“Pilot Production Management System” – everyone, come and take a look! The moderators should step in and take care of this too!
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Regarding the formulation of the \"Pilot Production Management System,\" I would like to thank all of you. This issue has been pending for almost 2 months now without any resolution, so I hope everyone can offer some suggestions for reference. The moderators should also help us out; thank you very much! This post was last edited by asdffg on 2009-3-23 10:42]
Thank you to the moderator for paying attention; I hope this issue can be resolved as soon as possible. Everyone, please help!
Here is an outline for you to refer to when drafting the document:
Chapter 1: Project Overview... 1
1.1 General Project Overview... 1
1.2 Construction of Production Units and Utility Systems... 6
1.4 Supply of Main Raw Materials... 12
1.5 Utility Systems... 13
1.6 Product Flow... 15
1.7 Transportation... 16
1.8 Flare System... 17
Chapter 2: Basis and Principles for Formulating the Commissioning Plan... 19
2.1 Basis for Formulation... 19
2.2 Principles for Formulation... 20
Chapter 3: Guiding Principles and Standards for Commissioning... 21
3.1 Guiding Principles... 21
3.2 Standards to be Met During Commissioning... 21
Chapter 4: Conditions Required for Commissioning with Feedstock... 23
4.1 Commissioning Framework... 23
4.2 HSE Framework... 24
4.3 Handover During Construction and Joint Commissioning... 25
4.4 Related Operations... 26
4.5 Employee Training... 26
4.6 Operation Support System... 26
4.7 Commissioning Plan... 27
4.8 Utility Systems... 28
4.9 Raw Materials and Auxiliary Materials... 28
4.10 Information and Automation... 29
4.11 Confirmation of Startup... 31
Chapter 5: Commissioning Organization and Command Structure... 32
5.1 Working Leadership Team... 32
5.2 Commissioning Command Center and Specialized Teams... 33
5.3 Technical Expert Advisory Group and Startup Team... 38
5.4 Commissioning Operation Support System... 39
Chapter 6: Commissioning Schedule... 43
6.1 Principles for Scheduling Commissioning... 43
6.2 Main Schedule for Commissioning... 43
6.3 Time for Feeding Feedstock and Product Qualification... 45
6.4 Commissioning Procedures... 45
6.5 Key Control Points and Their Timelines... 48
6.6 Comprehensive Commissioning Schedule Diagram... 55
Chapter 7: Material Balance... 75
7.1 Principles for Arranging Load during Commissioning with Feedstock... 75
7.2 Material Balance... 75
7.3 Material Requirements During Commissioning... 89
Chapter 8: Fuel and Power Balance... 99
8.1 Consumption of Utility Systems... 99
8.1.1 Design Values for Utility Consumption under Normal Operating Conditions... 99
8.1.2 Consumption under Operating Conditions in May... 99
8.1.3 Production Conditions in June... 100
8.1.4 Production Conditions in July and August... 100
8.1.5 Production Conditions in September... 101
8.2 Fuel Balance... 101
8.3 Fresh Water and Recirculated Water Systems... 107
8.4 Demineralized Water System... 108
8.5 Fire Fighting Water... 109
8.6 Steam Balance... 110
8.7 Nitrogen Balance... 117
8.8 Instrument Air and Unpurified Air... 119
8.9 Electricity... 119
Chapter 9: Environmental Protection Measures... 122
9.1 Environmental Protection Strategies... 122
9.2 Schedule for Environmental Protection Activities During Commissioning... 123
9.3 Environmental Monitoring... 124
9.4 Treatment of “Three Wastes”... 125
9.5 Emergency Response Plans... 125
9.6 Measures for Treating “Three Wastes”... 125
9.7 Summary Table of “Three Wastes” Emissions... 127
Chapter 10: Labor Safety, Health, and Fire Protection... 133
10.1 Labor Safety and Health... 133
10.2 Fire Protection... 139
Chapter 12: Economic Benefits... 156
12.1 Stages for Calculating Benefits... 156
12.2 Explanation of Calculations... 157
12.3 Summary of Calculations... 158
12.4 Conclusion... 160
12.5 Measures to Improve Economic Benefits... 161
Chapter 13: Other Issues That Need to Be Addressed... 162
13.2 RFCC Flue Gas Turbines... 162
13.3 Fuel Transportation... 163
Last edited by DAC Junlin Tianxia on 2009-3-31 at 10:38.]
