Requirements for Identifying Potential Hazards during CNPC’s Major Overhaul Work

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Requirements for identifying potential hazards during major maintenance at CNPC: Immersive reading in a novel reader. Enterprises should, based on the overall goal of conducting maintenance every four to five years, establish specific operational targets and maintenance schedules for each set of equipment and each individual device. They need to identify the bottlenecks associated with long-term operation, and in particular, they must conduct a thorough analysis of the risk factors related to those devices whose failure can lead to shutdowns. Effective preventive measures should be developed to address these bottlenecks within a specified time frame. Conduct hazard inspections in terms of process technology, production bottlenecks, equipment, safety, and environmental protection. Address any issues that can be resolved promptly, while for those that cannot be dealt with immediately, a remediation plan and control measures should be developed after risk assessment, to be included in the maintenance schedule 3 months before shutdown. 1. Process-related inspections: (1) Identification of bottlenecks in production operations (calibration of the equipment is carried out before maintenance); (2) Assessment of the impact of catalyst lifespan on long-term operation.
2. Safety and environmental protection inspections: (1) Special inspection for damaged or improperly used personal protective equipment; (2) Special inspection of escape routes; (3) Special inspection of the compliance of structural platforms; (4) Special inspection for uncontrolled leaks; (5) Special inspection for leaks at static sealing points (in conjunction with VOC control).
3. Equipment-related inspections: (1) Special inspection for the proper management of pressure vessels and pipelines; (2) Special inspection for the proper functioning of safety valves; (3) Special inspection of rupture disks; (4) Special inspection related to salt deposition and corrosion in hydrogenation systems; (5) Special inspection of air coolers regarding their operation and corrosion; (6) Special inspection of the flow rate in water coolers; (7) Special inspection of thickness data related to corrosion risks; (8) Special inspection for external corrosion of equipment and pipelines; (9) Special inspection of small connections; (10) Special inspection for seal leaks in storage tanks; (11) Special inspection of flanges that frequently leak; (12) Special inspection for plugging leaks under pressure; (13) Special inspection of potential hazards related to underground pipelines; (14) Special inspection of spring supports and hangers; (15) Special inspection of improperly installed pipelines; (16) Special inspection of expansion joints; (17) Special inspection of dead corners; (18) Special inspection of thermal pipelines and insulation; (19) Special inspection of boiler water supply systems; (20) Special inspection of obsolete equipment and pipelines; (21) Special inspection for missing data and documentation related to equipment (including instrumentation and electrical systems).
4. Instrumentation-related inspections: (1) Inspection of the utilization rate of interlocks; (2) Inspection of instruments that cannot operate in automatic mode; (3) Inspection of safety instruments; (4) Inspection of online environmental monitoring instruments.
5. Electrical-related inspections: (1) Inspection of relay protection settings; (2) Inspection of the completion rate of electrical tests; (3) Inspection of cable temperature monitoring; (4) Inspection of the operation and maintenance of UPS (EPS) systems.
6. Other inspections: (1) Inspection of data and documentation, as well as equipment required for measurement; (2) Inspection of issues remaining from previous maintenance tasks and items that have not been resolved during previous system audits; (3) Inspection based on lessons learned from maintenance accidents in other companies over the past few years; (4) Special inspection of equipment (including materials) that has exceeded its designed lifespan