100 typical overhaul operations for oil refining and chemical plants


100 typical overhaul operations for oil refining and chemical equipment

Article 1: All repair units must establish appropriate repair organizations. The creation of an organizational structure with strict organization and efficient operation is a reliable organizational guarantee to ensure the smooth progress of the overhaul. In the year of the overhaul of the device, each company and inspection unit should set up an overhaul headquarters respectively, and form a strong overhaul command organization system, so as to achieve unified command and unified action.

Article 2. For the purpose of "repair every few years" and long-term stable operation, prepare maintenance plans and programs. Repairs must be made, repairs must be done well, and maintenance costs must be reasonably controlled.

Article 3: Adhere to the principles of safety, quality control, environmental protection and environmental protection, scientifically coordinate and reasonably organize the time and period of maintenance.

Article 4: In line with the station-wide maintenance shutdown principle, public works systems must be regularly overhauled to minimize temporary maintenance shutdowns.

Article 5: Start preparing a technical equipment maintenance plan and a 24-month maintenance plan. The preparation of the maintenance plan should be based on the equipment maintenance plan and should be completed twelve months before the maintenance. Planning accuracy must be at least 95%.

Article 6: Plans and programs for inspections of special equipment must be combined with risk assessment in accordance with the requirements of the new "Regulations".

Article 7: Formulate corrosion inspection plans and programs in accordance with the requirements of the Guidelines for Corrosion Inspection During Shutdown and Maintenance.

Article 8: In accordance with the requirements of the "Static Seal Installation Manual", draw up a tightening plan and pattern.

Article 9: Two months before the overhaul, complete a survey and plan to eliminate hidden hazards such as small field joints.

Article 10: Projects for technological improvements and technical measures must be developed at least six months in advance and comply with the requirements of a long-term order, and can also be included in the maintenance plan after the approval of the changes. The approved plan cannot be changed.

Article 11: After approval of the device maintenance plan, the production area organizes the preparation of maintenance materials and spare parts plans. Materials and spare parts must have technical procurement standards, key equipmente and spare parts must be signed by the technical agreement, and special personnel must be appointed or a third party must be instructed to control production.

Article 12: The quality of repair materials and spare parts is the responsibility of the material purchasing department. Before the materials leave the warehouse, relevant quality inspection work must be completed in accordance with relevant requirements and national standards, and quality certification documents must be provided.

Article 13: The selection of major repair contractors must comply with the relevant regulations. The bidding companies must first select the first-class and second-class contractors of the frame companies for engineering construction issued in the current or previous year, but they must comply with the Bidding Law of the People's Republic of China Relevant requirements.

Article 14: Special maintenance work, such as mechanical cleaning of storage tanks, refractory and thermal insulation linings, inspection and testing, etc., must be selected through negotiations with the company.

Article 15: Six months before shutting down the device, the production area shall organize and complete the disclosure of the maintenance project and prepare an organizational plan for major maintenance.

Article 16. Three months before the shutdown of the device, perform the maintenance items one by one for the operation team and individuals according to the overall shutdown plan, and make the disclosure on site. Drafting and completion of the technical maintenance plan and construction plan for key projects, and coordinating the maintenance of key projects and devices.

Article 17: Two months before shutting down the device, operating instructions or operating instructions must be drawn up and completed. The construction department, including the department in which the self-monitoring project is located, must arrange for operators to be trained in the operating instructions or operating instruction cards.

Article 18: Before shutting down the device, the production unit must determine the hazards and environmental factors in the entire process of shutting down, checking and starting the device, prepare a risk assessment report and a safety and environmental report. contingency plan, and inform production workers and disclosure of information about construction operations.

Article 19: Before stopping the device, the building unit shall, according to the maintenance tasks and the risk assessment report provided by the production unit, identify and assess the risks of construction operation, formulate risk reduction measures, prepare the HSE operation. plans, and the HSE Work Plan shouldbe submitted to the production unit for review and registration.

Article 20: The building-operating unit must submit to the operating personnel the HSE maintenance plan and plant entry precautions prior to maintenance, and the personnel submitting the disclosure must sign for confirmation.

Article 21: Before entering the plant for the first time, the building unit must undergo special proficiency testing, safety training, and apply for safety training certificates and other relevant certificates in accordance with the local safety department management regulations. .

Article 22: The list of construction personnel is submitted to the production area, and the production area checks the qualifications of the operators and registers them. A responsible person responsible for safety and quality inspectors must be appointed at each workplace and indicated in the "List of Construction Personnel".

Article 23: Before starting a project, the building unit must inspect, inspect, repair and mark the tools to be used, especially lifting gear and power tools, to ensure safety, integrity and efficiency; and submit a complete list of tools to the project block.

