Regulations on the Management of Operating Procedures for Production Units in Refining and Chemical Enterprises – Summary Post

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This post was last edited by Guan Gongyu on 2015-7-29 at 18:19. Regulations on the Management of Production Units in Refining Enterprises. China National Petroleum Corporation – Regulations on the Management of Operating Procedures for Production Units in Refining Enterprises. Chapter 1: General Provisions. Article 1: These regulations are formulated to standardize the management of operating procedures, enhance their scientific nature and practicality, ensure controlled operations, and promote safe production. Article 2 These provisions apply to the preparation and management of operating procedures for the refining and chemical production units of joint-stock companies. Chapter 2: Management Responsibilities Article 3: The deputy general manager in charge of technology at the regional branch is the key leader responsible for the formulation and management of operating procedures, and is tasked with organizing the drafting (revision) and approval of such procedures. Article 4: The technical department is the designated authority in charge of operating procedures, responsible for organizing their formulation (revision), review, submission, and publication, as well as for conducting annual evaluations of these procedures. Article 5: The production and operation department is responsible for organizing the implementation of operating procedures. Article 6: The departments in charge of mechanical equipment, quality, safety, environmental protection, etc., are responsible for organizing the formulation (revision) of relevant content related to operating procedures, conducting professional reviews, as well as carrying out supervision and inspection during their implementation. -1- Article 7: The workshop (plant) is responsible for the preparation, review, submission, and daily management of operating procedures, as well as for the implementation of those procedures once they have been approved. Chapter 3 Principles and Methods for Formulating Operating Procedures Article 8 The formulation of operating procedures shall follow the following principles. (1) The operating procedures must be based on engineering design and production practice to ensure that the technical specifications, requirements, and operating methods are scientific and reasonable ； (II) The operating procedures must incorporate the operational experience gained from long-term production practices, ensuring consistency in the execution of the same tasks; they serve as guidelines that everyone must follow strictly, thereby contributing to production safety ； (III) The operating procedures must ensure that the operational steps are complete, detailed, accurate, and quantified, thereby facilitating the reliable operation of the installations and equipment ； (IV) The operating procedures must be integrated organically with optimized operations, energy conservation and consumption reduction, loss mitigation, improved product quality, as well as safety and environmental protection, in order to enhance the production efficiency of the facility ； (5) The operating procedures must clearly define the responsibilities of the personnel performing the tasks, ensuring clear division of labor and close coordination ； (VI) Operating procedures must be revised, supplemented, and continuously improved in production practice, to achieve ongoing advancement from practice to theory. -2- Article 9 operating procedures are formulated as follows. (1) Under the organization of the regional branch, each facility shall establish a team for drafting operating procedures; each team must consist of at least four members representing the management, technical, and operational levels. The workshop (plant) supervisor takes overall organization, with experienced technicians and operators (shift leaders, operation engineers, and station operators) participating. (II) During the preparation of operating procedures, collective discussion must be adhered to, with continuous revisions made during these discussions in order to draw on knowledge and work experience from various levels, thereby ensuring that the procedures are accurate and practical to follow. Chapter 4: Content and Compilation Methods of Operating Procedures Article 10: Operating procedures include sections such as process technical specifications, operation guides, start-up and shutdown procedures, basic operating procedures, and accident response plans (see Annex 1). Article 11 The contents of the process technology operating procedures include: (1) General information on the facility: production scale, capacity, date of completion, and past renovation history ； (II) Principles and Process: Description of the production principles and technological process of this device ； (III) Process parameters: including raw material parameters, parameters for semi-finished and finished products, parameters related to utility systems, main operating conditions, as well as parameters for raw material consumption, utility consumption, and energy consumption ； -3- (IV) Process flow diagram: process principle flow diagram, process piping and instrumentation control diagram, and description of the process flow diagram. The drawing method of flowcharts and the graphic symbols used in them shall comply with the provisions of **standards or