Instrument insulation and heat tracing management plan

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To ensure the safe, stable, and smooth operation of the instruments in various devices throughout the winter, and to guarantee the steady functioning of all production units during this period, the Instrumentation Management Team has formulated this winter anti-freezing and anti-condensation plan for the department, in line with the company’s guidelines. 1. Establish a leading group for winter anti-freezing and anti-condensation measures for instruments. Group leader: ### Deputy group leader: #### Group members: ####3 2. Responsibilities of group members. The head and deputy head of the leadership team are responsible for overall winter safety production in the operations department ； Activate the operation department’s emergency plan based on weather conditions ； Mobilize the resources of the Operations Department to handle various emergencies ； An assessment is conducted on the winter production of the production department. Properly manage the maintenance work to prevent freezing and condensation in the outsourced areas. Directors of each maintenance area: Responsible for winter work safety in their respective maintenance areas ； For instrumentation and metering, the focus is on preventing freezing and condensation; electricity systems are responsible for ensuring safe power supply during winter ； Responsible for implementing various work arrangements of the Operations Department ； Responsible for carrying out routine maintenance tasks in accordance with the management plan ； Responsible for evaluating winter maintenance in the maintenance area. III. Winter anti-freezing and anti-condensation measures (safe production) objectives: 1. Prevent any instruments or pipelines used by them from being damaged due to freezing ； 2. No unplanned shutdowns of the facility or major units caused by instrument freezing ； 3. Ensure proper maintenance of electric heating equipment to guarantee the safe operation of production and electrical equipment. 4. Ensure proper coordination and management of the outsourced maintenance areas. 5. Complete the establishment of the anti-freezing and anti-condensation records for the new equipment, as well as the preventive maintenance strategies. 6. Complete the drainage and purging of accumulated water following the deactivation of chemical process instruments; local灌注 of ethylene glycol ensures that none of the instruments freeze or get damaged. IV. Work Arrangements
The arrangements for winter safety production work are divided into four phases:
1. Preliminary inspection and preparation phase (timing to be determined based on actual circumstances)
During this phase, the Instrumentation Department formulates the “Anti-freezing and Anti-condensation Management Plan (Winter Safety)”. All subordinate instrument departments are required to develop their own winter anti-freezing and anti-condensation plans in accordance with the “Guidelines” and the characteristics of their respective facilities, while also taking into account past experiences related to anti-freezing and anti-condensation measures. In accordance with the plan, preliminary preparatory work is carried out, including a thorough inspection of the insulation and heating systems for the equipment’s instruments, in order to identify potential problems and defects. A comprehensive record-keeping system for preventing freezing and condensation of instruments is established. Based on the issues identified during the inspections, a detailed plan for preventing freezing and condensation is developed, while the electrical department formulates a winter safety production plan tailored to its specific requirements. Conduct inspections for potential freezing and condensation-related defects in new installations, and submit the rectification plans to the project department. 2. Implementation phase (timing to be determined based on actual circumstances): During this phase, all departments within the Operations Division are required to create forms for documenting the replacement of isolation fluid, and to assign specific responsibilities to individuals. Replace all instruments that require isolation fluid, emphasizing that the dilution of the instrument isolation fluid must be uniform to ensure the safety of the isolation fluid main pipes during winter. It is required to thoroughly address the potential issues and defects in the instruments identified during preliminary inspections in accordance with the anti-freezing and anti-condensation plan; to reinforce the insulation layers, and to replace any faulty steam traps. Ensure the preparation of emergency materials for winter. The instrument department shall supplement the anti-freezing and anti-condensation ledger by October 30. The new unit should begin replacing the instrument filling liquid by October 15, and the concentration of the filling liquid should be reduced to around 50% by November 10. The chemical plant completed the work of deactivating, purging, and isolating the instruments on October 20. Identify the instrumentation equipment for winter preventive maintenance, and submit applications for anti-freezing and anti-condensation preventive maintenance by the 29th of each month (applications should be submitted on a per-unit basis). 