Implementation Plan for the “Restore to Good Condition” Campaign for Equipment (Plant-level, Production Department-level)

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Bold + Size 7 = My personality. As a contribution post from the forum moderator, it has not been uploaded as an attachment; instead, the entire text is pasted here. The sensitive parts have been modified. Implementation plan for the “Ensure Integrity and Quality” campaign: In line with the company’s requirements for this campaign, and with the aim of further improving the integrity and reliability of equipment and facilities, this plan seeks to eliminate issues such as low standards, old faults, and poor maintenance practices. It aims to continuously improve the condition of equipment and facilities, thereby enhancing the company’s overall equipment management capabilities and ensuring efficient production activities as well as safe, stable, long-term, optimal operation of all equipment. Striving to achieve the goal of having all units in a \"sound\" condition, this plan has been formulated in line with the company’s \"Achieve Sound Condition\" initiative and the actual conditions of each unit. I. Guiding Principles: Guided by the Shareholding Company’s \"Standards for On-site Equipment Management in Refining and Chemical Enterprises,\" and utilizing the \"Strive for Optimal Equipment Condition\" initiative as a framework, these principles emphasize the adoption of entirely new management standards. By focusing on six key areas—production units, tank farms, process equipment, pump rooms, substations (power distribution rooms), and control rooms—efforts are made to prepare equipment for optimal condition. Thematic improvement activities are carried out in a thorough manner, with continuous efforts to address issues in equipment management. By strengthening internal capabilities and enhancing the external image, an equipment management system is sought that can meet the requirements for safe, stable, efficient, and high-quality operation of integrated refining and chemical plants, thereby lifting the level of equipment management to a higher standard. II. Scope of Activities
(1) Participation principles: All units shall carry out activities simultaneously.
(2) The scope of activities in which each unit may participate is determined by comprehensively classifying the four specific activity categories for each unit based on factors such as its functions, number of equipment items, and level of management complexity. Units may then enter competitions according to these categories (which may include the entire unit, pump rooms, process equipment, or instrument control rooms). The number of unit functions is assigned in accordance with the design documents, while the management complexity is determined based on the actual condition of the process equipment, as detailed below. ①Devices to be made sound: Serial number, Device name, Comprehensive classification, Estimated completion time, Remarks
1. Device A, Category 1, June 2015,
2. Device B, Category 2, July 2015,
3. Device C, Category 2, May 2015,
4. Device D, Category 4, August 2015,

② Tanks to be made sound: Serial number, Device name, Comprehensive classification, Estimated completion time, Remarks
1. Tank Area E, Category A, April–December 2015,

③ Pump houses to be made sound: Serial number, Device name, Comprehensive classification, Estimated completion time, Remarks
1. Pumps in Areas 10 and 20 of Device A, Category B, September 2015,
2. Pumps in Areas 30 and 90 of Device A, Category B, August 2015,
3. Pumps in Areas 40 and 50 of Device A, Category B, June 2015,
4. Pumps in Areas 70 and 80 of Device A, Category B, July 2015,
5. Pump room 3 of Device A, Category A, October 2015,
6. Cracking compressor room of Device A, Category B, August 2015,
7. Hydrogen compressor room of Device A, Category B, September 2015,
8. Oxidation compressor room of Device A, Category B, July 2015,

④ Substations to be made sound: Serial number, Substation name, Comprehensive classification, Estimated completion time, Remarks
1. Substation A, Category C, April–December 2015,
2. Substation B, Category C, April–December 2015,
3. Substation C, Category A, April–December 2015,
4. Substation D, Category B, April–December 2015,

⑤ Instrument control rooms to be made sound: Serial number, Production department, Device, Comprehensive classification, Estimated completion time, Remarks
10. Category A, May 2015,
11. Category B, May 2015,
12. Category A, May 2015,
13. Category C, May 2015,

⑥ Equipment devices to be made sound: Serial number, Device name, Evaluation level, Estimated completion time, Remarks
12. Device A, April–December 2015,
13. Device B, April–December 2015,
14. Device C, April–December 2015,
15. Device D, April–December 2015,

III. Organizational structure for the “Make Sound” campaign
(1) Campaign leadership team
Leader: You, Me, Him
Deputy leaders: You, Me, Him
Members: You, Me, Him

