work section should establish and implement a system of assigning specific personnel to specific machines. Operators must remain at the equipment at all times; the equipment should be under someone’s supervision. They need to be diligent in their actions, keep a close eye on everything, and be attentive to any signs of problems, so as to maintain the equipment properly. Any issues that arise should be resolved promptly or reported to the relevant personnel for immediate correction. 3. Technical personnel or managers in the work section must keep a good grasp of the operation status of the equipment in their section, check how the workers at various positions perform inspections and maintenance on the equipment, monitor its operational conditions at all times, and take prompt action to address any issues that arise. 4. Relevant personnel from the equipment management department conduct regular inspections of the online equipment across the entire production line, as well as periodic inspections of the main equipment, in order to monitor the operating condition of all equipment on the line. They also guide and supervise the equipment inspection tasks carried out by various work teams, so as to ensure the safe and efficient operation of the production equipment. Also, keep proper records of the routine inspections and the handling of any issues; these inspection records must be maintained in their entirety. III. Tasks involved in inspections 1. Equipment management department: (1) Organized by the equipment supervisor, with participation from the heads of equipment teams in various sections or technical staff. (2) Inspection cycle: Once a month, regular inspections are conducted on the production main equipment. (3) Inspection contents: a. Check the implementation of relevant equipment management systems by various units ； b. Check the records of daily inspections and routine inspections. c. Check the operation and technical condition of the main equipment. d. Organize monitoring of equipment in case of abnormalities and propose solutions. 2. Shift-level inspections: (1) Led by the shift’s equipment supervisor, with the participation of team leaders of technical staff. (2) Inspection frequency: once a week. (3) Inspection contents: a. Carry out inspections according to the items specified in the inspection standard sheet, and supervise and review the daily inspection records of the workstations and maintenance teams. b. Check the operation and technical condition of major and critical equipment; any abnormalities, damage, or wear detected should be recorded in order to determine the areas that need repair, the parts that must be replaced, as well as the type and timing of repairs, thereby enabling the formulation of a maintenance plan. c. Equipment testing, maintenance status, and equipment hygiene. (4) Inspection method: In addition to human senses, important equipment is regularly inspected and measured using specialized tools and instruments, with records kept to accurately assess the technical condition of the equipment. 3. Team post inspection: (1) Post inspection is carried out by the operators at the posts. (2) Inspection cycle: The staff members carry out inspections at the intervals specified in the \"Position Inspection Standards\" established for each work section, and are responsible for inspecting all the equipment within their assigned area of responsibility. (3) Inspection items: a. Abnormal noises and vibrations during equipment operation. b. Operation status of the lubrication system (oil temperature, oil pressure, oil level, cooling water, etc.). c. Whether the moving parts are displaced or out of position. d. Visually inspect the components for cracks, deformation, or weld separation. e. Check whether the equipment’s foundation bolts and fastening bolts are loose. f. Check whether the equipment components are complete and reliable. g. Check the safety protection devices. h. Check for any signs of leakage or other issues with the equipment. i. Substations and various electrical control equipment, among other specialized electrical devices, are handled in accordance with the specified requirements for such equipment. (4) Inspection methods: Use methods such as visual inspection, tactile examination, listening, and smelling, in combination with the equipment’s gauges and signal indicators. IV. Assessment 1. Incorporate it into the section’s assessment in line with the section’s economic assessment responsibility system. 2. Those who are responsible for inadequate inspection work and thereby cause equipment accidents that should not have occurred shall be held accountable, with appropriate action taken depending on the severity of the accident. Additional provisions: 1. Records of inspections at all levels shall be kept in the inspection standard documents and archived for reference (two copies should be filled out: one to be retained by the work section and one submitted to the equipment management department). 2. During operation, routine inspections at the relevant stations should also be carried out using the inspection standard sheets, with signatures required; any issues that cannot be resolved during operation must be recorded in detail. 3. Components that cannot be inspected during routine checks can be scheduled for a thorough inspection after the machine is shut down. 4. Formulate detailed rules for inspection and assessment. IV. Equipment Maintenance Management System I. Basic Principles of Equipment Maintenance 1. Equipment maintenance should adhere to the principle of \"prevention first,\" aiming to eliminate equipment failures at an early stage, ensure the safe operation of the equipment, and provide production equipment in optimal condition for manufacturing processes. 2. Operators must achieve the “three goods” in the daily maintenance of equipment (proper management, proper use, and proper maintenance), as well as the “four skills” (the ability to use it, to maintain it, to inspect it, and to troubleshoot faults). II. Key points of equipment maintenance 1. Implement a responsibility system for equipment maintenance: (1) A maintenance responsibility label should be prepared and displayed for each piece of equipment; the front side of the label shall show the name of the person responsible, while the back side shall show the name of the person who carries out the maintenance. (2) Use the equipment correctly in strict accordance with the specified operating procedures. (3) Before starting the vehicle, carefully inspect the essential parts of the equipment, such as bolts, oil level, and various instruments. Then conduct a no-load test run; if any problems or abnormalities are detected, stop the vehicle for inspection and report them to the person responsible for maintenance promptly so that they can be addressed immediately. (4) Properly add lubricating oil or grease at regular intervals as specified in the lubrication schedule established by the workshop, change the oil on a regular basis, and keep the oil passages unobstructed. (5) Before ending their shift, the operators shall wipe and clean the equipment and the work area to keep both the inside and outside of the equipment clean, free from oil stains and dirt, ensuring that the paint shows its true color and the metal appears shiny. (6) Strictly implement the shift handover system; both parties involved in the handover must sign the “Shift Handover Log,” and any issues that arise with the equipment after the handover are the responsibility of the person taking over. 2. Professional maintenance workers, under a equipment warranty system: (1) Teams are responsible for specific areas, while individuals are responsible for individual units. (2) A maintenance responsibility sign must be prepared and displayed for each equipment area and for every piece of equipment. Responsibility signs for team leaders should be displayed within the area, while individual responsibility signs should be attached to each machine; the front side of these signs should list the name of the person responsible, and the back side should outline the duties of that person regarding inspections and maintenance. (3) The responsible team for maintenance shall, in accordance with the equipment inspection points designated by the maintenance department, assign these tasks to individual personnel responsible for each machine, so as to carry out regular and scheduled inspections for maintenance purposes. (4) The maintenance department shall, based on the inspection records, arrange and implement a preventive maintenance plan for the equipment, file it with the equipment management department, and promptly resolve any equipment accidents or malfunctions. III. Standards for equipment maintenance 1. The equipment itself and its surrounding area should be clean and tidy, with no signs of leakage or spills. 