Synthetic ammonia plant maintenance system

Equipment Maintenance Management System: To enhance the maintenance of equipment and implement the principle of \"maintenance first, repair second,\" it is necessary to use the equipment correctly through a rigorous approach and scientific methods. This system is established to ensure that equipment is properly maintained and kept in good condition, thereby guaranteeing its long-term operation and safe production. (1) Vigorously carry out the “Red Flag Posts, Red Flag Machines” and “Leak-Free” campaigns. A dual-monitoring mechanism is implemented to ensure that every piece of equipment, every pipeline, every valve, and every instrument has a designated person in charge. Operators focus on maintenance, strictly following operating procedures and achieving the requirements of “four understandings and three abilities.” Maintenance personnel conduct regular inspections to ensure the proper operation of the equipment. (II) Operators must: 1. Remain at their posts, strictly implement the routine inspection system, and carefully fill in the equipment operation records. 2. Start, operate, and shut down the equipment strictly in accordance with the operating procedures. 3. Ensure proper lubrication of the equipment. 4. Keep the equipment clean, maintain hygiene in the surrounding area, and work closely with the maintenance team to address any leaks or spills promptly. 5. Strictly implement the shift handover system. (III) The equipment maintenance personnel are responsible for keeping the equipment under their care in good working condition. They must: 1. Conduct regular inspections on duty and proactively inquire from the operators about the operation status of the equipment. 2. Any defects found in the equipment must be eliminated promptly, and records must be kept; defects that cannot be eliminated should be documented in detail. Report it in a timely manner and resolve it along with the equipment maintenance. 3. All backup equipment must be inspected regularly. Be careful to protect it from dust, moisture, freezing, and corrosion. For all rotating equipment, it is necessary to regularly perform shaft turning operations together with the operators to ensure that the standby equipment is in good condition. 4. Complete maintenance tasks on time, in the required quantity, and to the required quality, ensuring civilized emergency repairs. 5. Work together with the operators to promptly eliminate leaks and spills. (IV) If the operator detects any abnormal conditions, they should immediately investigate the cause and report it promptly. In emergency situations, urgent measures should be taken to handle the issue promptly or stop the machine immediately, and the shift supervisor and relevant departments must be notified right away. Driving should not continue blindly until the cause is identified and any faults are ruled out; all such incidents should be recorded in the operation logs, and clear explanations should also be provided to those taking over the shift. (5) Personnel responsible for dual-protection systems must conduct inspections on the equipment at regular intervals and in designated locations, following the inspection methods outlined in the patrol schedule. They should check for abnormal noises during operation, as well as parameters such as pressure, temperature, cooling water levels, lubrication conditions, leaks, and the sensitivity of instruments. Any defects that can be fixed should be addressed promptly, while those that cannot be resolved should be reported immediately so that appropriate action can be taken. Equipment Planned Maintenance Management System: Planned maintenance of equipment is an important measure to ensure that it remains in good condition at all times, to eliminate defects promptly, to prevent equipment failures, and to maintain control over production processes. The Equipment Department shall, based on the specific conditions of the factory, mobilize the staff to develop proper equipment maintenance procedures, and establish practical maintenance intervals and quotas. These include standards, tasks, details, downtime required for maintenance, types of technicians needed, labor hours, estimated consumption of main materials, cost quotas, as well as reasonable quotas for spare parts and their consumption. The workshop shall prepare annual, quarterly, and monthly maintenance plans, which shall be submitted to the Equipment Department and the Production Department for coordination and implementation, before being approved and issued by the general manager. Once the maintenance plan is approved by the general manager, it must be implemented strictly and carefully, with no arbitrary changes allowed. In case of special circumstances that require modifications, such changes must be submitted to the Equipment Department for review and approval. Make the necessary preparations before equipment maintenance, including: construction plans, preparation of various materials, allocation of labor, safety measures, etc. Proper handover procedures before maintenance should be carried out: this includes taking care of all matters related to pipelines and power supplies, and installing signs stating “Do not touch” and “Work in progress – switching on is strictly prohibited”. Before entering the towers and tanks, cleaning, purging, and gas analysis must be conducted. At areas where welding is to take place, the necessary procedures for welding must be followed; the person in charge of the operation and the person in charge of the maintenance must both inspect the area, and only after both agree that it is safe to proceed can they sign the handover form before starting work. During maintenance, high standards and strict requirements must be applied to ensure quality; specialized personnel from key equipment and technical departments should conduct inspections. The measurement results before and after repairs (including the electrical test records of electrical equipment) should be detailed in the maintenance record. The maintenance record should include: the area that was repaired, the quality of the repair work, any modifications made to the replaced components or equipment, and any issues that need to be addressed during the next maintenance session. After the major overhauls of the main plant equipment (four furnaces, four towers, five machines, one apparatus, and one pump), the Equipment Department should organize thorough