New version of operating procedures for China National Petroleum Corporation

Currently, most use the Western Pacific version of the operating procedures. There is confirmation at each step.

In fact, sometimes confirming every step means not confirming any step at all! ! It depends on the specific operations involved. For some simple tasks, I don’t think it’s necessary to carry out confirmation; it’s sufficient to check and confirm only the key steps. If confirmation is required for every step, the operators may become careless or indifferent, which can lead to errors even in those critical steps. Therefore, in my opinion, it’s enough to conduct checks and confirmations at the important points! !

Provisions on the Management of New Version Operating Procedures Chapter 1 General Provisions Article 1 These provisions are formulated to standardize the management of operating procedures, enhance their scientific nature and practicality, ensure that operations are under control, and promote safe production. Article 2 These provisions apply to the preparation and management of the operating procedures for the production facilities of XX Company. Chapter 2 Management Responsibilities Article 3 The deputy general manager in charge of technology at the branch is the key leader responsible for the formulation and management of operating procedures, and is accountable for organizing the drafting (revision) and approval of such procedures. Article 4: The technical department of the branch is the designated department in charge of operating procedures, responsible for organizing their formulation (revision), review, submission, and issuance, as well as for conducting annual evaluations of these procedures. Article 5: The production and operation department of the branch company is responsible for organizing the implementation of operating procedures. Article 6: The departments in the branch company responsible for mechanical equipment, quality, safety, and environmental protection are tasked with organizing the formulation (revision) of relevant content related to operating procedures, as well as conducting professional reviews and supervision during their implementation. Article 7: The workshop (unit) is responsible for the preparation, review, submission, and daily management of operating procedures, as well as for the implementation of those procedures after they have been approved. Chapter 3 Principles and Methods for Formulating Operating Procedures Article 8 The formulation of operating procedures shall follow the following principles: (1) Operating procedures must be based on engineering design and production practices to ensure that the technical specifications, requirements, and operation methods are scientific and reasonable ； (II) The operating procedures must summarize the operational experience gained from long-term production practices, ensuring consistency in the execution of the same tasks; they serve as guidelines that everyone must follow strictly, thereby contributing to production safety ； (III) The operating procedures must ensure that the operational steps are complete, detailed, accurate, and quantified, thereby facilitating the reliable operation of the installations and equipment ； (IV) The operating procedures must, while meeting safety and environmental protection requirements, organically integrate optimized operations, energy savings and consumption reduction, loss minimization, and improved product quality, thereby helping to enhance the production efficiency of the facility ； (5) The operating procedures must clearly define the responsibilities of the personnel performing the tasks, ensuring clear division of labor and close cooperation ； (VI) Operating procedures must be revised, supplemented, and continuously improved in production practice to achieve ongoing advancement from practice to theory. Article 9 Operating procedures shall be prepared in the following manner: (1) Under the organization of the regional branch, each facility shall establish a team for preparing operating procedures; each team must consist of at least four members from management, technical, and operational levels. The workshop (plant) supervisor takes overall organization, with experienced technicians and operators (team leaders, operation engineers, and station operators) participating. (II) During the formulation of operating procedures, collective discussion must be adhered to, with continuous revisions made during these discussions in order to incorporate knowledge and work experience from various levels to the greatest extent possible, ensuring that the procedures are accurate and practical to follow. Chapter 4: Content and Compilation Methods of Operating Procedures Article 10: Operating procedures include sections such as process technical specifications, operation guidelines, start-up and shutdown procedures, basic operation procedures, and accident handling plans (see attachment). Article 11 The contents of the process technology operating procedures include: (1) General information on the facility: production scale, capacity, date of construction, and previous renovation history ； (II) Principles and Process: Description of the production principles and technological process of this device ； (III) Process parameters: including raw material parameters, parameters for semi-finished and finished products, parameters related to utility systems, main operating conditions, parameters regarding raw material consumption, utility consumption, and energy consumption, as well as parameters for pollutant generation and emission control ； (IV) Process flow diagrams: process principle flow diagrams, process piping and instrument control diagrams, process flow diagrams, and descriptions of the plant’s pollutant emission flow diagrams. The drawing method of flowcharts and the graphic symbols used in them shall comply with the provisions of **standards or industry standards** ； (5) Plan view of the installation: It is necessary to indicate the locations of hazardous points, waste discharge points, alarms, fire extinguishers, and other emergency equipment. If necessary, separate diagrams can be drawn showing the locations of hazard points, alarms, and fire extinguishers ； (VI) Details of equipment and instruments: List the equipment and instruments in categories, indicating their names, codes, specifications, and main design parameters. Article 12: The operation guidelines specify the methods for adjusting operating parameters during normal production as well as the operational requirements for handling abnormalities. Key points in their preparation are as follows: (1) They focus on adjusting for fluctuations in operations during production, with the aim of maintaining stability and preventing production accidents caused by such fluctuations. (II) First, determine the scope and objectives of the intervention; after analyzing the influencing factors, identify the specific targets (this must be shown in a diagram). If the values exceed the set targets, it is considered to be operational fluctuation. Explain the appropriate control methods, providing at least a qualitative description, and preferably a quantitative one. For the possible operational fluctuations that may occur, propose corresponding countermeasures. Finally, clarify the accident response plan for situations where the operational parameters get out of control. (III) The operation guidelines for each control target shall include: control range, control target, relevant parameters, control method, normal adjustment, and abnormal handling. The control range must not exceed the limits specified in the process card (maximum values); it is necessary to maintain a certain distance from the set pressure value of the safety valve and the parameter alarm values, so as not to reach the safety limits, thereby ensuring a safe operating margin ； More stringent indicators (specific metrics) should be set for control objectives to ensure smooth operations and optimization ； The control method should be described in text, along with a control circuit diagram. Article 13: The basic operating procedures are the fundamental steps for carrying out various complex operations in the plant; they mainly describe the procedures for starting, stopping, and switching between common equipment such as machines, pumps, heat exchangers, tanks, and towers. The main contents include: operation procedures and precautions for starting, stopping, and switching various pumps and motors, starting, stopping, and switching fans, putting medium- and low-pressure heat exchange equipment into operation or taking it out of service, as well as sampling from key areas. Article 14: The operational procedures such as startup procedures, shutdown procedures, basic operation procedures, operating procedures for specialized equipment, and accident response plans must be formulated in strict accordance with a unified format: (1) Page numbering sequence. The operating procedures are paginated in the following order: cover (first page), version history (second page), overview diagram, outline, operations, and explanations. (II) Compile in stages. Its content is organized and structured through a hierarchical classification system of categories and subcategories, with three levels of formulation: Level A constitutes the outline of the procedures, specifying the main sequence of operations and states involved; it provides detailed planning for all stable states and the operational objectives within those states, and is primarily used to coordinate the operations of various stations or systems. Level B describes the detailed procedures, the transitions between different states, and various specific operational actions. It includes the initial state card, the stable state card, the final state card, the operational objectives, and all the specific operational actions under those objectives. The numbering of the operation steps for Level B corresponds to that of Level A. Level C contains key points and explanations, primarily focusing on the operational procedures; it provides the necessary guidance for those who use these procedures, including information on safety, equipment, and process flow diagrams. The Class C codes correspond to those of Class B. (III) Sentence structure of the operation steps. The terminology used in writing operating procedures should be standardized to ensure readability; this way, the language used to describe the same operational action will convey the same meaning to users of different devices, preventing different interpretations of the same phrase across various devices. The sentence format is: “(operator code) + (operation type code) + (verb) + (object and object complement)”. This linguistic structure is used to express the content to be conveyed, with each sentence indicating only one action. An action specifies its nature, the person who carries it out, its content, and the goal to be achieved. (IV) Operator code and operation nature code. M, I, and P are used as operator codes to represent the shift supervisor, internal operator, and external operator respectively ； “( )、、< >” are used as operation property codes, where “( )” indicates confirmation of a certain operation, “” denotes a description of the specific action taken, and “< >” represents a description of safe operations or confirmations. (5) Steady-state card. When the operation steps reach the specified stable state, it is necessary to insert the initial state card, the stable state card, and the final state card, and list the items to be verified for the conditions. (VI) Hint cards. Between the operation steps, reminder cards can be inserted as needed to explain the points that require attention during the process. The content of the reminder cards must be detailed and quantified, avoiding general principle-based reminders. Article 15: The procedures for starting up operations, shutting down operations, basic operational procedures, and procedures for operating specialized equipment must be formulated in accordance with the following steps: (1) Determine the steady state. Based on the characteristics of the start-up and shutdown processes of the apparatus or equipment, the procedure drafting team conducts collective discussions to determine the stable state of the apparatus. Between the stable states are specific operational actions that facilitate the transition between them. By breaking down a complex and variable process