3. Winter operation period (the timing is determined based on actual conditions): General requirement: Promptly address any leaks in the instrument pressure transfer pipelines and heating pipelines, in order to reduce instrument failures caused by the loss of isolation fluid for the instruments ； Strengthen inspections to detect early signs of instrument failures promptly, strive to nip such failures in the bud, and take further preventive measures. Maintenance efforts should focus on key areas, with an emphasis on regular inspections of critical instruments such as interlocks and control systems. Proactive maintenance should be carried out on these key instruments as well as those that experience frequent failures. Isolation fluids should be replaced regularly, and instruments that use instrument air or media containing water should have their water removed periodically ； Organize technical personnel to address the issues with instruments that fail frequently; if measures cannot be implemented, proper records should be kept. Submit requests for activating trace heating based on weather conditions and instrument characteristics; adjust the operation of self-managed trace heating systems in accordance with company instructions ； The electrical department shall carry out proper operation and maintenance for winter-safe power supply and electric heating in accordance with the plan. Implementation of the plan: Each maintenance unit carries out various inspections and maintenance tasks on a regular basis, in accordance with the established preventive maintenance plan for preventing freezing and condensation ； Make proper records, and if necessary, adjust relevant plans based on inspection and maintenance conditions as well as weather conditions. Response to adverse weather: The Operations Department’s dispatch team monitors weather changes daily and, in accordance with relevant company requirements, coordinates efforts to respond to adverse weather conditions. Each maintenance unit shall, in accordance with the requirements of the operations department, promptly arrange for preliminary inspections and repairs to eliminate any signs of malfunction and ensure the steady operation of the equipment. 4. Summary of work on anti-freezing and anti-condensation measures (winter safety) (the timing shall be determined based on actual conditions). After the anti-freezing and anti-condensation period comes to an end, it is necessary to conduct a summary of these measures, identifying both the shortcomings and the positive aspects observed during that period, so as to use this information as a reference for improvements in the coming year. V. Requirements for freeze and condensation prevention of instruments
1. In areas where instruments and metering equipment are maintained, a management plan for freeze and condensation prevention must be formulated. Various instruments in these areas should be managed categorically, and a register for freeze and condensation prevention should be established. The plan should include: the leading group for frost and condensation prevention in the maintenance area ； Winter maintenance objectives ； Key points and measures for anti-freezing and anti-condensation ； Records of various anti-freezing and anti-condensation instruments and equipment, as well as control measures ； Freezing and condensation prevention plan ； Detailed Rules for Assessing Anti-freezing and Anti-condensation Measures in Workshops ； Requirements for regular inspections to prevent freezing and condensation in the maintenance area ； Special protection measures shall be taken for the shut-down and idle equipment. 2. The maintenance area should analyze the risks of possible freezing of instrument equipment, and determine regular maintenance procedures for each instrument. Prepare a regular maintenance record sheet for winter instruments. 3. The maintenance area should identify the key control instruments based on the characteristics of the instruments and past experience, to focus maintenance efforts on them. Establish a ledger and records for the key instruments designed to prevent freezing and condensation, and conduct regular inspections and maintenance. 4. The maintenance area should be integrated with the equipment area contracting system; the inspection and maintenance of anti-freezing and anti-condensation measures for each instrument should be contracted to individuals, thereby strengthening the responsibilities of maintenance personnel. 5. An emergency plan for preventing freezing and solidification should be formulated (it can be included in the overall plan). This plan should specify the measures to be taken when various instruments experience freezing or solidification failures, as well as the details of maintenance and inspection activities before and after periods of adverse weather. This ensures that preventive measures are taken in advance, inspections are carried out during such periods, and there are proper measures available to address any problems that may arise. 6. As a key aspect of instrument maintenance in winter, it is required to summarize the work related to anti-freezing and anti-condensation measures on a monthly basis, analyze existing problems, plan appropriate actions, and outline future work plans. 7. Detailed guidelines for freeze and condensation prevention