(2) Responsibilities:
① Departmental responsibilities:
1. Responsible for formulating and implementing plans and detailed rules for the campaign to make equipment sound. 2. Responsible for the organizational work related to the specific implementation of equipment restoration activities. 3. Responsible for the inspection, evaluation, assessment, and summary of the monthly equipment maintenance and improvement activities. 4. The department will strengthen supervision and inspection through regular checks and random audits, organize exchanges of experiences, and work on solving problems ； Problems identified and difficulties encountered during activities should be addressed as soon as possible to effectively resolve the conflicts between daily work and activity implementation ； Units and teams that do not pay enough attention to ideology in their activities and perform inadequately in their work are identified promptly, with a deadline set for them to make corrections. ②Responsibilities of equipment engineer: 1. Follow the department’s plan for achieving excellence, carry out the tasks step by step on a weekly basis, and supervise and inspect progress. 2. Summarize the progress of equipment maintenance activities on a monthly basis. Issue the activity plan for next month. 3. Conduct assessments and evaluations of the equipment maintenance activities carried out by each team on a weekly basis. ③Team responsibilities: 1. Actively participate in the department’s activities aimed at maintaining equipment in good condition, and carry out the tasks related to maintaining the equipment under the team’s responsibility area and according to the equipment assignment system. 2. Carry out proper publicity and mobilization within the team, so that every person responsible for the inspection is aware of the inspection contents and standards. 3. Conduct a check of the leased equipment at the end of each shift to ensure it is in good condition. IV. Timeline of the Activity This activity runs from April 1st to the end of December, and is divided into three phases: Phase 1: Deployment and preparation phase (April 20th – 30th). Formulate activity plans and implementation details, establish an organizational structure to lead the activities, and hold a kickoff meeting ； Formulate a phased and incremental implementation plan for achieving excellence: including a timeline, work schedule, and specific implementation plans for various tasks. Phase 2: Full Implementation Phase (April 21 – November 30). (1) Establishing models (4.20–5.20): Select the plant for Unit A’s three machines, Unit C, Unit A’s basic group, Unit A’s instrument control room, the D-process equipment, and Unit C as specific projects for model establishment applications; the activity leadership team will organize inspections and evaluations ； (II) Implementation of the plan (5.21–11.30): Each unit shall, in accordance with the implementation plan and focusing on the activities scheduled, refer to the standards for excellence and model examples to identify problems, address shortcomings, and enhance performance. It shall also coordinate efforts to ensure that all tasks related to achieving excellence are carried out properly within that unit. By November 30, complete all work plans and specific implementation details outlined in this device implementation plan. The Equipment Maintenance Department shall organize the maintenance devices to work together with various production departments to implement the plan for achieving excellent condition. (III) Monthly reporting and inspections, along with quarterly reviews: during the implementation phase of the plan, each facility conducts a thorough self-inspection of its activities against relevant standards and models, makes necessary corrections, and maintains the required standards. During this period, each unit can submit project applications on a monthly basis, either individually or for specific projects. The activity leadership team conducts on-site inspections and checks to ensure compliance with the requirements for these submitted projects on a regular but irregular basis, in conjunction with each unit. In accordance with the principle of \"monthly reporting, monthly inspections, monthly notifications, and quarterly reviews,\" continuous efforts are made to advance the \"strive for excellence in equipment condition\" initiative across all facilities, ensuring the overall progress of this initiative in terms of equipment management within the company. By November 20, each unit shall submit a written summary of its annual activities related to maintaining good condition to the department. Phase 3: Year-end acceptance, summary, and evaluation phase (December 1–December 31). At the end of the year, a summary of the entire year is conducted, an award ceremony is held, a “Create Excellence” evaluation is carried out, and the achievements are displayed. Recognize and reward advanced collectives and individuals in their activities, and set examples. V. Activity Content (1) Focus on comprehensive management and strengthen indicator assessment to create high-quality facilities. By adopting a comprehensive management approach that covers aspects such as the development of equipment technical documentation, operational efficiency, integrity management, maintenance, and aesthetic appearance, with a focus on the maintenance and monitoring of large-scale units, the lawful and safe use of special equipment, and the optimization of the operational efficiency of high-power equipment, efforts are made to improve key indicators such as equipment reliability, mean time between failures, leakage rates, and interlock management, thereby ensuring that the equipment remains in good condition over the long term. 1. In accordance with the process parameters of the on-site equipment, promptly correct the master data of equipment in the ERP system and the Equipment Management System (EM system); continuously expand the BOM, information on vulnerable components of equipment, and the material coding database. Ensure timely and accurate entry of data related to equipment operation, fault (defect) reports, and maintenance information, and improve the management of auxiliary