Thread Content
Chapter 1 General Provisions Article 1 These regulations are formulated in order to strengthen the management of pumps and motors, and to ensure the safe, stable, and long-term operation of the facilities, in accordance with **relevant laws and regulations as well as the \"Equipment Management Methods of Sinopec Group Corporation\" (hereinafter referred to as the \"Equipment Management Methods\"). Article 2 These provisions apply to the management of pumps in Sinopec Group Corporation, Sinopec Co., Ltd., Sinopec Group Asset Management Co., Ltd. (hereinafter referred to as the Group Corporation) and its affiliated petrochemical, catalyst, lubricant and other manufacturing enterprises; other enterprises shall follow these provisions accordingly. Article 3: The pumps referred to in these regulations are rotating equipment that is not included under the scope of management of large-scale units, including pumps, compressors, fans, steam turbines, expanders, drying, separation, and filtration machines, machinery for product shaping, packaging, and transportation, gearboxes, mixers, and special valves. Article 4: Strengthening the management of pumps and machinery relies on technological progress, and it is necessary to adhere to the principles of \"combining design, manufacturing, and use; integrating operation, maintenance, and repair; merging repair, renovation, and upgrading; combining professional management with overall employee involvement; and integrating technical management with economic management.\" Article 5: Depending on the importance of pumps in the production process, they are classified into main pumps and ordinary pumps for hierarchical management, with the classification criteria to be determined by the enterprise itself. Clarify the management authorities after the classification of pumps, and assign management responsibilities. Article 6: Enterprises shall conduct regular inspections of pump equipment, and include the results of these inspections in the assessment under the economic responsibility system. Article 7: Enterprises shall establish archives and records for each pump, ensuring that there is one record per pump. Chapter 2: Management Responsibilities Article 8: The relevant departments of the group company shall, in accordance with the provisions of the Equipment Management Measures and based on their respective responsibilities, carry out comprehensive management of the enterprise’s pumps. They shall guide the enterprise in continuously improving and strengthening pump management efforts, thereby raising the technical and managerial standards related to pumps as a whole. Article 9 Enterprises shall establish and improve a management system for pumps, and clarify the responsibilities of relevant departments and units. In accordance with the management requirements and responsibilities stipulated in the Equipment Management Regulations, take full responsibility for the management of pumps in the enterprise. Article 10 Responsibilities of the enterprise’s equipment management department: (1) To be responsible for the centralized management of pumps, to implement the relevant management systems, regulations, rules, and standards set by ** and the group company, and to formulate the enterprise’s own management systems for pumps. (II) Responsible for formulating guidelines for the design and selection of pumps, specifying requirements regarding the structure, materials, and vulnerable components of such pumps, in order to standardize the provisions of technical agreements. Responsible for the design review, selection of pumps, and drafting of technical agreements; involved in the supervision of pump manufacturing, installation, commissioning, and acceptance. (III) Responsible for the technical analysis of the operating conditions of pumps, organizing pump condition monitoring and fault diagnosis, as well as carrying out technical research and upgrades for pumps with poor operating performance. (IV) Organize the establishment of records and reports for pumps, prepare summaries of pump management work, and conduct regular inspections and evaluations. For new machine pump installations in new construction and renovation projects, the documentation process must be completed within three months after the equipment starts operating. The maintenance records should be filed in the archive within one month after the equipment maintenance is completed. The archive contents include: 1. Pump serial number, tag number, name, model and technical parameters, manufacturer, commissioning date, operating conditions, etc ； 2. Pump drawings, technical inspection documents, certificates of conformity, instruction manuals, packing lists, list of auxiliary equipment, etc ； 3. Catalog of vulnerable parts and main accessories for pumps ； 4. Data on the installation and commissioning of mechanical pumps, as well as trial operation and acceptance ； 5. Equipment operation time records, lubrication-related information ； 6. Records of machine pump maintenance, inspection, and spare parts replacement, as well as the technical plans for the maintenance of major machine pumps ； 7. Analysis of causes and records of failures and accidents in mechanical pumps ； 8. Technical documents for pump renovation. (5) Organize the preparation of maintenance plans for major pumps and motors, review the technical plans for their maintenance work, and be responsible for monitoring the maintenance process, as well as conducting quality inspections and assessments. (VI) Review the plans and proposals for the renewal and renovation of pumps, and organize their implementation. (7) Responsible for the technical management of machine pump spare parts, organizing the preparation of spare parts plans, and handling the quality tracking and analysis of such spare parts. Make efforts to localize spare