Article 24: The contractor must conclude a construction contract and a safety contract before maintenance. Before issuing a contract, the production area must check whether the qualifications of the building safety unit, the qualifications of project management personnel, the qualifications of technical personnel, the qualifications of construction personnel and the number of personnel, the auxiliary conditions of the types of work, and the signing of labor contracts meet the requirements of the project and retain the certifying documents.

Article 25: There must be an approved shutdown plan, a chemical cleaning plan (atmospheric and vacuum plants, catalytic fractionation and coking systems must be chemically cleaned during shutdown), a blowdown replacement plan and a cook plan, equipment and pipelines prone to the formation of FeS and H2S must be passivated and purified, and emissions must be strictly controlled to ensure that the environment is not polluted. During the material return and purge phase, construction personnel are strictly prohibited from entering the maintenance site.

Article 26: The production area must prepare an isolation plan for maintenance of devices. Boundary areas and pipelines of equipment that do not exit or are connected to combustible, explosive, toxic and hazardous materials must be completely isolated with plugs and marked with signs. It is necessary to appoint a special person responsible for the managementthe appearance of a blank plate, draw a blank plate and number it in a unified way.

Article 27: The unattended area where materials are stored in the device must be energetically isolated, enclosed with a warning rope and a warning sign posted.

Article 28: Grease traps, sewer wells, drains, trenches, industrial and domestic sewage systems in the installation area must be effectively blocked. In the event of rain and sewage entering within 15 m of the source of fire, fire-fighting measures should be taken.

Article 29: Pay attention to the cleaning of dangerous goods. Dangerous goods such as dirty oil, chemicals and accidental discharges coming out of the installation must be removed from the installation area, and the oil on the platform, ground, equipment and pipeline surfaces must be cleaned.

Article 30: All types of fire safety equipment, safety warning signs for operations and protective equipment are complete and ready for use, and fire roads are unobstructed.

Article 31: Environmental protection facilities must be closed after cleaning and emptying of production equipment.

Article 32: In order to strengthen the management of the three-waste discharge, the safety and environmental protection department of the production area will organize the completion of the “Three-waste discharge confirmation form” and the execution of the signing procedures.

Article 33. There must be a clear transfer interface for shutdown and overhaul. Prepare the "Device Disabled Status Confirmation Form", arrange the security status confirmation according to the management level of the disabled device, and complete the signing procedures. Important devices need to be updated and managed.

Article 34: All kinds of personnel entering the maintenance site must strictly abide by the company's "prohibition of violation" and the various safety management systems of the production area.

Article 35: Adhere to the principle of "whoever is in charge, who is responsible for safety management and supervision", establish a safety supervision and management system for major repairs, and, if necessary, involve a third party for supervision and safety management.

Article 36: Any maintenance and construction operations must be carried out in accordance with the relevant national and industry standards and regulations, strictly observe the "Sixteen rules for operating permit management" in the oil refining and chemical sector, and use the issued "Operation Permit" in as a basis for opening projects.

Article 37: The production area must train guardians of maintenance operations, formulate instruction cards for guardianship duties and list them asguardians.

Article 38 Construction workers must be given safety briefing before daily work, and the safety risks and quality requirements of daily operations must be disclosed. Operators should re-identify operational risks on site.

Article 39: When entering the site, construction personnel must carry their labor certificates, special operations certificates (or copies thereof) and operational tickets and accept inspections at any time; Workers, welders, crane operators, shelf workers, etc. must be assessed and tested before they can work with the certificate. When working at the facility, it is necessary to wear uniform work clothes, work shoes and safety helmets that meet the standards.

Fortieth Article: The building and maintenance unit shall keep the operating personnel fixed and shall not change them at will, and appropriate procedures shall be followed for personnel changes.

Article 41: In multi-type and multi-level cross operations, the production area shall organize and coordinate in a unified manner, identify security risks caused by cross operations, and take effective isolation measures.

Article 42: It is strictly forbidden for operators and unauthorized personnel to enter areas or places that are not served by the unit, and to establish warning and isolation zones.

Article 43. Construction units working in hazardous areas on a construction site must install warning signs, physical isolation measures and warning lights at night.

Article 44: It is forbidden to store flammable and combustible materials at the repair site. Cleaned flammable and combustible materials must be transported to a safe place in a timely manner, and appropriate security measures must be taken. It is strictly forbidden to use volatile flammable liquids such as gasoline to clean equipment, parts, clothing and soil.

Article 45: For the opening of the hatch, before and after the operation, hatch protection devices must be hung to prevent people from entering by mistake.

Article 46: JGJ130 "Safety Technical Specification for Steel Pipe Scaffolding with Fasteners in Construction" shall apply to erection, dismantling and inspection of scaffolding. It is forbidden to tie and install scaffolding supports on production equipment, technological pipelines, etc.