1) The winter period for freeze and condensation prevention runs from November 15 each year to March 15 of the following year. 2) Before November 15 each year, for pressure-inducing pipelines on production facilities that contain isolation fluid for media such as steam, water, gas, oil, and chemical materials, antifreeze must be filled into them. The antifreeze must meet the quality requirements at -20±2°C ； For circuits that are not filled with antifreeze (such as those using air or other media), water should be drained periodically (the interval is determined based on the characteristics of each instrument), and records must be kept. 3) The work related to preventing freezing and condensation must be assigned to specific individuals, with records kept in order to ensure there is evidence available for reference. 4) Depending on the seasonal conditions, stricter inspections should be carried out on outlets that are prone to freezing or solidification and are located in areas exposed to drafts, with regard to insulation and heating measures (it is necessary to prevent condensation of the fluid due to insufficient insulation, as well as prevent the antifreeze from vaporizing due to excessive insulation). Any abnormalities detected must be addressed promptly, and records must be kept. 5) For export packaging, pressure guiding pipelines, and pressure connection parts of transmitters that are prone to freezing and solidification, thermal insulation or steam tracing should be applied. It is necessary to ensure that the insulated/traced pipelines and their external insulation remain intact and are painted. 6) All air filters should be inspected once a week, and records of any water accumulation should be kept; if water accumulation is detected, the cause should be analyzed. 7) The instrument inspection and maintenance department shall establish a plan to prevent instruments from freezing in temperatures below zero, during strong winds in winter, or when temperatures are below minus 10 degrees. 8) When the pressure guiding pipelines, control valves, and transmitters are taken out of service, the outlet valve should be closed and the vent valve opened. For control valves, it is required that the workshop (operation area) close the upstream and downstream valves and open the vent valve. 9) Before the anti-freezing and anti-condensation period begins each year, conduct a thorough inspection of the traps; replace any defective components promptly. Check the drainage condition of the traps on a daily basis – drainage should occur in an intermittent manner – and address any issues that arise immediately. For cases where insulated steam is to be discharged directly, a sign can be posted to indicate this. 10) For media that tend to solidify at room temperature, proper insulation and anti-solidification measures should be implemented throughout the year. 11) Conduct a comprehensive inspection of the instruments in the shut-down equipment before winter arrives, to verify that the protective measures for these instruments have been implemented as per the plan. For chemical processing equipment, nitrogen purging is used to prevent liquid accumulation in the instrument heating systems, and the personnel stationed at the facility should carry out a comprehensive inspection once a week. Conduct inspections and emissions checks on the operating instrument air system. VI. Emergency Plan 1. Emergency preparedness measures in case the temperature drops below 0°C for the first time with the arrival of winter. 1) The operation department activates the emergency plan for the first drop in temperature in winter, in accordance with company notices or weather forecasts. 2) After the emergency plan is activated, the operations department’s dispatch team notifies the supervisors of each maintenance area to initiate their respective emergency plans. 3) The maintenance area carries out preliminary maintenance before work ends in accordance with the plan, replacing the isolation fluid in the relevant instruments. 4) Maintenance areas shall strengthen maintenance personnel at relevant posts in accordance with the contingency plan. 5) Conduct corresponding inspections during night shifts to promptly eliminate various early signs. 6) Duty personnel in the Operations Department must make emergency preparations and promptly coordinate maintenance resources within the department to handle various unexpected incidents. 7) The electrical maintenance personnel checked that the relevant electric heating systems were operating properly. 2. In winter, there are strong winds and temperature drops (when a cold snap occurs, the temperature drops by more than 5 degrees) ； Emergency preparedness measures when the minimum temperature is below -10°C. 1) The operation department activates the emergency plan for the first drop in temperature in winter, in accordance with company notices or weather forecasts. 2) The operations department arranges for an increased night shift crew depending on the circumstances. 3) After the emergency plan is activated, the operations department’s dispatch team notifies the supervisors of each maintenance area to initiate their respective emergency plans. 4) The maintenance area carries out preliminary maintenance before work ends in accordance with the plan, replacing the isolation fluid in the relevant instruments. 5) The maintenance area strengthens the maintenance personnel in relevant positions in accordance with the contingency plan. 6) Conduct corresponding inspections during night shifts to promptly eliminate various early signs. 7) Duty personnel in the Operations Department must make emergency preparations and promptly coordinate maintenance resources within the department to handle various unexpected incidents. 8) After the cooling-down process is completed, each maintenance area should compile a list of various problems that occurred during this period and analyze their causes. 9) In response to the failures that occurred during that period, various defects were rectified, the emergency response plans were updated, and corresponding preventive measures will be taken for these devices during the next cooling cycle. 