parts for imported equipment. (8) Responsible for the promotion and application of new technologies, new processes, new materials, and new equipment in pumps. (IX) Organize investigations and analyses of pump accidents and participate in accident handling. (10) Participate in the review of operating procedures. Article 11 Responsibilities of the enterprise’s production and technical management departments: (1) Participate in the selection, modification, and design review of pumps. (II) Participate in the operation tests and acceptance of mechanical pumps, and organize joint commissioning tests and performance evaluations for these pumps. (III) Organize the formulation and review of operating procedures, process cards, accident plans, etc., for pumps and machinery. (IV) Be responsible for the operational management of pumps, ensuring that they operate under the specified process and technical conditions. (5) Organize or participate in the investigation, analysis, and handling of pump accidents. Article 12 Responsibilities of the Procurement Department: (1) Participate in the selection, modification, and design review of pumps. (II) Responsible for selecting suppliers with the appropriate qualifications and capabilities. (III) Establish a management and assessment system for pump manufacturers to ensure that they have the capability to provide products and services that meet the requirements set by the enterprise. (IV) Organize the supervision of machine pump manufacturing, factory testing, and unpacking inspection. (5) Carry out proper inventory management of spare parts in accordance with the requirements set for reserve levels. Article 13 Responsibilities of the using unit: (1) Be responsible for the use, maintenance, and management of the pumps in the unit, operating them in strict accordance with the operating procedures to ensure their safe, stable, and long-term operation. (II) Responsible for establishing archives and records for pumps, as well as for drafting operating procedures, process cards, accident prevention plans, etc., for these pumps. (III) Manage equipment lubrication in accordance with the requirements of the lubricant management system; be responsible for carrying out regular inspection and analysis of lubricants (greases) used in pumps; establish operating procedures and maintenance standards for oil mist lubrication systems; and conduct regular inspections and assessments of the daily operation and maintenance of such systems. (IV) Responsible for preparing plans for the maintenance, renewal, and renovation of pumps and machinery ； In accordance with the requirements for hierarchical management of equipment, responsible for or involved in the implementation of maintenance, renewal, and renovation of pumps, as well as quality inspection and evaluation. (5) Actively carry out monitoring of the condition and fault diagnosis of pumps and motors, promptly identify equipment defects, implement corrective measures, and reduce unplanned shutdowns. (6) Participate in the investigation, analysis, and handling of pump failures, and formulate accident prevention measures to implement them ； (7) Participate in the selection, design review, trial operation, and acceptance of pumps. (8) Be responsible for carrying out technical research and development as well as technical upgrades for the pumps in the unit that are not performing well, formulating corresponding measures and overseeing their implementation. (IX) Be responsible for the technical training and assessment of relevant personnel in the unit, with the aim of continuously improving their skills in management, operation, and maintenance. Chapter 3: Design, Selection, and Procurement of Pumps Article 14: Enterprises shall conduct reviews for pump selection in accordance with the guidelines for pump design and selection, as well as carry out reviews of installation designs and technical negotiations regarding purchases. The procurement department shall organize purchases in accordance with the requirements of the technical agreement. Article 15: The design and selection of pump equipment shall comply with the corresponding latest versions of technical standards and specifications. Considering the flammable and explosive nature of petroleum refining and chemical industries, the selection is carried out in accordance with the following principles: (1) Adhere to the principles of advanced technology, economic rationality, safety and reliability, high efficiency and low consumption, as well as ease of maintenance. (II) Adhere to the principles of standardization, serialization, and generalization. (III) Adhere to the principles of safety, environmental protection, and health. (IV) Adhere to the principle of using mature new equipment, new materials, and new structures. (5) Give priority to the use of domestically produced equipment. (VI) It is prohibited to use equipment that has been explicitly designated for elimination. Article 16: The selection and installation design of pumps must meet the process requirements. Key parameters such as outlet pressure and flow rate must not have negative deviations, and the rated flow rate should fall within the range of 80% to 110% of the flow rate at the point of optimal efficiency provided. For pumps with significant variations in design flow rate, measures such as frequency conversion control should be adopted. Article 17: The design shall specify the on-site climate and environmental conditions. It mainly includes: (1) Instrument signals and power air pressure. (II) Steam parameters. (III) Division of explosion-proof areas, explosion-proof grades. (IV) Installation location of the pump. Indoor installation, outdoor installation, presence of heating facilities, presence of a ceiling, number of floors, operating level elevation, etc. (5) On-site climate conditions. Article 18: For