inspections and commissioning tests. For minor repairs as well as overhauls of ordinary equipment, the inspection and operation supervisors shall conduct the inspections together. Information related to repairs, documents (maintenance records, acceptance certificates, material certification for newly installed parts). High-pressure pipeline documents, equipment improvement materials, and test data, etc., should be promptly organized, stored, and archived. The Equipment Department assists the workshops in improving the management of repair costs; it determines the materials, spare parts, labor hours, and funds required for repairs based on the nature of those repairs. It encourages staff to save on repair expenses, and any leftover materials or spare parts after repairs must be returned to the warehouse. Boiler and Pressure Vessel Management System: To ensure safe production and protect people’s lives and property, this system is established to strengthen the management of boilers, pressure vessels (pipes). I. The management of boiler and pressure vessels must strictly comply with 1. the Safety Inspection Regulations for Steam Boilers. 2. Safety Inspection Regulations for Pressure Vessels. 3. Regulations for the safety supervision of gas cylinders. 4. Relevant regulations such as the Safety Management Regulations for Pressure Vessels in Chemical Enterprises issued by the former Ministry of Chemical Industry. 5. Safety Technical Inspection Regulations for Hot Water Boilers. 6. Methods for reporting accidents involving boilers and pressure vessels. II. Special personnel shall be assigned to oversee the daily operations of boilers and pressure vessels, and a management team for boilers and pressure vessels shall be established. 1. Responsible for organizing the preparation, compilation, and submission of annual, quarterly, and monthly maintenance plans for pressure vessels. 2. Responsible for the registration of boilers and pressure vessels, as well as the collection and compilation of related documentation. 3. Develop inspection and acceptance plans for pressure vessels, and organize regular inspections and acceptances of such vessels. 5. Conduct technical assessments of operators and maintenance workers in conjunction with relevant personnel. III. The operating parameters of pressure vessels, as well as any structural modifications, must be approved by the relevant authorities before they can be carried out. These authorities must be informed, and records must be kept for documentation. Without such permission, the person in charge of operating the pressure vessel has the right to prevent anyone from making any changes or adjustments. IV. The items included in the routine inspection of pressure vessels are safety devices, fastener tension, temperature, etc., with records to be kept. Pressure gauges and safety valves must be calibrated regularly, and there should be records available for verification. Quality Management System for Machinery Equipment Processing and Maintenance: In order to carry out extensive mass-based quality management activities, to firmly establish the principle that quality comes first, to implement a dedicated quality control system, to combine specialized inspections with collective inspections, and to strengthen quality management throughout the entire process of equipment manufacturing and maintenance, thereby ensuring continuous improvement in the quality of products and maintenance work, this system is established. I. Mechanical Repair Workshop 1. Equipment and spare parts manufactured in the mechanical repair workshop must be built strictly in accordance with the drawings; no arbitrary changes are allowed. 2. In cases where it is not possible to carry out construction in accordance with the drawings or to meet the relevant technical requirements specified in them due to reasons such as material processing techniques or equipment capabilities, and changes to the drawings are necessary, approval from the technical department must be obtained. 3. The mechanical repair workshop has the right to refuse to process parts based on drawings that lack signatures from the designer, draftsman, reviewer, or modifier. 4. The machinery repair workshop must have a full-time quality inspector responsible for overseeing all quality inspection tasks. 5. Adhere to the three-level quality inspection system of “self-inspection, small-group inspection, and workshop inspection”. For any finished products delivered to the warehouse or spare parts handed over to the production workshop, inspection records must be kept. 6. The machine repair workshop must calculate and publish on a monthly basis the pass rate and scrap rate for processed items such as castings, forgings, metal components, and welded parts. 7. For components or equipment that have been repaired by reusing old parts, a repair certification must be available; otherwise, they shall not be used. 8. For external processing, outsourced workers, and subcontracted workers, charges must be issued based on the processing calculation sheets from the Equipment Department. 9. The lending of tools and equipment must be approved by the deputy general manager in charge, and they can only be lent after charging a fee based on proper documentation. II. Chemical Processing Workshop 1. The equipment maintenance workers bear full responsibility for the quality of the equipment under their care; therefore, they must adopt a meticulous and thorough working attitude. 2. The equipment maintenance workers must recheck the quality and relevant dimensions of the new equipment and spare parts received; they have the right to refuse to use any defective items, and must report this to the workshop and relevant departments in a timely manner so that a solution can be found through consultation. 3. During maintenance, records should be kept carefully and realistically in accordance with the repair procedures, and assistance should be provided to the technical department to supply first-hand information for the proper management of the equipment. During repairs, the principle of \"quality first\" should be adhered to, striving to meet quality standards; after repairs, the equipment should reach level A and the pressure specified on its nameplate ； B. Repair interval. 4. The workshop should also adhere to a three-level quality inspection system; in particular, the main equipment in the workshop must be inspected and accepted by the workshop itself. 