Chapter 1: Project Overview... 1
1.1 General Project Overview... 1
1.2 Construction of Production Units and Utility Systems... 6
1.4 Supply of Main Raw Materials... 12
1.5 Utility Systems... 13
1.6 Product Flow... 15
1.7 Transportation... 16
1.8 Flare System... 17
Chapter 2: Basis and Principles for Formulating the Commissioning Plan... 19
2.1 Basis for Formulation... 19
2.2 Principles for Formulation... 20
Chapter 3: Guiding Principles and Standards for Commissioning... 21
3.1 Guiding Principles... 21
3.2 Standards to be Met During Commissioning... 21
Chapter 4: Conditions Required for Commissioning with Feedstock... 23
4.1 Commissioning Framework... 23
4.2 HSE Framework... 24
4.3 Handover During Construction and Joint Commissioning... 25
4.4 Related Operations... 26
4.5 Employee Training... 26
4.6 Operation Support System... 26
4.7 Commissioning Plan... 27
4.8 Utility Systems... 28
4.9 Raw Materials and Auxiliary Materials... 28
4.10 Information and Automation... 29
4.11 Confirmation of Startup... 31
Chapter 5: Commissioning Organization and Command Structure... 32
5.1 Working Leadership Team... 32
5.2 Commissioning Command Center and Specialized Teams... 33
5.3 Technical Expert Advisory Group and Startup Team... 38
5.4 Commissioning Operation Support System... 39
Chapter 6: Commissioning Schedule... 43
6.1 Principles for Scheduling Commissioning... 43
6.2 Main Schedule for Commissioning... 43
6.3 Time for Feeding Feedstock and Product Qualification... 45
6.4 Commissioning Procedures... 45
6.5 Key Control Points and Their Timelines... 48
6.6 Comprehensive Commissioning Schedule Diagram... 55
Chapter 7: Material Balance... 75
7.1 Principles for Arranging Load during Commissioning with Feedstock... 75
7.2 Material Balance... 75
7.3 Material Requirements During Commissioning... 89
Chapter 8: Fuel and Power Balance... 99
8.1 Consumption of Utility Systems... 99
8.1.1 Design Values for Utility Consumption under Normal Operating Conditions... 99
8.1.2 Consumption under Operating Conditions in May... 99
8.1.3 Production Conditions in June... 100
8.1.4 Production Conditions in July and August... 100
8.1.5 Production Conditions in September... 101
8.2 Fuel Balance... 101
8.3 Fresh Water and Recirculated Water Systems... 107
8.4 Demineralized Water System... 108
8.5 Fire Fighting Water... 109
8.6 Steam Balance... 110
8.7 Nitrogen Balance... 117
8.8 Instrument Air and Unpurified Air... 119
8.9 Electricity... 119
Chapter 9: Environmental Protection Measures... 122
9.1 Environmental Protection Strategies... 122
9.2 Schedule for Environmental Protection Activities During Commissioning... 123
9.3 Environmental Monitoring... 124
9.4 Treatment of “Three Wastes”... 125
9.5 Emergency Response Plans... 125
9.6 Measures for Treating “Three Wastes”... 125
9.7 Summary Table of “Three Wastes” Emissions... 127
Chapter 10: Labor Safety, Health, and Fire Protection... 133
10.1 Labor Safety and Health... 133
10.2 Fire Protection... 139
Chapter 12: Economic Benefits... 156
12.1 Stages for Calculating Benefits... 156
12.2 Explanation of Calculations... 157
12.3 Summary of Calculations... 158
12.4 Conclusion... 160
12.5 Measures to Improve Economic Benefits... 161
Chapter 13: Other Issues That Need to Be Addressed... 162
13.2 RFCC Flue Gas Turbines... 162
13.3 Fuel Transportation... 163
Last edited by DAC Junlin Tianxia on 2009-3-31 at 10:38.]