into simple states and straightforward, error-free actions, the operability and accuracy of the procedures are ensured. The stable state of a device should not have too many levels; generally, it is based on conventional large-scale start-up and shutdown steps. (II) Compile in stages. In accordance with the requirements for hierarchical compilation, an A-level outline, B-level procedures, and C-level explanations are prepared separately. (III) Prepare an overall plan diagram. Following the procedures for Level A, prepare a schedule for starting up and shutting down operations, determine the corresponding time frames, and coordinate the tasks of various positions during these processes. The operation steps and numbers in the overview diagram correspond to those of Level A. Article 16: The accident handling plan outlines the procedures to be followed in the event of a minor production accident or significant fluctuations in operations, in order to prevent the expansion of the accident and steer it in a controllable direction, thereby achieving a safe and controlled situation in the end. Its role is to assist operators in determining the truth behind an accident, deciding on the objectives for handling it, and clarifying the operational plans. The content and requirements are: (1) Accident name: Each accident response plan must have a specific and clear title. (II) Accident phenomena: The most direct abnormalities that occur at the time of an accident, such as unusual sounds, odors, flashing alarm lights, etc. (III) Cause of the accident: Analyze the reasons that led to the accident. (IV) Accident confirmation: List the necessary and sufficient conditions for confirming an accident, and make a ‘yes’ or ‘no’ judgment on these conditions to determine the attributes of the accident. (V) Accident handling, including: 1. Immediate action: Specify in clear and concise language the actions that must be taken right away. 2. Operational objective: State in concise terms the direction of efforts in handling the accident. 3. Potential problems: Consequences of accidents that should be avoided during the handling process. 4. Class A operation steps: List the operation steps in the form of a flowchart, assigning a number to each step; also identify the matters that require special attention throughout the accident handling process. 5. Level B operation steps: List the various processing steps that include the specific operations in sequence. (VI) Retracted state: After the operation plan is completed, the device should reach a relatively safe retracted state. Chapter 5 Approval and Use of Operating Procedures Article 17 The compilation team submits the formal draft of the operating procedures to the head of the workshop (plant). After the head of the workshop (plant) organizes a plant-level review and signs off, the documents are reviewed by the technical management department of the regional branch. Relevant departments such as production operations, mechanical equipment, and safety and environmental protection provide their approvals, and only after obtaining the approval of the senior management of the regional branch can these procedures come into effect. Article 18: During normal production, in addition to having bound copies of the operating procedures placed in fixed locations in the plant control room, single-page versions of these procedures that are required for approval processes must also be available in loose-leaf form, and they should be bound separately according to the responsibilities of each position. The single-volume operating procedures include the procedures for starting up the plant, procedures for shutting down the plant, procedures for putting individual equipment into operation (or taking it out of operation) and switching between them, accident response plans, and procedures for emergency shutdown of the plant. The quantitative indicators specified in the operating procedures must be closely integrated with the process cards in terms of operation guidelines, steps, and status verification, and the control ranges for these process indicators should be listed separately for each individual operating procedure. Article 19: The device management personnel shall form a supervision and guidance team for the use of operating procedures, with the workshop (device) supervisor serving as the team leader. At the site, at least one member of the supervision and guidance team serves as the person responsible for supervision and guidance, to address any issues that arise during implementation at any time. Article 20 Implementation of operating procedures: (1) Operating procedures shall be implemented by the production teams. Before the operator carries out the specific tasks, the workshop (plant) technicians prepare the job operation card with the necessary approval procedures completed. (II) The team leader issues operation instructions, while the operations engineer oversees the compliance with the procedures; any issues are reported promptly to the person responsible for supervision and guidance. (III) During the operation process, the person in charge inside must direct the personnel working outside to carry out the operations strictly in accordance with the prescribed steps. The personnel working outside must report any operations that have been completed to the person in charge inside, who will then make a mark on the card using either a “√” symbol or by signing. Ensure that operations are monitored, with confirmation at each step. (IV) The operation cards after use are collected by the workshop (unit) and handled in accordance with the records or as \"invalid\" documents. Article 21: For special situations not covered by the operating procedures, the facility may prepare temporary operation cards in accordance with the general requirements of those procedures. The temporary operation card comes into effect after being signed by the workshop (unit) supervisor, and is then carried out by the work team. The temporary operation cards used are collected by the workshop (unit) and handled according to the records or as \"invalid\" documents. The workshop (facility) determines whether temporary operations should be included in the regular operating procedures based