industry standards** ； (5) Plan view of the installation: The locations of hazardous areas, alarms, and fire extinguishers must be indicated. If necessary, separate diagrams can be drawn showing the locations of hazard points, alarms, and fire extinguishers ； (VI) Details of equipment and instruments: List the equipment and instruments in categories, indicating their names, codes, specifications, and main design parameters. Article 12: The operating guidelines outline the methods for adjusting operational parameters during normal production as well as the requirements for handling abnormalities. Key points in their preparation are as follows: (1) They focus on adjusting for fluctuations in operations during production, with the aim of maintaining stability and preventing production accidents caused by such fluctuations. (II) First, determine the scope and objectives of the intervention; after analyzing the influencing factors, identify the target entities (this must be illustrated with diagrams). If the values exceed the set targets, it is considered to be operational fluctuation. Describe the appropriate control methods, providing at least a qualitative description, and preferably a quantitative one. For the possible operational fluctuations that may occur, propose corresponding countermeasures. Finally, clarify the accident response plan for situations where the operating parameters get out of control. (III) The operation guidelines for each control target should include: control range, control target, relevant parameters, control method, normal adjustment, and abnormal handling. The control range must not exceed the limits specified in the process card (maximum values); it is necessary to maintain a certain distance from the set pressure value of the safety valve and from the parameter alarm values, so as not to reach the safety limits, thereby ensuring a safe operating margin ； More stringent criteria (specific indicators) should be set for control objectives to ensure smooth operations and optimization ； The control method should be described in text, along with a control circuit diagram. Article 13: The basic operating procedures are the fundamental steps for carrying out various complex operations in the plant; they mainly describe the procedures for starting, stopping, and switching between common equipment such as machines, pumps, heat exchangers, tanks, and towers. The main contents include: operating procedures and precautions for starting, stopping, and switching various pumps and motors, as well as for starting, stopping, and switching fans; activating and deactivating medium- and low-pressure heat exchange equipment; and sampling from key areas. Article 14: The operational procedures such as startup procedures, shutdown procedures, basic operation procedures, operating procedures for specialized equipment, and accident response plans must be formulated in strict accordance with a unified format: (1) Page numbering sequence. The operating procedures are paginated in the following order: cover (first page), version history (second page), overview diagram, outline, operations, and explanations. (II) Compile in stages. Its content is guided and structured through a hierarchy of categories and subcategories, organized in three levels: Level A constitutes the outline of the procedures, specifying the main sequence of operations and states involved; it provides a detailed plan for all stable states and the operational objectives within those states, and is primarily used to coordinate the operations of various positions or systems. Level B describes the detailed procedures, the transitions between different states, and various specific -5- operational actions. This includes the initial state card, the stable state card, the final state card, the operational objectives, and all the specific operational actions under those objectives. The numbering of the operation steps for Level B corresponds to that of Level A. Level C contains key points and explanations, primarily focusing on the operational procedures; it provides the necessary information for those who use these procedures, including details related to safety, equipment, and process flow diagrams. The Class C code corresponds to Class B. (III) Sentence structure of the operation steps. The terminology used in writing operating procedures should be standardized to ensure readability; this way, the language used to describe the same operation will convey the same meaning to users of different devices, preventing misunderstandings arising from the same phrase being interpreted differently across various devices. The sentence format is: “(operator code) + (operation type code) + (verb) + (object and object complement)”. This linguistic structure is used to express the content to be conveyed, with each sentence indicating only one action. An action specifies its nature, the person who carries it out, its content, and the goal to be achieved. (IV) Operator code and operation nature code. M, I, and P are used as operator codes to represent the shift supervisor, internal operator, and external operator respectively ； “( )、、< >” are used as operation property codes, where “( )” indicates confirmation of a certain operation, “” denotes a description of the specific action taken, and “< >” represents a description of safe operations or confirmations. (5) Steady-state card. When the operation steps reach the specified stable state, -6-