10) Electrical maintenance personnel inspect the electric heating systems in the maintenance area, check whether the heating current and temperature are within normal ranges, and address any related defects promptly. 3. In winter, various conditions such as ice and snow as well as heavy fog can affect the power supply system, resulting in partial or complete power outages or intermittent power supply in the company. Preventive measures include: 1) The workshop conducts a drill for the emergency plan in case of power outages, to improve employees’ ability to handle various electrical faults. 2) Conduct inspections of key areas before, during, and after various adverse weather conditions. Check the condition of overhead lines, the protection measures at substations, and the safety of transformer rooms to implement preventive measures in advance. Perform inspections during rainy or snowy weather, as well as safety checks after heavy snowfall, and promptly address any potential hazards. 3) During icy and snowy weather, check for ice accumulation and snow on overhead lines; if necessary, contact relevant authorities to arrange a power outage. 4) Emergency responses to various power outages are carried out in accordance with the workshop’s emergency plan. 4. Abnormal weather conditions in winter can easily lead to injuries among personnel. Preventive measures include: 1) Using team safety meetings to identify and discuss potential risks such as slips, injuries caused by ice on heights, and workplace accidents during winter, in order to raise employees’ awareness of prevention. 2) The workshop prepares various anti-slip mats to protect key areas such as stairways, slopes, steps, and corners in case of ice and snow ； 3) Check for ice formations at high locations within the area under responsibility on a daily basis, and take prompt action to prevent them from falling ； 4) During snowfall, clear the snow accumulated on roads in a timely manner as required, and remove it from the roads promptly ； 5) Bruising is likely to occur during winter work; it is required to wear gloves for all types of tasks ； 6) The workshop conducts inspections of personal safety equipment to ensure that employees can enter the work area safely ； 7) Educate employees working outdoors to keep warm and to take in the necessary amount of cotton clothing ； VII. Competition Plan for Anti-freezing and Anti-condensation Measures 1. Establish a monthly assessment system for anti-freezing and anti-condensation measures, with inspections and evaluations of these measures carried out on instruments and meters on a monthly basis. The reward amount is XX yuan per month. 2. After the monthly anti-freezing and anti-condensation assessment plan for the maintenance area is formulated and approved by the operations department, the same department oversees the organization of such assessments in that area. 3. In the course of maintenance, if an instrument anomaly occurs due to anti-freezing and anti-condensation measures, 20 points will be deducted; if an instrument failure occurs that affects production, 50 points will be deducted. 4. 50 points are awarded for maintaining anti-freezing and anti-condensation measures in the maintenance team, where such tasks are not assigned to individual members for assessment within their respective areas of responsibility. 5. If a defect in anti-freezing and anti-condensation equipment is identified during the weekly inspection by the operation department, 10 points will be deducted from the contractor and 10 points from the team. 6. In light of various instrument defects and past maintenance experience, the operations department solicits reasonable suggestions for preventing freezing and condensation. Those whose suggestions are adopted will receive an additional 20 points as a monthly bonus in addition to being evaluated based on those suggestions. A limit of 30 per unit. 7. Carry out inspections and maintenance in accordance with the established key instrument maintenance plan for anti-freezing and anti-condensation, and keep proper records. For inspection and discharge items that do not require a work order, each device unit counts as one item; for those that do require a work order, replacement of fluids and exhaust ventilation are counted as one item per instrument. 10 points are awarded for each task completed. (The reward-related tasks must be included in the preventive maintenance plan established in advance, with the maintenance unit providing the rewards in accordance with that plan.) 8. The established preventive maintenance plan has not been completed. Each assessment is worth 10 points. (Assessed by the maintenance unit) 9. If the preventive measures against freezing and condensation are not properly implemented in the maintenance area when such an emergency plan is activated, a penalty of 50 points will be imposed. 10. In the event of unplanned shutdowns due to anti-freezing and anti-condensation measures, 50%–100% of the monthly assessment score for the maintenance area will be reduced. 11. At the end of the competition period, based on the results of the winter maintenance assessment, five outstanding teams will be selected, as well as several individual contributors recognized for their excellence. 12. Each maintenance area that meets the anti-freezing and anti-condensation targets set by the operations department will receive an immediate reward of XX yuan per person. 13. Conduct monthly inspections of anti-freezing and anti-condensation measures in the outsourced areas, and submit assessment recommendations for the contractors to the company in accordance with the department’s evaluation regulations.