Guidelines for Equipment Integrity Management

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Guidelines for Equipment Integrity Management: I. Equipment numbering and inventory records II. Technical documentation of equipment III. Quota management for spare parts IV. Equipment operation management V. Equipment maintenance management VI. Personnel training and qualification assessment VII. Regular inspection of special equipment VIII. Inspection, repair, and maintenance of installations and equipment IX. Equipment change management X. Safety inspections prior to commissioning XI. Analysis of causes of abnormalities and reliability assessment XII. Archiving of maintenance records XIII. Scrap management. The mechanical integrity of equipment is an important means of ensuring that it remains in good condition after being put into use; it encompasses the management of all aspects related to equipment installation, use, maintenance, repair, inspection, changes, and scrapping. To ensure the mechanical integrity of equipment through standardized work procedures and norms, to guarantee good operability, and to provide a solid foundation for the safe and stable operation of the equipment as well as to achieve intrinsic safety, this guide is shared here. I. Equipment Numbers and Registers 1. To facilitate the tracking and management of equipment, all equipment owned by the company should be assigned a number, with one number per piece of equipment. Auxiliary equipment such as motors included in the complete set of equipment are not assigned separate numbers unless there is a special reason. 2. The equipment number shall be determined based on the equipment station number indicated in the PID diagram; for equipment without a station number or that operates independently, its name shall be specified by the user unit. The equipment number should be formatted according to the rule of workstation number + equipment name, and marked in a prominent position on the equipment. 3. Equipment management personnel in each unit shall establish an equipment register for their respective units in accordance with the principle of consistency between records and actual assets. The equipment registers shall be filled out in the format provided in the \"Notice on Issuing the Standards for Managing Basic Equipment Information of the Company\". The ABC classification of equipment should be indicated in the equipment register. (Class A refers to critical equipment, while Classes B and C refer to ordinary equipment.) 4. The equipment register must be complete, accurate, standardized, and updated in a timely manner. In addition to electronic documents, paper copies should also be kept for reference. II. Equipment Technical Records 1. Each unit shall establish and improve equipment technical records in accordance with the company’s relevant regulations on equipment management. The equipment technical records should be kept by a designated person. Units with the necessary facilities should arrange separate rooms for storage. 2. A separate technical file for each piece of equipment should be established. For the main contents of the equipment technical documentation, please refer to Article 7, Chapter 2 of the \"Company’s Regulations on the Management of Basic Equipment Information\" ； For the main contents of the technical archives for special equipment, please refer to the \"Company Standards for Establishing Technical Archives for Special Equipment\". 3. The equipment technical documentation is an integral part of the equipment; when there are changes such as the transfer of the equipment, the technical documentation must also change along with it. During the transition process, proper handover procedures should be followed to prevent loss of documents. 4. The equipment parts manual and structural diagrams are important components of the equipment’s technical documentation. Management should be carried out in accordance with the following principles. 1) The equipment parts manual and structural diagrams shall be provided by the equipment manufacturer. The equipment procurement department should specify this clearly in the technical agreement for equipment procurement. Equipment that fails to provide the parts manual and structural diagrams as required during acceptance shall not pass the inspection. 2) The equipment-using unit shall promptly collect and complete the equipment parts manual and structural diagrams. These should be archived and stored together with basic documents such as equipment files and instruction manuals. 3) To ensure the equipment is in good condition and to facilitate timely repairs and maintenance, the equipment parts manuals and structural diagrams should be updated by the equipment engineer using information provided by the manufacturer. III. Quota management of spare parts and accessories