Table of Contents for the Pilot Production Management System
1. Regulations on Pilot Production Management
2. Overall Pilot Production Plan
3. Emergency Response Procedures for Chemical Accidents
4. Management Measures for Volunteer Fire Teams and Factory Fire Protection
5. Classification Table for Explosive Hazardous Areas
6. Safety Data Sheets (MSDS) for Raw Materials Used in Production
7. List of Hazard Sources
8. Safety Management Regulations for Maintenance Work (Including On-site Safety Management in Explosion-proof Areas)
9. Management Measures for Lightning Protection and Disaster Reduction
10. Management Measures for Medical Examinations and Prevention of Occupational Diseases
11. Layout of Major Production Sites and Corresponding Process Flow Diagrams
12. Emergency Rescue Plans for Various Types of Safety Accidents in Key Areas, along with Operation and Evacuation Routes
13. Configuration and Layout Diagrams of Fire Protection Facilities
14. Maps of Designated Areas for Open Flaming and No-Flaming Zones
15. Management Measures for Vehicle Safety
16. Safety Management Manual for Laboratories
17. Management and Usage Methods for Fire Extinguishers
18. Gatekeeper Management System
19. Security Management Regulations Against Theft
20. Other Management Systems and Operating Instructions
21. Emergency Rescue Plans and Operation/Evacuation Routes for the Company Headquarters
22. Warehouse Management System
23. Management System for Defective Products
24. Product Inspection and Sampling System
25. Finished Product Management System
26. Process Discipline Management System
27. Assessment System for Process Discipline Compliance
28. Management System for Measuring Instruments
29. Management System for Technical Documents
30. Management System for Inspections of Semi-finished and Finished Products upon Entry and Exit from Storage
31. Management System for Raw Materials and Auxiliaries
32. Management System for Original Records, Statistical Ledgers, and Statistical Reports
33. Management System for Quality Control Points
34. Management System for Quality Incidents
35. Management System for Quality Complaints
36. Management System for Standardization Work
37. Several Regulations on Production Meetings
38. Regulations on Daily Production Operation Reports
39. Management Regulations for Reporting Outages of Water, Electricity, Steam, and Air Supply
40. Process Technology Management System
41. Management Regulations for Starting and Stopping Production Units
42. Management System for Production Accident Plans
43. System for Verifying Key Process Parameters of Production Units
44. Detailed Rules for Installation (Replacement) and Operation of Steam Traps
45. 24/7 Inspection System at Plant Sites
46. Management System for Energy Conservation Inspections
47. Management System for Production Operation Records and Shift Handover Records
48. Training System for On-the-Job Skill Development
49. Management Regulations for Dividing System Process Pipelines
50. Operation and Management Regulations for Material Pipelines in the Chemical Area
51. Management Regulations for Rectifying Defects in Production Facilities
52. Management Methods for Leak Detection in Circulating Water Systems
53. Detailed Rules for Chemical Analysis Quality Management
54. Quality Information Feedback System
55. Implementation Measures for Direct Metering of Internally Used Energy Sources such as Water, Electricity, Steam, and Air
56. Measurement Management and Assessment Methods for Inbound and Outbound Deliveries
57. Measurement Management Methods for Product Inbound and Outbound Deliveries in the Chemical Area
58. Management Regulations for Weighing at Truck Scales
59. Measurement Management Methods for Weighing Raw Materials in Non-fixed Packaging Before Entry into the Factory
60. Duty System for the Production Management Department
61. Interim Regulations on the Accident Scene Command System
62. Emergency Contact Procedures for Accidents
63. (Production) Hierarchical Management Standards
64. Management Regulations for Planned Shutdowns and Planned Maintenance to Rectify Defects
65. Interim Regulations on On-site Work Approval Procedures, Planning, Scheduling, and Production Management Systems
66. Annual Comprehensive Planning Management System
67. Workshop Statistics Work System
68. Management System for Original Records
69. Production Collaboration Management System
70. Safety Production Meeting System
71. Civilized Production Management System
72. Distribution and Management System for Personal Protective Equipment
73. Procedures for Handling Work-related Injury and Death Incidents
74. Management System for Tools and Equipment
75. Equipment Management System
76. Equipment Lubrication Management System
77. Management System for Equipment Technical Documentation
78. System for Reporting, Analyzing, and Handling Equipment Accidents
79. Three-level Equipment Maintenance and Inspection System
80. Planned Equipment Maintenance System
81. Quality Inspection, Acceptance, and Handover System for Major Equipment Repairs
82. Equipment Usage System
83. Spare Parts Management System
84. Management System for Special Power Equipment
85. System for Issuing Production Supplies
86. Management Methods for Waste Materials