documents related to equipment design and manufacturing, such as drawings and completion inspection documents (maintenance work orders) ； 2. Improve the management system for equipment maintenance, clarify job responsibilities, enforce and assess these responsibilities strictly, continuously refine various operating and maintenance procedures as well as technical standards for equipment management, and strictly apply the \"four-haves\" working method to ensure that production and maintenance activities are under proper control ； 3. Strengthen condition monitoring and improve the fault diagnosis database; ensure that the systematic and regular implementation of top-level maintenance management that integrates mechanical, electrical, instrumentation, operational, and management aspects is maintained. Hold regular top-level maintenance and analysis meetings to keep track of the performance of the key equipment in the system, thereby eliminating potential risks of downtime due to equipment failures. 4. Guided by the principles of lawful use and standardized management, strictly abide by the Special Equipment Safety Law as well as relevant **standards, technical specifications, and requirements** for boilers, pressure vessels, lifting equipment, etc. Proactively participate in training for operators and managers of special equipment and work only after obtaining the necessary certifications. Actively apply for registration and obtain a usage registration certificate. Conduct regular inspections of special equipment on schedule, and diligently carry out routine maintenance, annual inspections, and online inspections. In this way, ensure legally that each piece of special equipment maintains its status as a legitimate legal entity. (II) Focus on maintenance to strengthen basic management and create high-quality process equipment. 1. Taking Class A equipment as the core and Class B equipment as a priority, ensure that daily equipment inspections, checks, and maintenance activities cover every piece of Class C equipment, with responsibilities assigned to each level of equipment operators, managers, and maintenance staff ； Aiming for a 100% equipment availability rate and taking leak-free equipment and pipelines as a benchmark, continuous PDCA cycle improvements are carried out to strive to increase the average time between failures of the equipment. 2. The maintenance department has gradually improved its maintenance and periodic inspection systems. It strictly regulates the timing, routes, contents, and evaluation criteria for inspections. Inspection records are accurate and standardized, enabling timely identification, reporting, and resolution of any equipment defects. 3. Establish a equipment package mechanism to enhance operational monitoring and equipment maintenance, ensuring at all times that the equipment and facilities are complete and in good condition, with all indicators within normal ranges; there is no excessive operation or overload, and the equipment meets the output specified on its nameplate or its approved capacity. The instruments, signal interlocks, as well as various safety devices and automatic control devices, are all complete, functional, sensitive, and accurate ； Operating parameters such as temperature, pressure, speed, flow rate, and current at various locations meet the requirements. (III) Address leaks to promote cleanliness and standardization, and create well-maintained pump rooms. 1. Select materials and models scientifically, carry out thorough maintenance, perform regular switching, and systematically eliminate leaks of lubricating oil at on-site supply stations and in the pump lubrication systems, as well as leaks from mechanical seals and cooling water. Additionally, address leaks at flange connections and threaded joints used for process media ； Ensure good ventilation to prevent safety accidents caused by leaks. 2. Based on the principles of \"exposing the shafts, ensuring visibility of the trenches, and showing the true color of the equipment,\" regularly clean the equipment itself and its accessories as well as the floor; keep the trench covers level; promptly clear the sewage and oil drainage systems; check that all leak-proof equipment and facilities are in good condition; repair any defects in the insulation and anti-corrosion coatings on the equipment and pipelines to ensure they meet the standards; remove any unnecessary debris from the area. The pumps on site should operate reliably, without signs of dirt, disorder, deficiencies, or rust, and there should be no leaks. The operating parameters of the equipment should comply with the prescribed procedures, with vibration and noise levels not exceeding those specified by API or the equipment’s factory standards. (IV) Ensure the proper operation of interlock controls and create a well-functioning instrument control room. 1. Strictly implement the three-ticket system for managing the activation, deactivation, and modification of interlock protections in production facilities and large-scale units, and regularly check the compliance with this system. Risk identification prior to the deactivation/restoration or modification of interlock protection must be comprehensive, and corresponding preventive measures as well as emergency response plans must be established. 2. Carry out regular maintenance and inspection work on the interlock protection system. The instruments in the on-site interlock protection system should be equipped with interlock warning signs, and attention should be paid to the inspection and maintenance of the power supply, air supply, as well as other auxiliary facilities such as dust filtration and heat dissipation used in the interlock system. All components in the interlock system (including primary sensing elements), instruments, and actuators should be thoroughly inspected, cleaned, calibrated, or adjusted during shutdown overhauls. 3. Carry out proper maintenance work on the interlock protection system. During the shutdown and maintenance of the plant, the interlock protection system should be thoroughly inspected, tested, and calibrated. For important interlock systems, relevant mechanical, electrical, and process professionals should also participate in the calibration process to carry out inspections and confirmations. All maintenance and test results of the interlock protection system shall be carefully documented. 