1. All units within the company must strengthen the management of spare parts and accessories, establish and improve relevant management systems, and assign specific personnel to be responsible for such management. 2. Quota management: The using unit should establish a dynamic table for equipment parts. Based on the actual consumption of spare parts, organize the establishment of consumption quotas and reserve quotas for these parts within the unit, and revise and improve them annually. Quota management should establish a reasonable inventory level based on the principle of ensuring that equipment can be used for normal production, maintenance, and repair, thereby meeting the actual needs for safe, stable, long-term, full-capacity, and optimal operation of the equipment, without causing any accumulation of stock. 3. Plan management: The management of spare parts plans is crucial for ensuring their timely supply. The using units should formulate annual, quarterly, and monthly spare part demand plans based on the annual equipment maintenance schedule, spare part consumption patterns, and designated stock levels; these plans must be approved by the equipment management departments at various levels before procurement can take place. Considering the impact of approval and procurement cycles, to ensure production needs are met, imported components must be planned for one year in advance, while domestic components must be planned for three months in advance. 4. Parts procurement: Domestic supplies as well as imported oil-specific pipes are purchased by the Materials Procurement Department, while imported goods (other than specialized pipes) are purchased by the Foreign Affairs and Equipment Department. The procurement procedures must be carried out in strict accordance with the relevant provisions of the Company’s Materials Management Regulations. 5. Inventory management: There must be strict rules and procedures for the inspection upon receipt, storage, maintenance, and issuance of equipment parts. Proper storage requires that the material type be clear, the part number be accurate, and the items not be damaged or deformed, ensuring consistency among the records, cards, and actual items. IV. Equipment Operation Management 1. All units shall establish and improve equipment operation procedures and post responsibility systems. 2. Equipment operators must undergo training prior to starting work; they may only begin working after passing the examination and obtaining a work permit. Through technical training, operators of equipment should achieve the \"four understandings\" and \"three abilities\" regarding the equipment they use: understanding its performance, principles, structure, and purpose ； Able to operate, maintain, and troubleshoot. 3. Duties and rights of equipment operators: (I) Duties: (1) Strictly abide by the procedures for operating, using, and maintaining the equipment. Ensure thorough preparation before startup, repeated checks during startup, proper adjustments during operation, and appropriate handling after shutdown. Strictly adhere to the operational parameters; operation under conditions of excessive temperature, pressure, speed, or load is not permitted. (2) It is necessary to remain at one’s post and strictly implement the routine inspection system; regularly inspect the equipment under one’s responsibility along the designated inspection routes. Using the \"cross\" method of maintenance (cleaning, lubrication, corrosion protection, adjustment, and tightening), one should proactively eliminate defects such as dirt, rust, shortages, disorganization, and leaks, and carefully fill out the operation records. (3) Strengthen inspections of the lubrication, vibration, bearing temperature, and abnormal noises of rotating equipment; any abnormalities found must be properly addressed and reported immediately, with records kept. (4) Pressure vessels and industrial pipelines should be regularly inspected for insulation, cooling performance, corrosion, and leaks; any abnormalities detected must be reported immediately, and records should be kept. (5) If operators notice any abnormal conditions with the equipment, they should immediately investigate the cause and report it in a timely manner. In case of an emergency, corrective measures shall be taken in accordance with relevant procedures and reported accordingly. Without identifying the cause and rectifying the fault, one must not drive blindly. (6) Keep equipment, pipelines, and the floor clean and tidy to ensure civilized production. (II) Rights (1) The right to prevent personnel not assigned to a particular post from operating the equipment related to that post. (2) There is the right to refuse to operate equipment that requires maintenance or is malfunctioning. (3) Instructions to use the equipment in an unreasonable manner, such as by violating operating and maintenance procedures, can be refused. 4. Equipment operators should communicate with maintenance personnel in a timely manner to jointly carry out equipment management work. V. Equipment Maintenance Management 1. The entity using the equipment shall formulate equipment maintenance procedures. The procedures are prepared based on the equipment operation manuals and process requirements, following the company’s unified standard format and content. 2. The equipment maintenance procedures must be practical and actionable; they should be prepared and updated by operators with practical experience, and approved and issued in accordance with the principle of hierarchical approval. 3. Key points of equipment maintenance procedures: 1) The format of the procedures must follow the company’s standard format. 