2. The equipment lubrication systems must be complete and in good condition, with the principle of the five fixes (fixed location, fixed person, fixed timing, fixed quality, fixed quantity) being followed. 3. All connections of the equipment are tight and in good condition. The foundation bolts, as well as the connection bolts and pins in various parts, are all present in good condition, with no looseness after tightening. 4. Safety protection devices and various instruments must be properly maintained and stored, ensuring they are complete, in good condition, and accurate and reliable. IV. Management of Equipment Technical Archives 1. Equipment technical archives are a comprehensive record of the physical processes associated with equipment use (including the entire process from procurement, design, manufacturing, installation, commissioning, operation, maintenance, renovation, to disposal), providing original evidence for equipment management at various stages. Therefore, both the workshop departments and the equipment management departments should implement this by establishing technical records for each piece of equipment. 2. Technical records must be established for all equipment in use. (1) Record item by item in accordance with the “Equipment Technical Archive” established by the company. (2) There must be transmission schematics, as well as schematic diagrams for hydraulic, power, electrical systems, etc. (3) There must be a lubrication five-fixation chart. (4) A inspection form is necessary (including content, standards, time, personnel, and handling results). (5) The contents of the equipment records should be detailed as issues arise and are resolved (including the time and location of the issue, degree of damage, cause, handling results, responsible party, etc.). (6) The content and wording in the records must be neat and clear. 3. For all in-use main equipment, catalogs of spare parts and wear-prone components should be established. 4. Upon the arrival of new equipment, the equipment warehouse must submit all documents that come with it (including drawings, instructions, packing lists, etc.) to the technical documentation department for making two copies. The original documents shall be kept in the company’s documentation room, while one copy of the duplicated documents is to be given to the equipment management department and another copy to the department that will use the equipment. 5. For major and medium-scale repairs of equipment, it is necessary to archive the details of the repairs (including the repair time, the person in charge of the repairs, the components and bearings that were replaced, the main technical issues resolved, the improvements made along with relevant drawings, as well as records of testing and acceptance). 6. The management of the technical archives for equipment is the responsibility of the equipment management department. V. Inspection and Evaluation: The equipment management department is responsible for conducting regular inspections of the equipment’s usage in accordance with this system; the Production Technology Department is tasked with carrying out evaluations, while the Enterprise Management Planning and Infrastructure Department oversees these processes. Inspections are carried out on a quarterly basis. V. Pressure Vessel Management System 1. Before putting pressure vessels into use, the respective user units must go to the local labor department to complete the registration procedures in accordance with the relevant provisions of the \"Rules for the Registration and Management of Pressure Vessel Use\". II. Pressure vessels intended for operation must have the necessary documentation and undergo inspection; they can only be put into use after passing the inspection. Acceptance criteria: d. Design, manufacturing, and installation of pressure vessels. b. Trial operation, review of documents. c. Status of the registration procedures. III. The unit using the pressure vessel shall fill out a form for the disposal of fixed assets and submit it to the company. IV. Maintenance of Pressure Vessels 1. For the maintenance of pressure vessels, the entity using them shall prepare a maintenance plan, submit it to the factory’s production technology department for approval, and obtain a work order for the maintenance of enclosed vessels. 2. The inspection and maintenance of pressure vessels shall be carried out by units with the appropriate qualifications for such tasks, as designated uniformly by the company. 3. The entity using the pressure vessel is responsible for the actual implementation of its maintenance work, which includes gas displacement prior to the process and commissioning after it is completed. 4. The external inspection of pressure vessels is carried out by units qualified for such inspections, hired by the units that use them, while each production and technology department is responsible for keeping the relevant records. 5. The maintenance of the safety accessories of pressure vessels shall be carried out by the respective user units in accordance with the relevant provisions of the \"Inspection Regulations for In-service Pressure Vessels\". V. Operation, operation, and use management of pressure vessels 1. The entity using pressure vessels shall maintain a register of such vessels. 2. The entities that use pressure vessels must assign a number to each vessel, in accordance with the \"Provisions and Requirements for the Classification of Fixed Assets.\" The number of the pressure vessel must be marked in paint on a visible part of the vessel, and the registration plaque must be fixed in the designated location on the vessel. 3. Operators of pressure vessels must hold valid certificates to work, and they should receive regular professional training and safety education. 4. When a pressure vessel exhibits any one of the following abnormal conditions, the operator shall immediately take emergency measures and report it in a timely manner in accordance with the prescribed reporting procedures. ①When the operating pressure of the pressure vessel, the temperature of the medium, or the wall temperature exceeds the specified values, and effective control cannot be achieved despite taking measures. ②The main pressure-bearing components of pressure vessels develop safety-threatening defects such as cracks, bulging, deformation, and leaks. ③The safety accessory has failed. ④Takeover and damaged fasteners make it difficult to ensure safe operation. ⑤Fires and other incidents pose a direct threat to the safe operation of pressure vessels. ⑥overfilling ； The liquid level in the pressure vessel exceeds the specified limit, and measures taken fail to bring it under effective control. ⑦Severe vibrations occur in pressure vessels and pipelines, posing a threat to safe operation. 5. Pressure vessel operators must not arbitrarily change the process conditions as required by the process operation procedures and job instructions for the safe operation of pressure vessels; operating under conditions of overloading, excessive pressure, or high temperature is strictly prohibited. 6. Operators should conduct regular routine inspections. Safety accessories should be kept complete, flexible, and reliable, with inspection records maintained. 