【Haichuan’s Best Practices】High-pressure unit of the secondary compressor enables green and safe maintenance

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This post was last edited by Desert Fish on 2019-1-28 at 19:52. Maoming Petrochemical: Unit 2 of the high-pressure facility undergoes green and safe maintenance 2019-01-28 Source: Sinopec News Network. At 13:40 on January 24th, Unit 2 in the high-pressure workshop of Maoming Petrochemical’s chemical division began producing polyethylene with a grade of 2426K; the product quality met the required standards, enabling a successful start-up without any safety or environmental incidents. This planned shutdown for maintenance eliminated the risk of the unit’s second compressor operating under faulty conditions, laying a solid foundation for the facility to operate safely and at full capacity during the Spring Festival holiday, thus ensuring the achievement of the goal of starting operations successfully. This maintenance project consists of 22 main items and 36 sub-items. The work area on site is extensive and the operations involved are complex. The maintenance tasks include draining oil from the cylinders of each stage of the primary compressor, purging the gas lines that are leaking, replacing the bolts on the crankcase cover to eliminate leaks, reinstalling the outlet valves of stage 6, and reinstalling the tail rod of stage 6. Leak repair for the casing and oil pipelines of the secondary compressor ； Crankcase side panel replacement ； Oil injector maintenance (2478, 2472) ； Bolts for auxiliary pipelines of the secondary unit, clamping of pipe clamps; leakage correction at the cylinder block connections of 12A and 21A low-pressure systems ； Commissioning of bearing bush inspection system ； Numerous important maintenance tasks, including the reinstallation of 22 connecting rod crossheads, the handling of 10 high-pressure safety valves, and the calibration of the high-circulation high-pressure wax removal valve. The high-pressure workshop initiates the maintenance plan in advance, prepares the materials needed for maintenance, coordinates with relevant departments such as mechanical, electrical, and instrumentation teams regarding the maintenance tasks, breaks down these tasks according to their urgency and importance, sets specific time deadlines, and ensures systematic and organized management of all maintenance activities. Since the shutdown of the unit, the Party branch in this workshop established an HSSE supervision team composed of Party members and League members. In strict adherence to the \"six prohibitions,\" they strengthened safety and environmental management throughout the shutdown process, strictly controlled various emission indicators, ensured 100% recovery of materials from Unit 2, and achieved a shutdown with \"zero emissions.\" During maintenance operations, strict environmental protection requirements are implemented to ensure that \"no gases are released into the air, no dust falls to the ground, and no oil pollutants are discharged.\" Meanwhile, this workshop focuses on \"risk management\" and strictly adheres to HSSE management principles, controlling five key aspects: the planning stage, permit issuance, JSA analysis, information dissemination, and supervision. The workshop strictly controls the review of permits and tickets, holds JSA analysis meetings, ensures thorough three-level safety training for external workers, and imposes strict supervision and management on on-site supervisors. It has changed the practice of assigning supervisors with poor capabilities, instead assigning those who are most diligent and skilled to this role in order to ensure the safety of direct operations. By paying close attention to each stage of the work process, all aspects of on-site operations are kept under control, thereby effectively preventing accidents such as leaks, cross-contamination of materials, and conditions of excessive temperature or pressure. The HSSE supervision team composed of Party members and League members in the workshop conducts round-the-clock inspections 24/7, focusing on three aspects: the quality of maintenance work, safety during maintenance, and the safety of the maintenance personnel, in order to eliminate potential hazards from an early stage. The workshop safety team requires all employees to promptly identify and correct any violations in work procedures. It enforces strict supervision over the actual work processes, takes strict measures to curb behaviors that are risky, outdated, or defective. A quality inspection checklist is used for each maintenance task to ensure that the entire process remains safe and under control, with zero rework required for any task and no leaks at any maintenance point. This approach aims to achieve high standards and high-quality results in maintenance work, ensuring stable shutdowns, effective repairs, and smooth operations. (Liang Baowen)