2) Update of maintenance procedures: Maintenance procedures should be updated in a timely manner based on actual operational experience, and the update process shall be carried out in accordance with the company’s relevant regulations. The user unit should promptly communicate with and train the maintenance personnel regarding the updated maintenance procedures. 3) Maintenance procedures must be provided to all relevant positions. 4. Equipment maintenance personnel should have clear divisions of labor and work closely together to ensure proper equipment maintenance. (1) Strictly implement the routine inspection system; conduct inspections of the equipment under management at regular intervals along the designated inspection routes. Proactively inquire with the operators about the operating conditions of the equipment, identify and address any defects or potential issues promptly. Any problems detected in the equipment must be reported in a timely manner, along with proper documentation. (2) Use advanced instruments (such as vibration meters, thickness gauges, tachometers, thermometers, etc.) to conduct routine inspections on key equipment. VI. Personnel Training and Qualification Assessment 1. Equipment management departments at all levels of the company should urge their subordinate units to carry out effective training for equipment operators and maintenance personnel. It should be carried out in a planned and phased manner to ensure the effective implementation of training, to maintain the professional skills of equipment operation and maintenance personnel, and to improve their technical competence and overall capabilities. 2. Each grassroots unit should, in light of the actual production conditions and the employees’ needs regarding equipment operation and maintenance skills, develop targeted annual training plans for different types of employees. Please refer to the attached table for the format of the training plan. Equipment Training Plan for XX Unit in 20XX Training Type_______ (Basic Training, Pre-job Training, Refresher Training) Serial Number Training Content Trainer Training Date Training Method Target Participants Certification (Yes or No) Organizing Unit Remarks Compiled by: Reviewed by: Compilation Date: 1) Basic Training: The relevant basic training that every new employee must receive before starting work at a workplace (factory, work area, station, team, etc.). 2) Pre-job training: Training for equipment operation and maintenance personnel on the relevant knowledge and skills required for their new roles. (Training in essential skills such as equipment operation, maintenance procedures, and structural principles.) 3) Refresher training: For the operation and maintenance of critical equipment, as well as important safety procedures, refresher training should be conducted at regular intervals to ensure the stability and improvement of employees’ job-related skills. (The frequency shall be determined by each unit according to its actual needs.) 4. The training methods shall be based on the principle of effectiveness, and may include but are not limited to the following methods: For 2022, it is planned to carry out 1) theoretical training. 2) On-site drills. 3) Reading materials and self-study. 4) External cultivation. 5. Training assessment: All equipment operators and maintenance personnel must pass assessments such as written tests, oral exams, or practical operations after training, in order to determine the effectiveness of the training or to certify their qualifications. 6. Training records shall be updated and kept by the respective training organizations responsible for conducting the training. All levels of the company should urge their subordinate units to carry out training in strict accordance with the training plan and to maintain proper records. Please refer to the attached table for the training record format. 7. The selection of training instructors is based on the company’s relevant training standards. VII. Regular Inspection of Special Equipment 1. Definition of regular inspection of special equipment: (1) The inspection cycle for special equipment is determined based on its time of operation and safety level. (2) Types of inspections: annual inspections, comprehensive inspections, and pressure resistance tests. 2. The formulation, approval, and issuance of plans for regular inspection of special equipment are carried out in accordance with regulations such as the \"Regulations on the Management of Special Equipment\" and the \"Notice on Clarifying the Procedures Related to the Inspection of Special Equipment\". 3. Workflow for regular inspection of special equipment: ① The inspection plan is submitted by the user unit in the special equipment management information system; after review by the Department of Foreign Affairs and Equipment, the annual inspection plan for special equipment is issued. ②The user unit shall contact the inspection agency designated by the company to arrange the inspection. ③The equipment management department of the using unit shall organize the review of the inspection plan for special equipment; for the review of the inspection plan for critical pressure vessels, the Foreign Affairs and Equipment Department shall be notified to attend. ④The using unit organizes the implementation of the special equipment inspection plan. ⑤The user unit shall promptly obtain the inspection report, review the inspection