Article 47: Lifting of large equipment is strictly in accordance with GB50798 "Specification for lifting large scale petrochemical equipment" and the relevant requirements of the company.

Article 48: Process piping or equipment must not be used as an anchor point for lifting. During lifting operations, between the edges and corners of the stressed structure and the steel cable,gasket to be added. It is strictly forbidden to use the equipment for winding guide chains for lifting operations.

Clause 49: Hot work must comply with AQ3022 "Safety Requirements for Hot Work in Chemical Plants" and related requirements.

Clause 50: Working at height must comply with AQ3025 "Safety Specification for Working at Height in Chemical Plants" and related requirements. Working at height (or on a grid) must be equipped with a tool bag Tools and materials used by the operator must be placed in the tool bag when not in use Large tools and dismantled large parts must be placed in a safe place and in a stable condition. Garbage generated during operation should be placed in a safe place and cleaned up in a timely manner, and it is also forbidden to throw garbage and waste down.

Article 51: Culverts, openings, platforms, escalators, etc. in the maintenance area shall be provided with safe and secure permanent or temporary railings or coverings, and shall be clearly marked and warning safety signs.

Article 52: A safe working area shall be established at the hydrostatic test site and entry by unauthorized personnel is prohibited. During the test, the test personnel shall not stand in the direction of a possible high-pressure water leak, for example, at the welding points of plugs and flanges.

Article 53: JGJ46 "Technical Specification for the Safety of Temporary Power Use at Construction Sites" and related requirements shall be implemented for temporary power use operations. Temporary connection to electricity, transmission and power outage must strictly comply with work tickets.

Article 54: Acetylene cylinders used for maintenance must comply with GB11638 "Acetylene Dissolved Cylinders" and "Gas Cylinder Safety Supervision Regulations". It cannot be placed horizontally during storage and use, and must be fixed with a bracket to prevent fire and explosion caused by acetone leakage. When using, the distance from open fire should be at least 10 m, and the distance from the oxygen cylinder should be at least 5 m. Sun protection measures should be taken in summer.

Article 55: Establish a maintenance quality management system, clarify the division of labor in quality management, and ensure that one person is responsible for each maintenance project.

Article 56: Formulate quality management procedures, formulate related systems such as quality rewards and punishments, production supervision of critical equipment, raw material incoming inspection, special type of work inspection, prototype launch, and protection ofnew products and also check them out. performance.

Article 57 Drafting professional quality control specifications and quality control plans, clarifying professional quality control requirements for early, mid and late maintenance, and drawing up inspection and acceptance protocols.

Article 58: Welding operations must comply with GB9448 Welding and Cutting Safety and other relevant standards, and the welding process must be drawn up in strict accordance with the requirements of the welding process chart.

Article 59: Fully implement constant torque fastening technology and strictly comply with relevant requirements such as "Static Seal Installation Manual" in the oil refining and chemical industries. Proper use of fasteners and sealing parts such as flanges, bolts, gaskets, etc. must be signed by a designated person for their receipt, acceptance and use.

Article 60: Handle radioactive sources well, and their use, transport and storage must strictly comply with relevant national laws and regulations.

Article 61: Defects found during physical and chemical inspections, the inspection team must immediately notify the production area, and the production area must arrange for the construction unit to prepare a technical plan for repair and repair or correction after completing the approval procedure as necessary .

Clause 62: Preventive testing of electrical equipment must be carried out in accordance with DL/T596 "Procedures for preventive testing of electrical equipment" during the period of maintenance.

Article 63: When disassembling and transporting safety valves, protective measures must be taken. The production territorial unit appoints a special person responsible for the operation of safety valves at constant pressure, and requires that constant pressure units be placed in accordance with the middle and factory category , as well as in order to start work General measures for working with constant pressure. Newly replaced valves must be pressure tested prior to installation and test records must be archived.

Article 64: Perform maintenance operations in accordance with the general maintenance and construction plan and daily work list. Complete worksheets and agree on the use of fire and electricity to ensure the overall control of maintenance projects.

Article 65: According to the content rules of "five prohibitions", "three do not see the sky", "three do not fall to the ground", "three lines" and "ten do not use indiscriminately", scientific and environmentally friendly service must be achieved.

Article 66: At the maintenance facilitytinning should be a floor plan. Notice boards with clear signs and obvious positions should be installed on the territory of the construction site.

Article 67: Temporary structures at the repair site are arranged in accordance with the uniform requirements of the production territorial unit and should not block repair and fire emergency passages.

Article 68: Toolboxes and tools for site maintenance must be placed in a fixed position, and they must be taken back and returned to their original position after a time of use. The disassembled parts must be located and placed in the order of their reassembly.