6. Lubricant Management System: Lubricants include two types: solid lubricants and liquid lubricants. Only by proper management of lubricants can their technical properties be utilized, ensuring the proper operation of equipment, extending its lifespan, saving on lubricant costs and energy use, and improving the economic efficiency of the enterprise. I. Selection of oil products 1. Operating conditions (i.e., working conditions) under which mechanical equipment is actually used ； 2. Designations or recommendations in the manufacturer’s instructions for mechanical equipment ； 3. Regulations or recommendations from lubricant manufacturers. II. Substitution of oils 1. Different types of lubricants have their own specific characteristics or differences in terms of performance. Therefore, it is necessary to select lubricants correctly and appropriately, avoid using substitutes, and under no circumstances use them indiscriminately. 2. Principles for substituting lubricating oils (1) Try to use oils of the same type or those with similar properties as substitutes. (2) The viscosity must be comparable; the viscosity of the substitute oil shall not exceed ±15% of that of the original oil. Oils with slightly higher viscosity should be given priority for substitution. (3) Higher quality takes precedence over lower quality. (4) When selecting alternative oils, attention should also be paid to the equipment’s operating and ambient temperatures. III. Mixing of oils 1. It is advisable to avoid mixing oils of different types and grades, from different manufacturers, as well as old and new oils. The following oils must never be mixed together. (1) Special oils and dedicated lubricants must not be mixed with other types of oils. (2) Oils with anti-emulsification requirements must not be mixed with oils that do not have such requirements. (3) Anti-ammonia turbine oil must not be mixed with other turbine oils. (4) Zn-containing anti-wear hydraulic oil cannot be mixed with silver-resistant hydraulic oil. (5) Gear oil must not be mixed with worm gear oil. 2. The following situations allow for mixing: (1) Products of the same manufacturer with similar quality and basic characteristics. (2) Products of the same type but different grades from the same manufacturer. (3) For oils of different types, provided it is known that neither component in the mixture contains additives. (4) When oils of different types are mixed together, no abnormal phenomena or significant changes in performance occur. 3. There are a large variety and quantity of additives added to diesel engine oils, with varying performances ； Care must be taken when mixing oils with unknown performance characteristics. To avoid adverse consequences or even equipment lubrication failures. IV. Management of Oil Use (1) The containers used for storing and transporting lubricants must be clean and airtight, and must not come into contact with metals such as copper and tin, which can facilitate the oxidation and deterioration of lubricants. (2) The oil must undergo sedimentation and filtration before being fed into the equipment, to ensure that its clarity reaches level 5 or higher. (3) Fuel containers must not be left exposed to the atmosphere; in particular, fuel storage containers must not be left uncovered. (4) Install air-filtered respirators on oil tanks or containers; use filters with a mesh size of 100 or finer along with dust caps at the filling ports. Ensure proper sealing in all areas, and install filters and drain valves at appropriate locations in the lubrication system. (5) Electrical oils such as transformer oil have high requirements regarding moisture content; oil should be changed whenever the weather is dry, and the oil that has been poured out must be immediately added to the equipment. (6) Used oil should be collected for centralized treatment. Buckets or bottles containing lubricant must not be discarded carelessly; they should also be handled properly in a centralized manner, with proper records kept. (7) The oil storage area should be kept well-ventilated and protected from light. Oil stored outdoors must have measures to protect it from rain and sunlight. The lighting and electrical switches in the warehouse should have an explosion-proof design. The warehouse must be equipped with reliable fire-fighting equipment. When using an open flame in the warehouse, procedures must be followed as per regulations, and appropriate measures must be taken. Gasoline, kerosene and other light oils, as well as other flammable and explosive materials, must not be stored in the oil depot. (8) The workshop should have a dedicated person responsible for the management of lubricants and lubrication equipment. The lubricating oil used in critical equipment must be sampled and analyzed regularly; for ordinary equipment, sampling and analysis should be carried out at least once every 3 months, and the results of these analyses should be recorded in the lubrication records. If the oil quality does not meet the requirements, it should be replaced promptly. (9) Select lubricating oils (greases) appropriately according to the equipment requirements and process conditions; do not misuse or mix them arbitrarily. Changing the oil type must be approved by the Equipment Power Department. Without compromising the lubrication performance, the number of types of lubricants (greases) should be reduced as much as possible to facilitate management. 7. Management System for Special Care Equipment 1. Scope of Management This standard applies to the management of special care equipment within the factory’s maintenance scope. II. Management Responsibilities 1. The Production Department is responsible for checking the implementation of inspection signs and records in the workshops ； Organize major hazard rectification and emergency repair efforts ； Review of maintenance plans and quality inspection ； Assessment work. 2. The production workshop is responsible for conducting inspections and installing signs ； Check the implementation of inspection tags and records by the inspection team. The maintenance workshop is responsible for organizing the rectification of potential hazards and emergency repairs ； Review of maintenance plans and quality inspection ； Assessment work. 3. The workshop teams are responsible for the inspection, labeling, and recording of specially protected equipment within their respective areas. III. Management Contents 1. Special care equipment includes: omitted. 2. The supervisor of workshop equipment updates the signs once on Tuesdays and Fridays from 9:00 to 10:00, while the work teams update the signs and make records once each day from 8:30 to 9:30 and from 14:00 to 15:00. 3. Any issues identified during inspections should be carefully analyzed and addressed; serious problems that threaten production must be reported immediately to the workshop and plant dispatch team, who will then notify the relevant personnel to handle them. 4. Factories, workshops, and teams participate in the special care activities for various installations. It is organized once a month, on the 25th of the month, and the issues identified are carefully addressed in accordance with the \"five-fixing principles\". 5. For each activity, the team should prepare a special care summary detailing the equipment’s operating status ； Resolution of the issues from last time ； Status of emergency repairs and hazard rectification, existing hazards and countermeasures. The supervisors of each workshop should conduct random inspections of the records on a monthly basis and include this in the performance evaluations. 6. The factory organizes an analysis meeting for key special equipment in each workshop once per quarter, to discuss existing problems and solutions, and to initiate targeted efforts to address major and complex issues. 7. The workshop must submit a summary of special care activities for the first half of the year by June 28, and a summary for the entire year by December 28. IV. Assessment Methods 1. The Production Department is responsible for assessing and distributing the Special Care Contract Award. 2. Failure to carry out inspections and make records, or failure to post signs, results in a fine of 30–50 yuan per incident. 