on actual needs. Article 22: Operational actions that are difficult to describe in formal language during the production process may be expressed through operational specifications, which have the same validity as standard operating procedures. Among them: (1) Long-term operation regulations. Each item in the long-term operation regulations should specify only one operation, striving to meet the requirements of simplicity, clarity, and specificity ； If necessary, the relevant charts can be included in the operating procedures ； Long-term operation regulations can be used multiple times and remain valid for an extended period. (II) Regular operation regulations. For each scheduled operation, the date and time at which it is to be carried out must be specified ； Supporting documents can be prepared as needed for the regular operation regulations. When the supporting document is an operating procedure, it must be used and managed in the form of an operation card. (III) Provisional operating regulations. Temporary operating procedures are valid for a specified period of time (indicated in the validity period field) ； Temporary operating procedures are approved for implementation by the workshop (plant) supervisor, and all relevant team leaders must sign to confirm them ； According to the temporary operating regulations, it is necessary to withdraw from the site promptly if the specified valid time has passed. Article 23: Operation cards shall be placed in the filing cabinets of the control room in a loose-leaf format in accordance with the following requirements; they must be labeled with their names and distinguished using folders of different colors: (1) The operation procedures (in bound form) shall be published as a whole ； (II) The accident handling plan is stored in a red folder ； (III) Temporary operating procedures shall have no cover and be stored in a green folder ； (IV) Procedures for starting up operations, procedures for shutting down operations, operation cards for individual equipment, and other specific operation procedures are placed in separate blue folders. Chapter 6 Review and Revision of Operating Procedures Article 24 Review before the use of operating procedures: (1) Before the use of procedures for starting up and shutting down equipment during major overhauls, they must be reviewed and approved through consultation by the technical management department of the regional branch. (II) After technical or equipment modifications are made to the device, the technical department of the regional branch must organize a review and joint approval of the corresponding operating procedures. Article 25 Amendment of operating procedures: (1) Amendments during the use of operating procedures. When modifications are required during the implementation of the operating procedures, they must be approved with the signature of the workshop (plant) supervisor. The modifications are recorded on the blank page opposite the operating procedures, with the corresponding operation number indicated. (II) After being used once, the plans for starting up and shutting down operations, accident handling procedures, as well as the operating procedures for individual equipment, must have any modifications made and added to the official version of those procedures. The operating procedures also need to be revised in a timely manner according to actual circumstances. (III) For modifications that have a significant impact on safe production and cannot be confirmed independently by the workshop (unit), a new joint approval process shall be organized in accordance with the original procedures specified in the operating regulations. Article 26: For newly built, renovated, or expanded units, an interim version of the operating procedures shall be prepared first; after one year of trial use, it shall be updated to become the official operating procedures. Article 27: The operating procedures shall be reviewed annually to confirm any modifications, additions, and improvements to them. Article 28: The operating procedures shall be comprehensively revised every five years, and then re-approved, published, and distributed. Chapter 7 Supplementary Provisions Article 29 The terms used in these provisions are defined as follows: Stable state refers to a necessary transitional state that is relatively stable and safe, during which a device or equipment can remain in operation for an extended period of time to allow for condition verification or issue resolution, while it is being turned on or off. The steady state includes the initial state, the final state, and the transitional steady state. The initial state corresponds to the starting condition when the device or equipment is turned on or off, while the final state is the target condition after it has been turned on or off. The start-up and shutdown process of process units or equipment must go through multiple steady states. A state of retreat, which is a relatively stable and safe condition reached through a series of operational procedures, in order to ensure the safety of personnel and equipment when there are significant fluctuations in operation or accidents occur, and to prevent those fluctuations or accidents from spreading. In a defensive state, it is possible to calmly consider the next steps for handling the process units or equipment. Operating procedures are a series of precise operational steps, rules, and protocols that enable a device or apparatus to transition from its initial state to its final state through a specific sequence. If an exception occurs during the execution process, it is possible to revert to the previous stable state, ensuring a safe gradual transition to the final state. Appendix: Table of Operating Procedures
Chapter 1: Process Technical Specifications
1.1 General Information on the Equipment
1.1.1 Introduction to the Equipment
1.1.2 Process Principle
1.1.3 Description of the Process Flow
1.1.4 Process Principle Flowchart
1.2 Process Parameters
1.2.1 Parameters for Raw Materials
1.2.2 Parameters for Semi-finished and Finished Products
1.2.3 Parameters Related to Utility Systems
1.2.4 Main Operating Conditions
1.2.5 Parameters for Raw Material Consumption, Utility Consumption, and Energy Consumption