87. Product Technology Management System
88. Management System for Defective Products
89. Safety Management Regulations for Electrical and Welding Operations
90. Management Regulations for Safe Storage and Transportation of Hazardous Chemicals
91. Patrol Inspection System for Pressure Vessels
92. Fire Safety System
93. Management System for Outsourced Construction Workers
94. Safety Management System for Hazardous Operations
95. Maintenance Safety Management System
96. Sewage Management System
97. Open Flaming Management System
98. Management System for Distribution and Use of Personal Protective Equipment
99. Safety Accident Management System
100. Safety Management System for Hazardous Chemicals
101. Medical Examination and Occupational Disease Screening System
102. Fire and Explosion Prevention Safety Management System
103. Safety Management System for Working at Heights
104. Safety Management System for Earthwork Operations
105. Safety Management System for Lifting Operations
106. Safety Management System for Cutting Operations
107. Safe Open Flaming System
108. Safety Management System for Construction Sites
109. System for Rectifying Potential Hazards
110. Safety Management System for Fire Protection Equipment
111. Dust Prevention Management System
112. Poison Prevention Safety Management System
113. System for Preventing Acute Poisoning and Providing First Aid
114. Safety Inspection System
115. System for Detecting and Evaluating Occupational Hazards
116. Warehouse Safety Management System
117. Electrical Safety Management System
118. Production Scheduling System
119. Post Responsibility System
120. Chemical Analysis System
121. Safety Production Management System
122. Equipment Patrol Inspection System
123. Two-ticket Management System
124. Basic Management Systems
125. Bonus and Assessment System
126. Three-level Equipment Acceptance System
127. Process Management System for the Production Process
128. Management System for Process Operation Accidents
129. Process Parameter Management System
130. Management System for Analysis Items and Frequency
131. Management System for Process Operation Procedures
132. System for Compiling Monthly Process Reports
133. Management System for the Central Control Room
134. Management System for Original Records
135. Process Ledger Management System
136. System for Compiling Start-up and Shutdown Plans for Systems
137. Management System for Catalyst Usage
138. Solution Management System
139. Energy Conservation Management System
140. Regulations Prohibiting Smoking and Using Mobile Phones within the Factory Production Area
141. Traffic Safety and Road Management Regulations for the Factory Area
1. Regulations on Pilot Production Management
2. Overall Pilot Production Plan
3. Emergency Response Procedures for Chemical Accidents
4. Management Measures for Volunteer Fire Teams and Factory Fire Protection
5. Classification Table for Explosive Hazardous Areas
6. Safety Data Sheets (MSDS) for Raw Materials Used in Production
7. List of Hazard Sources
8. Safety Management Regulations for Maintenance Work (Including On-site Safety Management in Explosion-proof Areas)
9. Management Measures for Lightning Protection and Disaster Reduction
10. Management Measures for Medical Examinations and Prevention of Occupational Diseases
11. Layout of Major Production Sites and Corresponding Process Flow Diagrams
12. Emergency Rescue Plans for Various Types of Safety Accidents in Key Areas, along with Operation and Evacuation Routes
13. Configuration and Layout Diagrams of Fire Protection Facilities
14. Maps of Designated Areas for Open Flaming and No-Flaming Zones
15. Management Measures for Vehicle Safety
16. Safety Management Manual for Laboratories
17. Management and Usage Methods for Fire Extinguishers
18. Gatekeeper Management System
19. Security Management Regulations Against Theft
20. Other Management Systems and Operating Instructions
21. Emergency Rescue Plans and Operation/Evacuation Routes for the Company Headquarters
22. Warehouse Management System
23. Management System for Defective Products
24. Product Inspection and Sampling System
25. Finished Product Management System
26. Process Discipline Management System
27. Assessment System for Process Discipline Compliance
28. Management System for Measuring Instruments
29. Management System for Technical Documents
30. Management System for Inspections of Semi-finished and Finished Products upon Entry and Exit from Storage
31. Management System for Raw Materials and Auxiliaries
32. Management System for Original Records, Statistical Ledgers, and Statistical Reports
33. Management System for Quality Control Points
34. Management System for Quality Incidents
35. Management System for Quality Complaints
36. Management System for Standardization Work
37. Several Regulations on Production Meetings
38. Regulations on Daily Production Operation Reports
39. Management Regulations for Reporting Outages of Water, Electricity, Steam, and Air Supply
40. Process Technology Management System
41. Management Regulations for Starting and Stopping Production Units
42. Management System for Production Accident Plans
43. System for Verifying Key Process Parameters of Production Units
44. Detailed Rules for Installation (Replacement) and Operation of Steam Traps