3. Lacking a sense of responsibility, failing to address issues promptly; a fine of 100–500 yuan will be imposed each time ； A fine of 100–500 yuan will be imposed in case of quality issues during maintenance or emergency repairs that result in downtime ； A fine of 200–500 yuan will be imposed for causing the equipment to stop operating. 4. Those who fail to participate in special care activities or special care analysis meetings as required, or fail to submit summaries, will have 100–300 yuan deducted from their payment. 8. Equipment Patrol Inspection System: In order to ensure the long-term operation of equipment, to adhere to the principle of giving priority to maintenance and using repairs as a supplementary measure, to continuously improve the level of equipment management, and to enforce responsibility systems and assignment mechanisms in order to fully motivate the operators and maintenance workers in the production workshops, thereby enhancing the overall condition of the equipment, this system has been revised. I. Maintenance workers (for machinery, electrical systems, and instrumentation) must have clear divisions of labor; they are responsible for maintaining the equipment assigned to them. At the same time, they must: (1) check the operation of the equipment under their responsibility at regular intervals each day, actively inquire with the operators about the equipment’s performance, and review the operation records. (2) If a defect is detected in the equipment, it should be rectified immediately if this can be done without shutting down the machine. If shutdown is required to fix the defect, it must be reported promptly to the person responsible for that equipment in the maintenance workshop, who will then include it in the equipment maintenance schedule for correction. When equipment defects are severe and affect safe production, emergency measures should be taken, and the situation should be reported to the dispatch team promptly. (3) Check whether the equipment parts are complete and in order. (4) Check the operation of the equipment, as well as any issues related to leaks, spills, or untidiness; also verify that the anti-corrosion, anti-freezing, and insulation measures are in good condition and effective. (5) Check the operating pressure, temperature, etc. of the equipment to ensure it is not operating under overload. (6) Check the lubrication of the equipment and whether the temperature of the lubricated areas is within the specified range. (7) Keep records of the equipment’s operation, inspection, and maintenance for that day. II. Operations must be carried out with a serious attitude and scientific methods; equipment should be used and maintained properly, and this must be ensured. (1) Stay at one’s post, regularly check the operation of the equipment along the designated inspection route, and carefully fill in the operation records. (2) Regularly check the lubrication of the equipment. If the lubricant level is found to be below the minimum level, it should be topped up promptly. If the lubricant becomes deteriorated or emulsified, it must be replaced immediately. (3) For rotating equipment, it should be switched regularly, and the shaft should be turned daily as a precaution. (4) Keep the equipment clean and the surrounding area tidy. (5) Strictly implement the shift handover system and the “Cross-Operation Method”. (6) Actively support the work of maintenance staff and promptly inform them of the equipment’s operating conditions. III. The work safety department has the authority to supervise and guide the workshops in implementing the equipment inspection system. (1) Regularly conduct random inspections of the patrol inspection records and on-site conditions of operators and maintenance (inspection) workers; units (individuals) that perform their patrol inspection duties well shall be recommended to higher-level departments for praise and material rewards, while those that fail to do so adequately shall be criticized and subject to appropriate financial penalties. (2) For any signs of equipment failure or abnormal conditions detected during inspections in the workshop, personnel should be immediately assigned to investigate the causes and eliminate them as soon as possible. When there are significant hazards that do not yet pose a threat to safe production, measures to eliminate those defects must be explored promptly. If the defect is severe and endangers safe production, immediate measures should be taken for emergency handling, and the matter should be reported to the relevant higher-level departments. 9. Safety Management System for Special Equipment: In order to standardize the procurement and use management of special equipment and their safety accessories in our factory, ensure the safe operation of such equipment, prevent and reduce accidents, protect the lives and property of those who work with special equipment, and promote the safe development of the enterprise, this system has been formulated in accordance with the **revised Regulations on the Safety Supervision of Special Equipment**. I. Scope of safety management for special equipment: This regulation applies to all production workshops that use special equipment within the jurisdiction of our factory, as well as to the units that provide services to our factory. Special equipment refers to devices that are related to life safety and pose a high level of risk, such as boilers, pressure vessels (including gas cylinders, the same hereinafter), pressure pipelines, elevators, lifting machinery, and specialized motor vehicles used within the factory. II. Planning and procurement of special equipment and its accessories 1. The procurement plan for special equipment and its safety accessories must specify parameters such as model numbers and key safety technical specifications. 2. The special equipment and its safety accessories purchased must be manufactured by units that hold special equipment qualification certificates issued by **; they must meet the requirements regarding safety performance and energy efficiency standards. It is not allowed to purchase special equipment that has been explicitly designated for elimination under industrial policies. 3. For the acceptance of special equipment and their safety accessories upon arrival, the following safety technical documents must be provided: (1) Proof of production license for the special equipment and their safety accessories ； (2) Documents such as product quality certification, installation and operation/maintenance instructions, and supervision and inspection certificates ； (3) Product safety technical inspection certificates and inspection reports issued by special equipment inspection agencies ； (4) For new products, new components, and new materials of special equipment, type test and energy efficiency test reports must be provided. III. Installation, Modification, and Maintenance of Special Equipment 1. The construction units responsible for the installation, modification, or maintenance of special equipment must submit a written report detailing the planned work to our factory’s Equipment Department for review and approval by the relevant management officials. They must also inform the local municipal authority responsible for the supervision and management of special equipment before proceeding with the work. 2. For the on-site fabrication, installation, modification, and maintenance of special equipment, it is necessary to provide certification of the qualifications of the units responsible for the production and maintenance of such equipment, as well as certification of the qualifications of the operators. Work may only proceed after approval by the relevant authorities. During the construction process: (1) there must be professional technical personnel and skilled workers qualified for the manufacturing, installation, and modification of special equipment ； (2) It has production conditions and testing methods suitable for the manufacturing, installation, and modification of special equipment ； (3) It has a sound quality management system, responsibility system, and safety assurance measures ； (4) Units engaged in boiler cleaning shall carry out boiler cleaning in accordance with the requirements of safety technical specifications, and shall undergo supervision and inspection of the boiler cleaning process conducted by special equipment inspection and testing institutions. 