the main components of the pumps to be ordered, clear material requirements must be specified. It is not allowed to reduce the material grade of the pumps in order to control costs; in particular, the corrosion properties of the medium should be fully taken into account when selecting materials that come into contact with it. Article 19: The type and material of the seal shall be selected reasonably based on the properties of the medium transported by the pump. For media with high toxicity, high pollution potential, and high value, reliable sealing methods such as double-end mechanical seals and dry gas seals should be employed. Article 20: When a pump is equipped with forced lubrication, the materials used for the equipment, pipes, and fittings of the lubrication system should, in principle, be austenitic stainless steel. Flange connections should be used for the piping of the lubricating oil. Lubricating oil pumps should be designed to start automatically when needed, and equipped with an interlock system. Article 21: Pressure vessels attached to pumps and machinery shall be designed, manufactured, and inspected according to GB150 \"Steel Pressure Vessels\", GB151 \"Steel Shell-and-Tube Heat Exchangers\", and the \"Safety Technical Inspection Regulations for Fixed Pressure Vessels\". Article 22: The technical documents for pumps shall specify the performance assurance requirements. It mainly includes the allowable deviation range between the actual characteristic curve and the designed characteristic curve, maximum operating condition noise control, vibration parameters, etc. Article 23: After an enterprise, a design unit, and a manufacturer sign a technical agreement for the ordering of pumps, the enterprise enters into a commercial contract with the manufacturer. The enterprise supervises the manufacturer in carrying out design, manufacturing, and testing in accordance with the provisions of the contract and technical agreement ； Any changes require confirmation by the enterprise, the design unit, and the manufacturer. Article 24: Before the main pumps leave the factory, the enterprise shall organize relevant professional technicians to conduct quality inspection in accordance with the contract and the technical ordering agreement. Chapter 4: Installation, Maintenance, Commissioning, and Acceptance of Pumps and Compressors. Article 25: Enterprises shall organize the maintenance of pumps and compressors based on the principle of primarily conducting condition-based maintenance supplemented by preventive maintenance, so as to prevent both under-maintenance and over-maintenance. Article 26: The installation and maintenance of pumps must be entrusted to units with the appropriate qualifications. Installation and maintenance units must establish a quality assurance system, and implement various construction measures in accordance with the requirements of the HSE system to ensure safe and civilized construction, as well as to complete tasks on time and to the required standard. Article 27: After the new pumps are installed, the construction management unit organizes the relevant departments to carry out the \"three inspections and four determinations,\" and conducts the project handover and completion acceptance in accordance with relevant regulations. After the construction unit prepares a commissioning plan and it is approved by the relevant departments, the construction management department organizes the debugging of the pump equipment as well as individual unit tests, while keeping proper records of these tests. Article 28: The maintenance of pumps and machinery must strictly adhere to the work order system to ensure safety during maintenance. Article 29: Only after the defective pump has been switched to a backup pump and it is confirmed that there are no abnormalities can maintenance work be carried out on the defective pump. Article 30: The maintenance of pumps shall be carried out in accordance with the provisions of the \"Code for Maintenance and Repair of Petrochemical Equipment\" and the equipment’s operation manual. For the maintenance of major pumps, a maintenance construction technical plan should be prepared; for the maintenance of ordinary pumps, control cards for key maintenance procedures should be developed. The user unit submits the maintenance requests, and the maintenance contractor prepares a technical plan for the maintenance of the main pumps. This technical plan is put into practice after being reviewed by the relevant departments and approved by the management authority. For the repair of sudden major equipment failures, the relevant personnel from the repair unit, the user unit, and the management department shall determine on-site the scope of repair, the depth of repair, the details of the repair work, the standards to be followed, and the timeline for completion. Article 31: Strengthen inspection and quality control during the maintenance of pumps. The maintenance of main pumps should be carried out in strict accordance with the designated maintenance technical plans. For the key stages of this maintenance process, confirmation shall be provided by professional technicians from the enterprise’s operating unit, professional technicians from the maintenance unit, and the maintenance workers themselves. The maintenance of general pumps is carried out by the equipment staff and maintenance personnel of the using unit, who conduct acceptance checks in accordance with the control cards for key maintenance steps. After the maintenance of pump equipment is completed, the maintenance records should be filled out accurately and completely. Article 32: After the maintenance of pump equipment is completed, a trial run shall be conducted; it may be put into operation only after the trial run is successful. The maintenance unit shall submit the complete completion