45. 24/7 Inspection System at Plant Sites
46. Management System for Energy Conservation Inspections
47. Management System for Production Operation Records and Shift Handover Records
48. Training System for On-the-Job Skill Development
49. Management Regulations for Dividing System Process Pipelines
50. Operation and Management Regulations for Material Pipelines in the Chemical Area
51. Management Regulations for Rectifying Defects in Production Facilities
52. Management Methods for Leak Detection in Circulating Water Systems
53. Detailed Rules for Chemical Analysis Quality Management
54. Quality Information Feedback System
55. Implementation Measures for Direct Metering of Internally Used Energy Sources such as Water, Electricity, Steam, and Air
56. Measurement Management and Assessment Methods for Inbound and Outbound Deliveries
57. Measurement Management Methods for Product Inbound and Outbound Deliveries in the Chemical Area
58. Management Regulations for Weighing at Truck Scales
59. Measurement Management Methods for Weighing Raw Materials in Non-fixed Packaging Before Entry into the Factory
60. Duty System for the Production Management Department
61. Interim Regulations on the Accident Scene Command System
62. Emergency Contact Procedures for Accidents
63. (Production) Hierarchical Management Standards
64. Management Regulations for Planned Shutdowns and Planned Maintenance to Rectify Defects
65. Interim Regulations on On-site Work Approval Procedures, Planning, Scheduling, and Production Management Systems
66. Annual Comprehensive Planning Management System
67. Workshop Statistics Work System
68. Management System for Original Records
69. Production Collaboration Management System
70. Safety Production Meeting System
71. Civilized Production Management System
72. Distribution and Management System for Personal Protective Equipment
73. Procedures for Handling Work-related Injury and Death Incidents
74. Management System for Tools and Equipment
75. Equipment Management System
76. Equipment Lubrication Management System
77. Management System for Equipment Technical Documentation
78. System for Reporting, Analyzing, and Handling Equipment Accidents
79. Three-level Equipment Maintenance and Inspection System
80. Planned Equipment Maintenance System
81. Quality Inspection, Acceptance, and Handover System for Major Equipment Repairs
82. Equipment Usage System
83. Spare Parts Management System
84. Management System for Special Power Equipment
85. System for Issuing Production Supplies
86. Management Methods for Waste Materials
87. Product Technology Management System
88. Management System for Defective Products
89. Safety Management Regulations for Electrical and Welding Operations
90. Management Regulations for Safe Storage and Transportation of Hazardous Chemicals
91. Patrol Inspection System for Pressure Vessels
92. Fire Safety System
93. Management System for Outsourced Construction Workers
94. Safety Management System for Hazardous Operations
95. Maintenance Safety Management System
96. Sewage Management System
97. Open Flaming Management System
98. Management System for Distribution and Use of Personal Protective Equipment
99. Safety Accident Management System
100. Safety Management System for Hazardous Chemicals
101. Medical Examination and Occupational Disease Screening System
102. Fire and Explosion Prevention Safety Management System
103. Safety Management System for Working at Heights
104. Safety Management System for Earthwork Operations
105. Safety Management System for Lifting Operations
106. Safety Management System for Cutting Operations
107. Safe Open Flaming System
108. Safety Management System for Construction Sites
109. System for Rectifying Potential Hazards
110. Safety Management System for Fire Protection Equipment
111. Dust Prevention Management System
112. Poison Prevention Safety Management System
113. System for Preventing Acute Poisoning and Providing First Aid
114. Safety Inspection System
115. System for Detecting and Evaluating Occupational Hazards
116. Warehouse Safety Management System
117. Electrical Safety Management System
118. Production Scheduling System
119. Post Responsibility System
120. Chemical Analysis System
121. Safety Production Management System
122. Equipment Patrol Inspection System
123. Two-ticket Management System
124. Basic Management Systems
125. Bonus and Assessment System
126. Three-level Equipment Acceptance System
127. Process Management System for the Production Process
128. Management System for Process Operation Accidents
129. Process Parameter Management System
130. Management System for Analysis Items and Frequency
131. Management System for Process Operation Procedures
132. System for Compiling Monthly Process Reports
133. Management System for the Central Control Room
134. Management System for Original Records
135. Process Ledger Management System
136. System for Compiling Start-up and Shutdown Plans for Systems
137. Management System for Catalyst Usage
138. Solution Management System
139. Energy Conservation Management System
140. Regulations Prohibiting Smoking and Using Mobile Phones within the Factory Production Area
141. Traffic Safety and Road Management Regulations for the Factory Area