3. The design and manufacture of special equipment, as well as the installation design of safety accessories, must meet the requirements regarding safety performance and energy efficiency; special equipment that is explicitly designated for elimination under industrial policies shall not be designed. The design units and personnel must possess the qualifications required by the regulatory authorities in charge of safety supervision of special equipment, and the design technical documents must be complete. 4. The authorities in charge of special equipment and the units that use such equipment must ensure proper supervision over the manufacturing, installation, modification, and maintenance of special equipment. 5. After the on-site fabrication, installation, modification, or repair of special equipment is completed, it must undergo supervised inspection by an inspection and testing institution approved by the state council’s department in charge of safety supervision and management of special equipment, in accordance with the requirements of safety technical specifications ； Completion acceptance will not be carried out unless the inspection is passed without supervision. Once the acceptance is successful, the construction unit must transfer the relevant technical documents and acceptance records to the user entity within 30 days. IV. Use of Special Equipment and Their Safety Accessories 1. The workshop using such equipment must properly handle the receipt of the special equipment and its safety accessories, carefully check the delivery receipt and safety technical documents, and transfer the original documents to the archives; the using unit should keep copies of these documents for reference. 2. All units that use special equipment must, in accordance with the Regulations on the Safety Supervision of Special Equipment, obtain registration certificates and operation permits from the local authorities responsible for the safety supervision of special equipment. 3. Establish and improve a responsibility system for the safety and energy-saving management of special equipment; the person in charge of the using unit shall be fully responsible for the safety and energy efficiency of such equipment and ensure that relevant measures are implemented. 4. Establish registers for special equipment and safety technical documents (1) Design documents for special equipment, information on the manufacturing unit, certificates of product quality compliance, user maintenance instructions, as well as installation technical documents and materials ； (2) Records of regular inspections and periodic self-inspections for special equipment ； (3) Records of the daily usage status of special equipment ； (4) Records of daily maintenance for special equipment, as well as its safety accessories, safety protection devices, measurement and control devices, and related auxiliary instruments and meters ； (5) Records of operational failures and accidents of special equipment ； (6) Energy efficiency test reports for high-energy-consuming special equipment, records of energy consumption, and technical documents related to energy-saving upgrades. 5. Establish and improve safety operation procedures as well as maintenance and repair protocols for special equipment. In accordance with the company’s equipment management system, carry out regular inspections of the equipment and its timely maintenance, while keeping proper records of all activities ； When special equipment malfunctions or exhibits abnormal conditions, the user unit shall conduct a thorough inspection of it; it can only be put back into use after potential accident hazards have been eliminated. 6. Managers and operators of special equipment must undergo training and assessment, and work only with valid certificates. The personnel holding such certificates in each using unit are responsible for carrying out training and assessment while at work; those who fail the assessments are not allowed to work. 7. Carry out regular inspection (calibration) of special equipment and its accessories. The equipment itself, safety accessories, safety protection devices, measurement and control devices, as well as related instruments and meters must be calibrated regularly to ensure continuity of compliance with calibration standards. 8. Conduct statistical analysis of the energy consumption of special equipment in accordance with the company’s energy management system; if such equipment fails to meet the energy efficiency standards, the entity using it must take appropriate measures to make corrections. 9. Each user unit shall formulate emergency response plans for special equipment in order to effectively prevent and reduce the occurrence of accidents, and shall comply with the company’s management procedures for emergency response plans as well as the methods for handling accidents. 10. If special equipment poses serious accident risks, has no value for renovation or repair, or has exceeded the service life specified in the safety technical regulations, the entity using such equipment shall promptly scrap it and go through the cancellation procedures with the original department responsible for the supervision and management of special equipment safety. 11. Units that use rented mobile pressure vessels or gas cylinders for filling purposes must enter into a usage contract with the provider. The units responsible for filling mobile pressure vessels and gas cylinders must have been authorized by the special equipment safety supervision and management departments of provinces, autonomous regions, or municipalities directly under the Central Government to carry out such filling activities; the pressure vessels, gas cylinders, and their safety accessories supplied for use must be within their valid inspection period, and proper records must be kept ； Personnel who go to the company site to perform filling tasks (such as for fire extinguishers) must have the necessary qualifications to operate the equipment, which must be in good condition, and emergency procedures must be in place. V. Inspection and Assessment: Inspections and assessments are carried out in accordance with the company’s safety management system and equipment management system. VI. Other Matters: Any matters not covered by these regulations shall be handled in accordance with the Regulations on the Safety Supervision and Administration of Special Equipment. 10. Equipment Sealing Management System: Strengthening sealing management and carrying out initiatives to create \"leak-free factories\" are important measures for enterprises to reduce leaks, increase production, lower consumption, eliminate pollution, and ensure the health of their employees. This system is formulated to achieve and maintain the standard of leak-free factories and to create conditions for safe and civilized production. I. Classification of sealing points and scope of statistics 1. Dynamic sealing: The sealing between two mating surfaces in mechanically-driven devices (including machine tools) that undergo continuous motion (rotation and reciprocation) falls under dynamic sealing. Seals for rotating shafts such as compressor shafts and pump shafts all belong to dynamic seals. 2. Static sealing equipment (including machine tools and plant heating equipment), along with their associated pipelines and accessories, involves static sealing in cases where there is no relative motion between the two mating parts during operation. Flanges on equipment pipelines, various valves, plug plugs, union joints, oil gauges on pumps and machinery, auxiliary pipelines, transformers, oil switches, cable terminals, instrument orifice plates, control valves, auxiliary leads, as well as the connection points of other equipment, all fall under the category of static seals. 