documents to the user unit within 7 days after the completion of routine maintenance, and within 30 days after the completion of major repairs or construction work. Article 33: Enterprises shall implement a quality assessment and evaluation system for the installation and maintenance of pumps. The quality assessment of pump installation and maintenance is divided into three grades: excellent, qualified, and unqualified (including conditional acceptance). Based on the results of this quality assessment, economic responsibility assessments are conducted for the relevant units. Article 34: Contents of quality assessment for the installation and maintenance of pump equipment: (1) Process parameters. (II) Control and recording during installation and maintenance. (III) Assessment of bearing vibration and temperature. (IV) Leakage assessment. (5) The couplings and exhaust caps are in good condition, and the oil and water sight glasses are clear and intact. (VI) On-site standardization. (7) Special quality assessment for specialized pumps and machinery. Chapter 5: Operation and Management of Pumps Article 35: Operators must follow the operating procedures strictly; it is strictly prohibited to allow pumps to operate at excessive temperatures, pressures, loads, or speeds. Article 36: Operators, maintenance personnel, and equipment managers shall strictly implement the routine inspection system and carry out the \"three types of inspections\" (routine inspections by operators, spot checks by maintenance personnel, and specialized inspections by equipment managers). Inspect all parts of the pumps in accordance with the patrol inspection route, contents, and standards, and carefully fill out operation records, defect records, and operation diaries. Preventive measures should be taken for defects that cannot be addressed promptly, and they should be included in the maintenance plan until the defects are eliminated. Article 37: When operators and maintenance personnel detect abnormal operation of the pump, they shall immediately investigate the cause, take corrective actions, and report it promptly. To ensure the safety of equipment and personnel, in emergency situations, operators have the authority to take decisive actions in accordance with the operating procedures, up to shutting down the equipment immediately. Article 38: The user unit shall strengthen the lubrication management of pumps and machinery, and strictly implement the lubrication management system. All lubrication points of the pump should be properly recorded, and lubricating oil (grease) should be added and replaced as specified; the quality of the oil at each lubrication point should be checked and analyzed regularly. Article 39: Enterprises shall establish regulations for the management of standby pumps and ensure their regular maintenance. The standby pump should be rotated and switched regularly to keep it in good standby condition. For pump units equipped with auxiliary systems, self-starting tests should be conducted regularly to ensure that the auxiliary systems are in good condition. Article 40: Mechanical, electrical, and instrumentation maintenance personnel shall, in accordance with the requirements of their respective specialties, carry out routine maintenance on mechanical equipment, electrical equipment, control instruments, and interlock protection systems to ensure that the equipment remains in good condition. Article 41: Enterprises shall actively adopt advanced monitoring technologies to carry out condition monitoring and fault diagnosis of pumps. Pumps should be inspected regularly, and the inspection results shall be recorded and analyzed. For pumps that are operating beyond the specified standards, analytical recommendations or measures for supervised operation shall be provided. Pay close attention to the monitoring of high-temperature oil pumps. Chapter 6: Update and Renovation of Machinery Pumps Article 42: The update and renovation of machinery pumps shall be carried out in a planned and targeted manner, in line with the enterprise’s safety production, energy conservation, consumption reduction, and technological development objectives. Article 43: When a pump is in any of the following conditions, it should be updated or modified: (1) It fails to meet the production requirements. (II) There are serious defects or it poses a threat to safe production. (III) **Pumps explicitly designated for elimination.** (IV) Outdated technical performance, poor quality, frequent failures, high maintenance costs, and high energy consumption. Article 44: The equipment utilization department of an enterprise shall organize assessments of the condition of pumps, and conduct technical and economic analyses when necessary; based on the results of these assessments or analyses, it shall formulate plans for the renewal or modification of the pumps. The enterprise’s equipment management department is responsible for reviewing and submitting the renovation plans. Once the renovation plan is approved by the higher-level authorities, it shall be implemented carefully. Article 45: Technical and economic evaluations should be conducted for the renewal and renovation of important pumps, with new technologies being actively adopted to improve their performance, thereby achieving the goals of safety, reliability, and economic Reasonableness. Article 46: The scrapping of pumps and machinery shall be handled in accordance with the relevant regulations of the group company. Chapter 7 Supplementary Provisions Article 47 Each enterprise shall formulate detailed rules for the management of its own pumps in accordance with these provisions. Article 48 These provisions shall be interpreted by the Production and Operation Management Department of the Group Company. Article 49 These provisions shall come into force as of the date of issuance.