findings, and enter the results of the inspection report into the special equipment management information system by December 15 of this year. 4. Organization and implementation of the regular inspection plan for special equipment: (1) Pre-inspection preparations ① Preparation, review, and approval of the inspection plan for special equipment; ② Preparation, review, and approval of the inspection scheme; ③ Selection of specialized inspection teams and teams responsible for supporting the inspection process; ④ Preparation of materials needed for maintenance. (2) Monitoring during the inspection process ① The using unit should assign personnel with experience in the technical management of special equipment to oversee and inspect the inspection process. ②Complete the work volume visa for inspections (3). Handling of defects identified during inspections: ① Defects that require welding repairs or assessment before they can be put into use must be reported in writing to the Foreign Affairs and Equipment Department promptly, and appropriate actions must be taken in accordance with established procedures. ②Any issues related to inspection quality that arise during the inspection process should be addressed promptly, and the inspection contract must be strictly followed. (4) Entry of inspection information. ①The user unit should promptly request the inspection report from the inspection unit to review the inspection findings. ②The user entity shall enter the results of the special equipment inspection reports into the special equipment management information system by December 15 of this year.③ If there are any doubts regarding the safety rating or the date of the next inspection, it is necessary to promptly inform the inspection agency or the Department of Foreign Affairs and Equipment. VIII. Management of Inspection, Maintenance, and Repair of Installations and Equipment: Installation maintenance refers to the annual shutdown for maintenance of entire oil and gas treatment installations or individual units. The main aspects of installation maintenance include inspection and testing of special equipment such as tanks, pipelines, valves, and furnaces, as well as their accessories; inspection and maintenance of mechanical equipment such as pumps and compressors; inspection and testing, cleaning, and upkeep of instrumentation and electrical automation systems; major repairs and replacements; maintenance and upgrading of power systems, utility systems, and communication systems. It also involves carrying out partial modifications, expansions, and adjustments during the shutdown period, as well as ensuring the proper connection of various components. The maintenance cycle for the equipment is generally once a year, and it can be extended appropriately depending on production conditions and the status of the equipment. Equipment inspection and maintenance can be classified into three levels: major equipment overhauls, project-based repairs, and routine maintenance. Major equipment maintenance refers to the situation where the equipment has reached the maintenance interval specified in the equipment maintenance manual, or when there are serious defects in the equipment; with the company’s approval, maintenance can be carried out ahead of schedule. The purpose of major equipment maintenance is to restore the equipment’s performance. Equipment repair refers to the corrective maintenance carried out when equipment is damaged due to sudden failures, the preventive maintenance performed when there are signs of impending failures in the equipment, or the retrofitting maintenance done when the equipment does not meet specific process requirements. Equipment level maintenance refers to the equipment upkeep carried out in accordance with the requirements of the equipment operation and maintenance manual. 1. Equipment maintenance and repair process
1) Preparation work for maintenance:
(1) Formulation, review, and approval of maintenance plans;
(2) Initiation, review, and development of technical improvement projects along with construction plans;
(3) Preparation of maintenance materials (imported components, domestically supplied materials provided by the client, and materials supplied by third parties);
(4) Selection of the maintenance team;
(5) Formulation, review, and approval of maintenance plans, construction plans, and emergency response plans;
(6) Inspection of the preparation work completed.

2) Execution of maintenance work:
(1) Procedures for shutting down operations;
(2) Replacement of equipment in the plant;
(3) Standardized management of the maintenance site (visual management, TnPM, proper storage of tools and materials, etc.);
(4) Maintenance-related systems (preparation meetings, summary meetings);
(5) Assignment of tasks for maintenance work and on-site instructions;
(6) Confirmation of key processes (key process confirmation forms, implementation confirmation sheets);
(7) Quality inspection;
(8) Management of technical improvement projects (with different responsible parties);
(9) Change management for maintenance projects;
(10) Inspection and acceptance of maintenance work;
(11) Safety inspections prior to restarting operations;
(12) Restarting of the plant after maintenance is complete.

3) Summary of maintenance work and collection/archiving of related documents.

