Equipment integrity management

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How to manage equipment integrity effectively? I. Establish a equipment integrity management system 1. The equipment integrity management system should cover all aspects of the equipment’s life cycle, including procurement, acceptance, installation, operation, maintenance, inspection, testing, preventive maintenance, defect management, and leak management, and it should clarify the responsibilities of various departments and individuals. 2. At the same time, standards and regulations for equipment management must be established, including procurement standards, operating procedures, and maintenance guidelines, to ensure that all tasks are carried out in an orderly manner. II. Intrinsic Safety Design 1. When designing, it is necessary to select a design firm that meets the required qualifications, and require it to carry out intrinsic safety design work, including the proper selection of materials and specifications, as well as the inclusion of appropriate safety margins. 2. Enterprises should be deeply involved in the project design phase, and based on the operational experience of similar projects or installations, provide suggestions and recommendations regarding the design of equipment and facilities. III. Quality Control in Procurement, Manufacturing, and Installation 1. Define procurement and acceptance standards; select qualified suppliers. For critical equipment or those with special quality requirements, representatives should be sent to supervise the manufacturing quality on-site ； During the acceptance inspection of equipment upon arrival, it must be ensured that it meets the procurement plan and design requirements. 2. Proper installation of equipment: Install the equipment in accordance with design standards and the installation guidelines provided by the manufacturer, carry out initial inspections, checks, and tests, prepare a report, and keep it on file. IV. Operation and Maintenance 1. Formulate operating procedures and maintenance rules for equipment and facilities, and operate and maintain the equipment in accordance with these procedures. 2. Establish a management system for regular inspections of equipment and facilities, specifying the periodic inspection requirements for operators, technical professionals, and management personnel, so as to promptly detect any abnormalities in the equipment and conduct analysis and handling accordingly. 3. Define the daily maintenance requirements such as equipment lubrication, turning of the equipment, and regular switching, in order to carry out proper maintenance of the equipment. 4. Implement ledger management for equipment and facilities; number all of them, and establish ledgers as well as technical records for the equipment and spare parts (safety accessories). V. Inspection and Testing 1. In accordance with the requirements for the safe operation of equipment and facilities, a plan for equipment inspection and testing should be developed, and such inspections and tests should be carried out on a regular basis. 2. Based on the operation status of the equipment and the results of risk analysis, strengthen the inspection and testing of high-risk equipment and facilities as well as components prone to failure; determine the inspection locations, methods, and frequency, and ensure strict compliance with them. 3. Online monitoring systems should be installed for key units and equipment to enable real-time monitoring and early warning of equipment operation parameters, as well as timely analysis and handling of any abnormalities in equipment operation. VI. Preventive Maintenance 1. Establish a management procedure for preventive maintenance of equipment, develop preventive maintenance plans based on this procedure, and carry out the maintenance as planned. 2. Conduct timely inspections and tests of equipment and facilities, as well as analyze fault data; adjust the preventive maintenance plans for such equipment and facilities based on the results. 3. Regularly evaluate the effectiveness of inspections, tests, and equipment preventive maintenance, dynamically update the plans for equipment inspection, testing, and preventive maintenance, and continuously improve the level of such preventive maintenance. VII. Defect Management 1. Establish a closed-loop management system for the identification, analysis, reporting, and handling of defects in equipment and facilities, with continuous improvement. 2. Establish defect identification criteria, use these criteria to identify defects, and determine their severity levels. 3. Establish defect response procedures based on the defect severity level, and address defects in a timely manner. 4. Establish acceptance criteria for defect resolution, evaluate the status of defect fixes, and confirm that the defects have been eliminated. VIII. Leak Management 1. Establish a leak management system, define the objectives and plans for leak management, assign responsibilities to specific individuals, and ensure adequate funding is allocated. 2. Thoroughly identify the areas where leaks may occur, assess the leakage risks, and maintain a register of static and dynamic sealing points. Pay special attention to leakage risks associated with toxic materials, flange seals for liquefied hydrocarbons, seals for high-temperature oil pumps, pressure pipelines for combustible gases, as well as during loading and unloading operations, and define specific preventive measures. 3. Take measures to prevent leaks at the source, such as adopting advanced production processes, selecting equipment in accordance with standards, using high-quality components that meet the required specifications, and establishing anti-corrosion management systems. 4. For devices (facilities) that handle flammable, explosive, toxic, or hazardous substances, relevant gas detectors should be installed on-site; video surveillance equipment should be installed in key areas. In addition, all types of leakage detection and alarm instruments should be calibrated regularly to ensure accurate and reliable readings. 5. By adopting measures such as Leak Detection and Repair (LDAR) technology, leak sources are continuously identified in order to control unorganized emissions. 5. Implement hierarchical management of equipment leakage risks based on the hazard level of the materials and the potential amount of leakage. For equipment whose leaks could lead to serious consequences, technical measures should be taken to cut off the source of leakage as soon as possible, along with effective protective measures. 6. At high-risk leakage sites, necessary on-site emergency response facilities and supplies should be provided. IX. Database Management 1. Establish a database for equipment and facilities; documents, records, information, and data related to the entire life cycle management of equipment should be incorporated into this database for unified management. The database should also include basic data on the equipment, operational parameters, inspection and testing data, maintenance data, failure data, etc. 2. Conduct timely analysis and research on various data in the database, and use the results of these analyses to guide tasks such as equipment inspection and testing, preventive maintenance, and defect management. 4. Update the equipment database in a timely manner based on the equipment’s full life cycle management.