3. Calculation method for sealing points (1) Calculation method for dynamic sealing points: A sealing point is considered to be a dynamic sealing point when there is sealing between two mating parts that are in continuous motion (rotation or reciprocation). (2) Calculation method for static sealing points: One joint of a static sealing point is counted as one static sealing point. For example: a pair of flanges, regardless of their size specifications, is counted as one sealing point ； A valve is generally considered to have four sealing points; if there is a plug behind the valve or if it is immediately followed by a vent, one additional point should be counted for each of those cases ； A threaded union counts as three sealing points ； In special areas, such as the bolt holes of the connection flanges, there is a connection to the inside of the equipment; aside from the joint surface which counts as one sealing point, each bolt hole requires its own sealing point. (3) The method for calculating the number of leakage points is such that one leakage point is counted for each instance of leakage; whether it is at a sealing point or due to weld cracks, porosity, corrosion, or other reasons, all such instances are counted as leakage points. (4) Formula for calculating the leakage rate: Leakage rate (‰) at static (dynamic) sealing points = Number of leaking points at static (dynamic) sealing points / Total number of static (dynamic) sealing points × 1000‰. 4. Inspection standards for static seals: (1) The joints of equipment and pipelines, when inspected visually, should show no coking, no smoking, no signs of leakage, no seepage, and no dirt. (2) Test for leaks in the instrumentation equipment, air ducts, welding areas, and other connection points using soapy water; there should be no bubbles (for vacuum areas, use a thin piece of paper to check). (3) At the joints of electrical equipment, transformers, oil switches, oil-impregnated paper-insulated cable ends, etc., no leakage is visible to the naked eye. (4) For systems involving flammable, explosive, or toxic gases such as acetylene gas, gas, ethylene, ammonia, and chlorine, perform a leak test using soapy water – no bubbles should appear – or use special test strips; no color change should occur. (5) For the oxygen, nitrogen, and air systems, use a 10 mm wide and 100 mm long piece of thin paper for leak testing; there should be no signs of air leakage, or no bubbles should appear when checked with soapy water. (6) The steam system shows no leaks and no scale when inspected visually. (7) In chemical systems such as acids and bases, there are no signs of leakage or seepage when observed with the naked eye, no scaling occurs, and there is no premature smoking; moreover, using precision test strips for leak detection shows no color change. (8) A visual inspection of the water and oil systems or feeling them by hand shows no leaks or scale. (9) For the various gearboxes, vertical shafts, and speed control levers of different machine tools, a macroscopic inspection reveals no obvious leaks; areas without seals, such as slides and guide rails, are not included in the statistics or evaluation. 5 Inspection standards for dynamic seals: (1) Slight oil leakage is permitted from the crankcase covers of various reciprocating compressors (as well as from the bearing shells of turbine compressors), but it must be wiped clean regularly. (2) Packing for various reciprocating compressors (gas seals for turbine compressors) must be leak-free at the beginning of use, but slight leakage is allowed by the end of the operating interval. The condition of the packing for toxic, flammable, and explosive media is analyzed by taking samples within 300 millimeters of the outer packing cover, ensuring that the concentration of harmful gases remains within the specified safe limits. The stuffing box must not allow oil leakage, while the piston rod should have an oil film. (3) Various oil injectors may allow for slight leakage, but they must be wiped clean regularly. (4) Slight leakage is permitted in gear oil pumps. Range: 1 drop per 2 minutes. (5) Bearings equipped with oil rings in various transmission devices must not leak oil, while bearings that require lubrication may allow slight seepage, which should be wiped clean at all times. (6) The allowable leakage rate for the water pump packing is no more than 20 drops per minute in the initial stage and no more than 40 drops per minute in the final stage (1 month for minor repairs, 3 months for major repairs). (7) The medium filler for transporting materials shall drop at no more than 15 drops per minute. (8) For all types of pumps equipped with mechanical seals, there shall be no leakage at the beginning, and no more than 5 drops per minute at the end. II. Management Measures 1. For all production units, equipment, and pipelines that are put into operation, records and inventories of static and dynamic seals must be maintained, with accurate statistics on the seal locations. (Secured archives should generally include: a schematic diagram of the production process, a register of static and dynamic sealing points on the equipment, a register of sealing points on the equipment’s pipelines, and a summary table categorizing these sealing points.) The ledger generally includes: the breakdown of sealed points in chronological order, the number of leakage points, the leakage rate, etc.). 2. Establish and improve the sealing management responsibility system at all levels, with clear definitions of responsibilities; factories (companies) and workshops should conduct regular inspections, evaluations, and assessments. 3. Carry out activities to create and maintain leak-free factories, making leak detection and repair tasks regular, concrete, and institutionalized. The leakage rate at static sealing points remains at 0.5‰, while the leakage rate at dynamic sealing points is below 2‰. Leakage points that cannot be eliminated immediately should be documented, and a plan for elimination should be developed. 4. Conduct inspections of sealed leakage points on time, and carry out statistics and reporting tasks. 5. Organize research on various sealing technologies, and promote the application of new sealing technologies and materials. Appendix: Standards for leak-free factories and leak-free areas 1. Standards for leak-free factories (1) A sound sealing management and assurance system is in place, with clear responsibilities and comprehensive management. (2) The records related to static and dynamic seals, as well as the management logs, records of leak detection and repair, and basic technical documents on seal management, are complete and accurate; the statistics on seal locations are precise. (3) Maintain the leakage rate at static sealing points below 5 per ten thousand, and the leakage rate at dynamic sealing points below 2 per thousand, with no significant leakage points. (4) All major production workshops in the plant must be leak-free, with the overall equipment integrity rate exceeding 90%, and the integrity rate of key equipment reaching 95%. 2. Standards for leak-free workshops (areas): (1) A sound organizational structure for seal management is in place, with clear responsibilities and effective management. (2) The basic documents related to sealing management, such as static (dynamic) sealing records, management logs, and records of leak detection and repair, are complete and accurate; the statistics on sealing points are also precise. (3) Always maintain the leakage rate at static sealing points below 5 per ten thousand, and the leakage rate at dynamic sealing points below 2 per thousand, with no significant leaks. (4) The overall equipment integrity rate should exceed 90%, while the integrity rate of key equipment should reach 95%. III. Inspection and Assessment: Inspections are carried out by the department in charge of equipment, and these inspections are included in the assessment of the responsible units. 