2. Major equipment repairs:
The company’s equipment management department is fully responsible for the technical management, supervision, evaluation, training, and guidance related to major equipment repairs. The costs associated with such repairs are subject to “total amount control, dedicated use of funds, and specialized management”. (2) When setting the annual financial budget, the company allocates a separate amount for major equipment repairs, ensuring that these funds are used specifically for that purpose and thus guaranteeing the repair of the equipment. (3) Preparation of the major maintenance plan: Each unit prepares the equipment major maintenance plan for the following year in accordance with the requirements, based on the technical condition of the equipment and actual production conditions. Once approved by the relevant departments of the company, the annual equipment major maintenance plan is finalized. (4) Implementation of the major repair plan: When implementing the equipment major repair plan, each unit must fill out the \"Company Equipment Major Repair Approval Form\", have it signed by the unit’s responsible person for equipment management, and then submit it to the Foreign Affairs and Equipment Department for approval. For major equipment repairs, the repair manufacturer must prepare a major repair plan for the equipment. After technical discussions and mutual signature for confirmation, the user shall conduct a tender or negotiation in accordance with the company’s relevant bidding management procedures. (5) Selection of the overhauling team: Manufacturers participating in the bidding or negotiation process for overhauling projects must, in principle, hold certification for mechanical maintenance services. (6) Supervision during major repairs: During the major repair of equipment, the user should assign technical personnel to supervise the process, ensure the quality of key stages, keep track of the progress of repairs, record the replacement of spare parts, and maintain proper documentation. The replaced main components and parts should be properly stored as evidence for equipment acceptance. (7) Acceptance of overhauled equipment: The acceptance of overhauled equipment includes performance acceptance and documentation acceptance. Performance acceptance refers to the verification that the repaired equipment has regained its original performance and output, while document acceptance refers to the review of all documents generated during the overhaul process once the repairs are completed. The performance acceptance for major equipment repairs includes: 1) The quality of the equipment maintenance meets the specified standards ； 2) Eliminate equipment defects ； 3) Output is restored, and efficiency is improved ； 4) The leakage problem has been eliminated ； 5) The safety protection devices and automatic systems operate reliably, and the main instruments, signals, and indicators are correct ； 6) The equipment site is clean, and the insulation layer is intact. The acceptance of documentation related to major equipment repairs includes: 1) Technical agreement for major equipment repairs; 2) Repair certification; 3) Report on major equipment repairs; 4) Acceptance form for major equipment repairs. 3. Item-based equipment repairs (partial repairs): (1) The contractor responsible for the repairs must prepare a repair plan in accordance with the client’s requirements and obtain approval for it. (2) The repair unit shall specify detailed requirements for parts, materials, and tools. (3) The contractor shall carry out the maintenance in accordance with the maintenance procedures, and relevant records shall be filled out during the repair process; the repair unit shall supervise the key stages of the repair. (4) After the repair is completed, the equipment engineer from the repair unit shall organize the commissioning of the repaired equipment; for large-scale equipment, the using unit shall prepare a commissioning and trial operation plan. (5) The equipment engineer at the repair unit should analyze and summarize the equipment repairs after completion, and share relevant experiences. 4. Level-based maintenance: (1) The equipment user unit shall prepare the equipment maintenance plan for the following month based on the equipment maintenance manual, and submit it to the unit’s equipment engineer for review. (2) The equipment user shall ensure that the spare parts, materials, and tools required for the proper maintenance of the equipment are available in sufficient quantities, in good condition, and effective. (3) The equipment maintenance unit shall carry out scheduled maintenance on the equipment in accordance with the equipment maintenance procedures; any issues identified during the maintenance process should be reported promptly to the equipment engineer, who is responsible for overseeing the maintenance work. (4) After completing the routine maintenance for the equipment, the maintenance records should be filled in the equipment file. IX. Change management of equipment: Any changes or improvements to equipment, as well as any modifications to the documented operating and maintenance procedures, shall be carried out in accordance with the company’s \"Process Equipment Change Management Standards\". X. Safety Inspection Before Commissioning: For newly installed, modified, or expanded process facilities and equipment, major changes to process