【Haichuan’s Best Practices】Reducing unnecessary maintenance tasks and conducting targeted maintenance efforts – resulting in a reduction of maintenance costs by nearly 4 million

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During the upcoming major maintenance campaign, Jilin Fuel Ethanol Company strictly controlled costs by reviewing each maintenance item on seven occasions; as a result, the number of items to be maintained was reduced from 84 to 54, cutting repair costs by 3.98 million yuan. This major maintenance campaign is expected to last 17 days, and it will involve 19 production units. It will address various potential issues that could hinder stable and efficient operation, as well as carry out necessary technical upgrades, ensuring that these units can fully rest and recover, thereby providing a solid foundation for stable operation in the next cycle. Scientific project approval. Adhering to the principle of avoiding excessive maintenance, the company carefully manages the addition and reduction of maintenance projects. By continuously optimizing and refining the major maintenance plan, and by re-evaluating the issues related to bottlenecks in long-term operation as well as the results of previous hazard inspections, and through thorough consideration, guided by the principle of \"identifying problems promptly and eliminating hazards as soon as possible,\" maintenance tasks such as replacing the bottom of the hot water tank, replacing the H0514 heat exchangers, and replacing pipelines lined with chemical acids and bases have been supplemented and improved ； In addition, a comprehensive inspection was carried out on the two turbines and generator sets in the cogeneration plant, focusing on operational parameter verification, condition monitoring systems, and production processes, which led to the decision to carry out major repairs on Turbine No. 1 and minor repairs on Turbine No. 2. It was with a scientific attitude and a spirit of seeking truth from facts that the 54 maintenance items were ultimately determined. Prepare meticulously. Taking into account factors such as maintenance timelines, construction complexity, and safety risks, the company identified 14 projects as key and challenging tasks, including high-pressure cleaning at 2800/1400 kg, disassembly and reassembly of heat exchanger heads, maintenance of the 1/2# turbines and generators, major repairs to the 1# main transformer, and major repairs to the new ethanol-ethylene line’s circuit breakers. By setting clear objectives and assigning responsibilities, the company ensures that maintenance work is carried out safely, with consistent quality and within schedule. Not only that, but desk simulations for key projects are also carried out. By conducting thorough analysis, the responsibilities of personnel, material preparation, construction sequence, and key construction milestones are identified; any omissions in various stages are detected, allowing for continuous improvement of all preparatory work. Prepare a list of major maintenance projects and identify the responsible persons for each project. To ensure the construction quality of all tasks during the major maintenance, responsibilities are assigned to specific individuals.