11. Equipment Anti-corrosion and Insulation Management System: This system is established to strengthen anti-corrosion and insulation management, ensure the effectiveness and integrity of such facilities, prevent and delay corrosion and damage to equipment and installations, reduce energy losses, and achieve safe, anti-corrosive, and insulated conditions for equipment and pipelines. I. Division of Responsibilities 1. Maintenance Workshop ① The Maintenance Workshop is the responsible department, in charge of managing anti-corrosion and insulation efforts across the entire plant. ②Responsible for preparing the work plans for major and medium-scale repairs related to corrosion protection and insulation across the entire plant. ③Responsible for the technical management of anti-corrosion and insulation work throughout the plant ； Take the lead in preparing construction plans for major anti-corrosion and insulation projects, and clarify the engineering technical standards and requirements. ④Responsible for conducting monthly inspections and evaluations of the anti-corrosion and insulation work in each workshop. ⑤Organize the implementation of anti-corrosion and insulation work plans, and be responsible for supervising, inspecting, and approving the anti-corrosion and insulation projects for key equipment or major renovation projects, as well as controlling the project schedule. ⑥Actively promote and apply new technologies, processes, and materials for corrosion prevention and heat insulation, and organize the implementation as well as experimental research. ⑦Establish and fill in the records for major anti-corrosion and insulation equipment in a timely manner. 2. Production Department ① Formulate construction plans for anti-corrosion and thermal insulation works in large-scale technical transformation projects. ②Supervise the construction process and participate in quality inspection. ③Actively promote and apply new technologies, processes, and materials for corrosion prevention and heat insulation, and organize the implementation as well as experimental research. ④Supervise the construction process and participate in quality inspection. ⑤Responsible for testing new materials, new processes, and new technologies for corrosion prevention and heat insulation. 3. Each production workshop: ① Is responsible for the daily maintenance and management of anti-corrosion and insulation work in its own workshop, and strictly complies with all technical standards and construction specifications related to anti-corrosion and insulation. ②Responsible for the daily technical management of corrosion prevention and insulation, and oversees the implementation of corrosion prevention and insulation plans in this workshop. ③Organize the relevant personnel in this workshop to conduct regular inspections of equipment corrosion; report any issues found promptly, keep records, and take preventive measures. ④Responsible for the inspection of anti-corrosion and insulation measures in this workshop. 4. Professional construction units for anti-corrosion and thermal insulation works. ① The Chemical Machinery Branch is a professional construction unit for anti-corrosion and thermal insulation works; it is responsible for the construction and maintenance of anti-corrosion and thermal insulation facilities in the production system. ②Responsible for the inspection and acceptance of the construction quality of anti-corrosion and insulation projects ； Complete completion documents should be available for important projects. ③Responsible for testing new materials, new processes, and new technologies for corrosion prevention and heat insulation. II. Specific requirements for anti-corrosion and insulation management work 1. Anti-corrosion and insulation management projects must be planned in a unified manner, with strengthened oversight. 2. All anti-corrosion and insulation facilities as well as the materials used shall not be canceled or altered arbitrarily without reason ； If a change or cancellation is indeed necessary, it must be approved by the Equipment and Power Department, and a change form must be filled out. 3. Strengthen the supervision and control of construction quality; settlement procedures shall not be processed for construction projects that have not passed inspection. 4. For problems caused by severe corrosion that lead to production disruptions, experimental research should be conducted as a matter of priority to determine appropriate protective measures. 5. For any equipment requiring anti-corrosion and thermal insulation treatments, it must be processed and approved by the applicable workshop before it can be handed over to the construction unit for work. 6. The construction and installation of anti-corrosion and thermal insulation works must be carried out in accordance with the relevant construction and acceptance standards to ensure the quality of the work as well as personal safety. 7. Equipment and pipelines should undergo anti-corrosion treatment, insulation, as well as a comprehensive internal and external inspection in conjunction with shutdown maintenance. 12. System for the installation, commissioning, and acceptance of equipment. Purpose: To establish a system for the installation, commissioning, and acceptance of equipment, ensuring that its installation and testing meet production requirements. Scope: Management of devices awaiting installation that are new, transferred in, or relocated. Responsible parties: Equipment Department, workshop supervisors, maintenance workshop. Procedure: 1. Preparatory work before equipment installation (1) Inspect the installation site, and conduct on-site measurements of the floor and walls that will support the equipment to determine whether they meet the requirements for installing the equipment. (2) Check whether the locations of the water, electricity, gas, and steam pipelines required by the equipment meet the requirements for its installation. (3) Check whether the entrances and exits that the equipment must pass through are large enough for it to go through; if not, take appropriate measures to ensure that the equipment can reach its installation location smoothly. (4) Prepare the tools and mechanical equipment commonly used for equipment installation. (5) Develop the equipment installation procedure. 2. Equipment installation (1) Installation shall be carried out in accordance with the established installation procedure. (2) Installation should be carried out in one go once the preparation is complete, to avoid loss of components due to their not being placed in place in a timely manner after unboxing. (3) Equipment installation should be carried out under the on-site guidance of relevant technical personnel. (4) Clean the site promptly after installation is complete, and keep proper installation records. 3. Equipment commissioning and acceptance: (1) After installation, the equipment shall be commissioned item by item in accordance with the technical specifications; records of whether each specification is met shall be kept, and these original records shall be included in the equipment archive. (2) After the equipment is tuned and tested, fill out the installation, tuning, and testing acceptance form; once signed by the inspection personnel, it shall be filed. (3) Equipment that passes the acceptance test and can be put into normal operation shall go through the handover procedures in accordance with relevant regulations. (4) The installation and commissioning of the equipment should be carried out promptly, so that claims can be filed in a timely manner once issues are identified during the claim period. 13. Equipment Accident Management System I. General Provisions An equipment accident represents damage to a company’s assets; it directly hinders the normal progress of production. Production shutdowns and casualties resulting from such accidents cause significant economic losses to the company. Therefore, leaders at all levels and all employees must attach great importance to this, strictly enforce various equipment procedures and management systems, and ensure the safe operation of the equipment. The goal of equipment accident management is to achieve zero accidents. II. Classification and Hierarchical Management of Equipment Accidents 1. Equipment that has been put into operation and suffers damage to its mechanical, power, transportation, or coke oven components due to abnormal factors; or industrial buildings that experience sudden fractures, collapses, or deformation; or situations in which production, transportation, or construction processes are interrupted as a direct result of defects in the equipment itself – all these are considered equipment accidents. 