4. Ensure proper management of all details in the instrument control room. In accordance with assessment requirements such as equipment condition, maintenance, indoor cleanliness and order, as well as proper storage of documents, these aspects must be implemented one by one; responsibilities for making corrections must be assigned to specific individuals, and all work must be documented. (5) Ensure safe operation and maintain an orderly appearance to create a well-managed tank farm. 1. Implement strict management systems for hazards in the tank farm to ensure safe operation. In recent years, safety accidents in the tank areas of petrochemical enterprises have occurred frequently, posing a direct threat to the development of these enterprises as well as to the safety of people’s lives and property. All facilities must continuously check that their equipment, along with the pipeline components and instruments attached to them, are installed in accordance with relevant standards; they must be secure and intact, with clear markings, to ensure safe operation. These include components used to connect or assemble into pressure-bearing and airtight piping systems, such as pipes, pipe fittings, flanges, seals, fasteners, valves, safety devices, as well as elements like expansion joints, flexible connectors, pressure-resistant hoses, filters (such as Y-type and T-type), throttling devices in the pipelines (such as orifice plates), and separators. All these accessories must be complete and function reliably. 2. Focus on controlling the sources of issues, utilize monitoring and detection facilities to improve management of production operations, enforce strict approval procedures, strictly regulate special types of work, standardize tank farm renovation and maintenance projects, ensure that the quality of new constructions is excellent, and keep the construction process under control. 3. Continuously improve corrosion prevention, heat insulation (cold protection), anti-freezing and anti-condensation facilities; ensure that the paint (including color codes) is in good condition and effective ； Fully promote visual management to improve the appearance of the tank area. VI. Methods of Implementation (1) The “Perfect” Creation Initiative involves first concentrating efforts on creating 1 perfect production unit, tank farm, pump room, substation (power distribution room), control room, as well as 1–2 units of various types of process equipment as models. Once these are approved by the leadership team, the approach is gradually extended to all the equipment in the entire facility, using these model units as a starting point. (II) The inspection and evaluation of well-maintained production facilities, tank farms, process equipment, pump rooms, substations (distribution rooms), and instrument control rooms shall be carried out in accordance with the “well-maintained” criteria issued by the joint-stock company. Guidance is provided by Annex 2 of the “Standards for Well-Maintained Equipment on Site”, and the evaluation shall be conducted based on Annex 3, the “Inspection and Scoring Sheet for Well-Maintained Equipment on Site”. (III) For the evaluation based on positive feedback, the focus is on the appearance of the installation and the condition of the equipment; on-site standardized management criteria and the long-term operational performance of the equipment serve as supplementary evaluation indicators, with the specific circumstances of the installation taken into account in making the assessment. (IV) The indicator of intact equipment is included in the assessment of intact production units, tank farms, pump rooms, substations (power distribution rooms), and instrument control rooms; it is generally not evaluated separately. (5) A ‘in good condition’ sign shall be issued after meeting the evaluation criteria and passing the inspection. (VI) During the activity period, inspections are conducted on the progress of activities for each device on a monthly basis, and results are reported during regular equipment meetings to ensure proper progress and effectiveness of the activities ； At the end of each quarter, a summary is made of the status of device setup completion, followed by a centralized review. VII. The target for these activities is that the integrity rate for each specific item should be over 90%. VIII. Evaluation methods for the “Achieve Integrity” campaign: 1. Based on the scale of construction of various installations, the number of equipment, and the level of management complexity, the “Achieve Integrity” projects are classified into different categories. Intact installations are divided into categories 1, 2, 3, and 4, while tank areas, pump rooms, substations (power distribution rooms), and control rooms are classified into categories A, B, and C. The classification of process equipment grades follows the current A, B, and C equipment grading system. 2. Advance the implementation progress at various stages of the campaign to ensure achievement of the company’s overall goals for achieving \"excellent condition,\" and conduct monthly evaluations based on performance regarding the monthly checks of each facility’s condition. 3. The number of qualified “Creative Maintenance” projects serves as a criterion for selecting outstanding equipment management systems and individual contributors in equipment management each year. 4. Devices that fail the final acceptance assessment for the application to be recognized as excellent projects are subject to an annual evaluation. 5. Units that are shut down for long periods or undergoing maintenance are not evaluated during such periods. 6. The bonuses for achieving “excellent condition” for each device are mainly awarded to those who make direct contributions to this goal, and they should be given in conjunction with the device’s “charter operation” and “zoning management” initiatives as much as possible. 7. Units that are not “in good condition” and have not been reported shall be evaluated separately based on their performance.