Chapter 2: Operating Guidelines

Chapter 3: Commissioning Procedures
3.1 Commissioning Plan
3.2 Commissioning Outline (Level A)
3.3 Commissioning Operations (Level B)
3.4 Explanations (Level C)

Chapter 4: Shutdown Procedures
4.1 Shutdown Plan
4.2 Shutdown Outline (Level A)
4.3 Shutdown Operations (Level B)
4.4 Explanations (Level C)

Chapter 5: Operating Procedures for Special Equipment

Chapter 6: Basic Operating Procedures
6.1 Starting, Stopping, and Switching of Pumps
6.1.1 Starting, Stopping, and Switching of Centrifugal Pumps
6.1.2 Starting, Stopping, and Switching of Metering Pumps
6.1.3 Starting, Stopping, and Switching of Screw Pumps
6.1.4 Starting, Stopping, and Switching of Magnetic Pumps
6.1.5 Starting, Stopping, and Switching of Reciprocating Pumps
6.2 Activation and Deactivation of Cooling Equipment
6.2.1 Activation and Deactivation of Water-cooled Heat Exchangers
6.2.2 Activation and Deactivation of Air-cooled Heat Exchangers
6.3 Sampling Procedures for Key Areas and Relevant Precautions

Chapter 7: Accident Handling Plans
7.1 Principles for Handling Accidents
7.2 Methods for Emergency Shutdown
7.3 Accident Handling Plans
7.4 Regulations for Conducting Accident Handling Drills

Chapter 8: Operating Regulations
8.1 Regular Operation Regulations
8.2 Long-term Operation Regulations
8.3 Temporary Operation Regulations

Chapter 9: Operating Methods for Instrumentation and Control Systems
9.1 Overview of the DCS System
9.2 Explanation of Logic Control for Key Process Operations and Process Control Flowcharts (PID)
9.3 Logic Control Procedures for Equipment Protection
9.3.1 Logic Control Diagram for Equipment Protection
9.3.2 Explanation of Logic Control for Equipment Protection
9.3.3 Explanation of Logic Control for Unit Protection

Chapter 10: Safety Production and Environmental Protection
10.1 Knowledge on Safety and Environmental Protection
10.2 Regulations on Safety and Environmental Protection
10.3 Anti-freezing Measures for the Equipment
10.4 Major Accidents That Have Occurred in the Past, Their Handling Methods, and Lessons Learned
10.5 Safety Properties of Flammable and Explosive Substances in This Equipment: Explosion Range, Flash Point, Auto-ignition Point
10.6 Relevant Parameters of Hazardous Substances and Media (Flammable, Explosive, Toxic) in This Equipment
10.7 Main Emission Sources of Pollutants from This Equipment and the Main Pollutants Emitted

Chapter 11: Appendices
11.1 List of Equipment
11.2 Structural Diagrams of Key Equipment
11.3 Plan Layout of the Equipment
11.4 Layout Diagram of Flammable Gas and Hydrogen Sulfide Detectors
11.5 Layout Diagram of Fire Protection Facilities in the Equipment
11.6 Set Pressure Values for Safety Valves
11.7 Alarm Values for Control Parameters
11.8 Common Basic Data

Last edited by daobaliu_1982 on 2009-2-13 at 12:56

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