2. Classification and management of equipment accidents: Based on the degree of damage, and the extent of loss to production as well as the cost of repairs, these accidents are classified into: major equipment accidents, serious equipment accidents, significant equipment accidents, ordinary equipment accidents, and minor equipment accidents ； The classification criteria are as follows: (1) Major equipment accidents: a. The cost of repairing the equipment is 200,000 yuan or more ； b. The loss due to reduced production amounts to 500,000 yuan or more ； (2) Major equipment accidents: a. The cost of losses due to equipment accidents (equipment repair costs + losses from reduced production) is 150,000 yuan or more ； b. The repair costs for equipment failures are 30,000 yuan or more ； c. An accident involving the main production equipment caused the production system to stop operating for more than 16 hours ； d. An accident occurs in the kinetic energy equipment, resulting in a sudden interruption of the kinetic energy supply; regardless of the duration, as long as it causes a disruption in production in the main manufacturing facilities or severe damage to the production equipment, or meets any one of the conditions outlined in a, b, and c above ； e. Advanced equipment imported from abroad, which becomes unable to be maintained and used properly due to accidents. f. Any equipment failure that directly causes fires, floods, explosions, etc., leading to the collapse of buildings and resulting in poisoning, serious injuries, or death ； (3) Major equipment accidents: a. The cost of equipment accident losses (equipment repair costs + losses due to reduced production) is 50,000 yuan or more, but less than 150,000 yuan ； b. The repair costs for equipment accidents are between 10,000 yuan and 30,000 yuan ； c. An accident occurs on the main production equipment, resulting in a shutdown of the associated unit or production system for more than 3 hours but less than 8 hours ； d. Damage to equipment above the substation busbar, resulting in a power supply interruption of more than 30 minutes but within 1 hour. (4) General equipment accidents a. The cost of equipment accident losses (equipment repair costs + losses due to reduced production) is 50,000 yuan or less ； b. The repair cost for equipment failures is between 1,000 yuan and 10,000 yuan ； c. An accident occurs on the main production equipment, resulting in a shutdown of the associated unit or production system for more than 2 hours but less than 4 hours ； (5) Minor equipment accidents: a. Equipment failure that causes the main unit to stop operating for more than 30 minutes but less than 2 hours ； b. Those that are not severe equipment accidents are all minor equipment accidents ； 3. The following situations are not considered equipment accidents: (1) Shutdowns caused by production processes (without damage to the equipment). (2) Temporary maintenance carried out due to poor technical condition of the equipment. (3) If the components of the equipment are damaged or have ceased to function, but the operator and maintenance personnel are able to detect and identify the defects (as evidenced by records) or abnormal conditions in advance, and take effective measures to shut down the equipment in accordance with the prescribed procedures promptly, thereby preventing the expansion of the defect (even if the shutdown time exceeds the allowed limit), it can be considered a equipment failure. (4) Interruptions in production caused by the proper operation of safety protection devices on the equipment during the production process, or by damage to safety components. (5) Buildings on the production line that suffer natural damage due to long-term use, thereby threatening production or forcing shutdowns. (6) Those whose production tools are damaged, resulting in a disruption of production. (7) Force majeure natural disasters that cause equipment damage and lead to production interruptions. 4. Reporting of equipment accidents and emergency repairs (1) In the event of major or severe equipment accidents, the scene must be preserved, and immediate reports must be made to the section supervisor, the dispatch officer, the head of production technology, as well as the leader in charge of equipment. The production technology department is required to report to the manager within 10 minutes, to investigate the extent of the damage, take photographs for record-keeping, and develop an emergency repair plan. The production leader in charge will oversee the emergency repair work ； (2) In the event of a major equipment accident, immediately report to the section chief, the dispatcher, and the equipment management supervisor; within 5 minutes, report to the senior production manager, who will then take charge of the emergency repair efforts. (3) After general accidents and minor accidents occur, the section chief and the equipment supervisor are responsible for overseeing emergency repairs and organizing accident analyses. 5. Analysis of equipment accidents: (1) In the event of major, significant, or serious equipment accidents, the production manager in charge or another appropriate supervisor shall preside over the analysis. The equipment maintenance director, section chiefs, the enterprise’s management planning and infrastructure department, the equipment maintenance team, as well as the personnel from the unit where the accident occurred are also involved. The analysis is carried out within two weeks after the accident occurs and after emergency repairs are completed. Its purpose is to determine the nature and causes of the accident, identify the losses incurred and the responsible parties, and identify the lessons to be learned and the preventive measures to be taken ； (2) For ordinary accidents, the section chief takes charge of the analysis, with the participation of equipment management personnel and maintenance staff, as well as the supervisors of the relevant sections (teams) and the parties involved. Through this analysis, it is necessary to determine the cause, nature, extent of damage, and responsible party for the accident, and to establish preventive measures. (3) Accident reporting procedure: a. In the event of major, significant, or serious accidents involving equipment, the Production and Technology Department shall submit an accident report to the company’s Enterprise Management Planning and Infrastructure Department within three days after repairs are completed. b. For ordinary equipment accidents, the section chief shall submit a report on the equipment accident to the Production and Technology Department within two days after repairs are completed. c. In the event of an accident, failure to report it in a timely manner or concealing such reports shall hold the leaders of the relevant unit accountable. III. Principles and standards for handling accidents 1. For cases of general liability or minor equipment accidents, the person directly responsible shall be fined between 100 and 200 yuan, and the matter will be reported to the Production Technology Department; if an accident occurs at the same position within a consecutive period of 20 days, the fine shall be doubled. 2. In the event of major, severe, or significant equipment accidents, the performance-based salary of the team involved for that month will be deducted. The person directly responsible shall be fined between 500 and 2,000 yuan, while the person who is directly in charge shall be fined between 200 and 500 yuan. Such incidents will be reported within the company. If two or more serious accidents occur consecutively within half a year, the leaders of the departments involved in those accidents will not only face doubled fines but also have their positions reduced or they will be removed from their posts; in severe cases, they will be dismissed on the spot and held legally accountable. 3. Fines resulting from accidents are uniformly recorded in the accounts maintained by the Finance Department, and are used for specific expenses related to equipment management as well as as rewards for units and individuals who excel in equipment management.