equipment, as well as process equipment that has been taken out of service for maintenance, a safety inspection prior to commissioning must be carried out in accordance with the company’s \"Safety Review Management Standards for Process Equipment Before Operation\". XI. Causes of Abnormalities and Reliability Analysis 1. Equipment abnormalities refer to situations where the equipment does not operate properly, or is unable to function due to some fault. The reliability of a device refers to the stability of its functions over time, that is, the ability of the device or system to perform its designated functions without failures within a specified period of time under specified conditions. Reliability is the probability that a system, machine, product, or component will perform its functions under specified conditions and within the expected service life. 2. Methods for analyzing the causes of abnormalities 1) Condition monitoring and fault diagnosis. Instrumentation, meters, sensors, and associated equipment on the device are used to monitor parameters such as temperature, pressure, voltage, current, vibration frequency, thickness corrosion, machine noise, power consumption, efficiency, and the dynamic changes in the device’s output parameters, in order to determine the technical condition of the device and identify the locations of any faults. 2) Collect data on equipment operation, testing, and inspection at regular intervals and in specific locations, and conduct comparative analysis based on past fault occurrences, causes of faults, and troubleshooting methods. 3) Common methods for cause analysis: (1) Material testing and inspection; (2) Destructive/non-destructive testing; (3) Curve/trend analysis; (4) Fault tree analysis; (5) Analysis of fault types and their impacts. 3. Improving the reliability of equipment: 1) Relevant units should establish a comprehensive equipment condition monitoring system, assign full-time or part-time personnel for condition monitoring, and formulate various management regulations for such monitoring. 2) Key equipment should be monitored in accordance with the principle of \"designating specific equipment, measurement points, intervals, standards, and parameters.\" Based on the analysis of the monitoring results, maintenance recommendation sheets should be prepared to guide the repair work, and information regarding the progress of such repairs should be promptly recorded and archived. 3) For critical equipment, a standard operating parameters database, status monitoring systems, records of unit failures and repairs, as well as parameter archives for important components should be established. 4) Conduct regular analysis of data on equipment condition monitoring and the causes of faults. Identify the trends in when problems occur, understand the patterns, and take preventive measures or make corrections. To improve the reliability of the equipment. 5) Promote and refine condition monitoring and fault diagnosis technologies on large-scale, continuously operating equipment; regularly conduct evaluations of the technical performance, safety, and reliability of the equipment; and promptly detect and rectify any equipment malfunctions. 4. For equipment that has been repaired or technically improved, continuous improvement efforts should be made; tracking and monitoring management must be strengthened. Operating parameters are recorded in detail, and other monitoring instruments are used to continuously monitor the equipment’s vibration, noise, temperature, etc., so as to promptly detect any abnormalities during operation and ensure the safe and stable functioning of the equipment. XII. Archiving of Maintenance Records 1. To ensure traceability of equipment maintenance activities, records related to the installation, use, maintenance, and repair of equipment must be kept in accordance with relevant regulations, archived, and properly stored in the equipment’s technical documentation. 2. Records during the installation, use, maintenance, and repair of equipment shall be filled out truthfully by the persons performing these tasks. Equipment managers in each unit are responsible for managing the archiving of equipment-related documents and records within their respective units. 3. Maintenance records that need to be documented and archived (including but not limited to the following): 1) Equipment maintenance plans; 2) Statistics on the consumption and inventory of spare parts; 3) Statistics on oil used for equipment; 4) Statistics on costs associated with equipment maintenance; 5) Reports on equipment accidents; 6) Records of equipment repair and assembly; 7) Equipment operation cards and maintenance cards; 8) Other relevant materials related to equipment maintenance. 4. During the management of maintenance records, it is necessary to carry out tasks such as data collection, transfer, analysis, and archiving. 5. Equipment management departments at all levels of the company should carry out inspection and supervision of the archiving of equipment documents and records. 13. Scrapping Management 1. The management of equipment scrapping is carried out in accordance with Articles 64 to 68 of the Company’s Equipment Management Regulations. 2. The procedure for scrapping equipment shall be initiated by the user; after a technical assessment is conducted by the company’s equipment management department, the scrapping procedures will be carried out.