[Haichuan. Lessons from Others] Jilin Petrochemical Fertilizer Plant adopts the “DuPont” model to enhance risk management in maintenance activities

Thread Content

Since early October, the catalyst replacement and maintenance work for the ammonia synthesis unit at Jilin Petrochemical Fertilizer Plant has been fully underway. The ammonia synthesis workshop of this plant applied the lessons learned from DuPont’s safety management practices to the maintenance work related to filter replacement, thereby strengthening risk control and quality inspection during the maintenance process, with positive results. The guardianship card has a big impact despite being small. The workshop designed and produced the \"48 Guidelines for Supervisors\" cards, which cover 9 categories of tasks including the use of fire in industrial settings, work at heights, lifting operations, and entry into confined spaces. By carrying these cards, supervisors can truly meet the requirements of \"understanding the safety risks associated with each task, knowing how to verify that safety measures are in place, and being familiar with emergency response procedures.\" During the short-term shutdown for maintenance, 928 hot work tasks, 628 work tasks at heights, 52 tasks in confined spaces, and 96 lifting operations were all carried out safely and under control. The number of violations resulting from inadequate implementation of safety measures decreased by 17% compared to the previous round of maintenance. Visualization of risk warnings. The workshop has designed and created a risk level dashboard for short-term maintenance tasks; it assigns risk levels to the 98 maintenance operations carried out on site. Red, yellow, and green are used to represent high risk, moderate risk, and low risk respectively. The risk levels are posted on the dashboard daily, allowing those involved in the maintenance work to see information such as the number of hazardous tasks to be carried out each day and their locations, thereby enhancing precise control over such hazardous operations. Quality acceptance inspection system. The workshop uses welding procedure cards for process pipelines, which include information on welding standards, selection of welding materials, and welding methods, thereby enhancing the quality control of welds. A total of 139 welding tasks were carried out during this maintenance effort, and 100% of these welds passed the inspection tests. Quality inspection checkpoints are established for key maintenance tasks such as the maintenance of the four major units; only after the contractor and the workshop managers confirm that the quality of the maintenance work is satisfactory can work proceed to the next stage, thereby ensuring the quality of these important projects. There were a total of 8 key tasks in this maintenance work, achieving 100% quality acceptance. Source: Jiangcheng Daily