5. For the main equipment in the factory, after maintenance is completed, the Equipment Department must organize relevant professionals to conduct an inspection before the equipment can be put into use. During a full-system shutdown for maintenance, the company should establish a quality inspection team responsible for checking the quality of the main equipment. Workshops should form their own quality inspection teams to oversee the quality of the equipment there. For each maintenance task, a three-level inspection system must be followed, which includes self-inspection, mutual inspection, and inspection by a dedicated team. Equipment Installation and Acceptance System: This system is established to manage equipment properly, ensure its proper operation, and comply with safety regulations. 1. For the purchased equipment, the Equipment Department is responsible for unboxing and inspection, and submits the technical documentation to the archives room for storage. II. After passing the inspection, it shall be delivered to the processing workshop and the user unit for installation; self-made equipment shall be inspected, forms filled out, and signatures obtained jointly by the Production Department, Safety Department, Equipment Department, and the manufacturing unit. It shall be delivered for use and installation only after passing the acceptance test. III. The Equipment Department issues the tasks, designates the installation department, and specifies the technical and installation requirements. The Process Pipeline Production Department and the Technology Department prepare process flow diagrams for use by the installation department. The installation department shall carry out the installation in accordance with the requirements; these requirements must not be altered arbitrarily. In special cases, any changes require the approval and signature of the competent authority. IV. Once the operating equipment has been installed, the Equipment Department shall organize the installation unit, the user unit, and the Safety Department to conduct an inspection and acceptance. The process equipment is inspected and accepted by the Production Department in conjunction with the Equipment Department, Safety Department, installation unit, and user unit. No entity shall lower the standards and technical requirements. After passing the acceptance inspection, relevant departments must sign before the equipment can be put into use. 5. The operating equipment shall be started up and subjected to load testing only after its alignment accuracy and various clearances have been verified as satisfactory; the entire process must comply with the requirements outlined in the user manual. Device Sealing and Disposal System: 1. Idle devices can be sealed in place; for devices sealed in the workshop, the workshop assigns dedicated personnel to maintain them to ensure that all accessories are present. The equipment stored in the warehouse is maintained by the custodians or designated personnel assigned by the Equipment Department. Equipment that is planned to remain unused for more than a month will not be subject to equipment evaluation or assessment. II. The procedure for approving the sealing of equipment is as follows: the using unit decides, based on production plans, to submit a report on equipment sealing to the Equipment Department; after review by that department, the matter is approved by the company’s relevant management official. III. For production equipment that is severely damaged in structure and cannot be repaired or is not suitable for production needs, the personnel in the production equipment team shall assess whether it should be scrapped, and submit the decision to the company’s relevant management for approval. IV. Energy-consuming equipment whose use is prohibited by higher-level directives may only be discontinued with the approval of the company’s relevant management officer. V. The valuation for the sale of scrapped equipment shall be determined jointly by the Equipment Department and the Finance Department, with approval from the General Manager. VI. When selling scrapped equipment and recycled items that involve ** or locally allocated materials, the relevant regulations must be complied with. Equipment Selection and Procurement System: I. For the procurement of important production equipment, it is necessary to have the relevant department heads of the company oversee the process, with departments such as production, equipment, supply and marketing, and finance conducting economic and technical evaluations on the basis of investigations before making a decision to place an order or proceed with the purchase. The specific measures should be as follows: the production and equipment departments shall prepare a written plan for purchasing equipment based on this year’s production needs and the factory’s equipment capacity, after which relevant personnel shall conduct investigations and evaluations regarding the model and origin of the equipment. II. The competent department shall prepare a written justification for the selected equipment, which will then be reviewed by the company’s relevant management for its feasibility. III. Submit the plan and related justification to the general manager for approval, after which the relevant departments may carry out their tasks according to their respective responsibilities. IV. For general equipment and equipment purchased sporadically, the unit using it shall submit information on the technical specifications or exact model and parameters of the equipment to the Production Equipment Department. After reviewing this information, the Production Equipment Department will submit it to the company’s relevant management for approval, after which the Supply Department will be responsible for making the purchases or placing orders. V. After the equipment arrives at the factory, the Production Equipment Department organizes a team of relevant personnel to form an acceptance group to unpack and inspect the equipment. Once inspected, the equipment is either put into use or installed, or stored in the warehouse in accordance with the technical requirements set by the Equipment Department.

Please check the following two links to see if they contain what you’re looking for: 1. \"Practical Manual on Technical Specifications for Installation, Commissioning, Operation, Maintenance, and Repair of Chemical Engineering Machinery and Equipment\" 2. Equipment maintenance