Article 69: Traction cables of electric welding equipment must be horizontal and vertical and must not cross. Used welding rods should be put back into the barrel at any time, and not thrown away at will.

Article 70: All materials, components, pipes, valves, flanges, bends, uninstalled equipment and prefabricated components entering the maintenance site must be classified and marked, placed neatly, and the quantity, specification and model must be clearly marked . measures to prevent rain and moisture, as well as the timely storage of small items. When receiving, it is necessary to determine the face, fixed point and quantitative distribution, and the distribution must be traceable.

Article 71: Pay attention to the sealing and coating of finished or semi-finished products that have been built, and take appropriate protective measures in the cross-building process to prevent damage and pollution.

Article 72: The maintenance site must be kept clean and tidy, free of water, oil, or gas, and the ground free of dirty water, oil, or debris. Garbage should be produced by Nissin.

Article 73: Acids, alkalis, resists, and other solvents and chemicals used to clean equipment must not be dumped on the ground, and cleaning fluids, waste acids, and alkaline water must be neutralized to appropriate levels before being drained. into a wastewater treatment plant.

Article 74: Organic solids (such as autopolymers, oil sludge, tank bottom sludge, etc.) removed from equipment and pipelines must be disposed of in accordance with the relevant hazardous waste requirements.

Article 75: Maintenance waste shall be stored by the construction unit in accordance with the storage location and requirements set by the production unit, and the replaced old equipment shall be returned or disposed of by the production unit.

Article 76: After major repairs are completed, work must be completed, materials must be clean, and the site must be clean. Installation area, factorybuilding, pump room, top tower, bottom tower, pumps, tools, doors and windows, etc. must be cleaned before starting installation, so that there are no maintenance materials, sundries, debris, no dust, to achieve "level" , standards of "two purges, three looks, four nothings, and five faults".

Article 77: Insulation, corrosion protection and markings damaged during maintenance must be repaired in a timely manner, and abandoned and blindly broken pipelines during maintenance must be dismantled and removed in a timely manner.

Article 78: Plots, roads, lawns, fences, etc. damaged by construction must be repaired in time after completion.

Article 79: Strengthen service management and production interface. Before the completion of the overhaul of the device and the start of delivery, before putting the device into operation, a safety check must be carried out (performed according to the points according to the list of the PSSR in the "Regulations on conducting a safety check before commissioning"). Use").

Article 80: During the start-up period of the device after the overhaul, each unit participating in the inspection must retain the transport personnel, and the auxiliary types of transport work must be completed. The scope of the warranty covers all equipment and facilities (including safety and environmental protection) within the entire technological process of the disconnecting device and is not limited to equipment and facilities for maintenance. The content of the guaranteed transportation consists in dismantling the blind slab at the beginning of construction, tightening the system with heat and cold, etc., as well as troubleshooting equipment and pipelines at the beginning of construction.

Article 81: Transport personnel must be checked and registered by inspection personnel who are on standby at a designated location 24 hours a day, and communications must remain open. After the power is turned on, maintenance and transport personnel are not allowed to enter the territory of the device at will. If they need to enter for work, they must enter the work site accompanied by the personnel of the device.

Article 82: During the start-up of the device, the control of parts with sudden changes in temperature and voltage should be strengthened. Focus on checking the expansion and contraction of pipelines in high temperature equipment, steam systems, cryogenic low temperature systems, high pressure equipment or rapidly changing equipment.

Article 83: During the start-up of the device, it is important to check whether the expansion joint of high-temperature equipment or pipelines (such as boiler drums, manifolds, etc.) is in good condition, and the indication is normal.

Article 84: During the start-up of the device, it is important to check whether the deformation exceeds the compensationthe maximum compensation value, and whether the supports at both ends of the compensator are in good condition.

Article 85: During the start-up of the device, it is important to check whether the support and suspension are correctly installed according to the design position of the lifting point and the amount of deviation, whether the fixed bracket is tilted or the sliding guide bracket is stuck, check whether the displacement of the spring suspension within its operating range.

Article 86: During the start-up of the installation, it is important to check that the safety devices of the equipment or pipelines are not damaged and that they are in working order.

Article 87: During the start-up period of the device, thermal imaging inspections of high-temperature cold-walled equipment such as heating furnaces and catalytic converters must be carried out.

Article 88: During the start-up of the device, check the lubrication of all rotating equipment and take notes.

Article 89: Before starting a large installation, make sure that the oil transportation is qualified, the single test of the turbine lubricating oil pump and the auxiliary oil pump is qualified, the bypass valve and the outlet valve on the oil pipeline are closed, the safety valve is activated, and the oil tank is heated. The device has the conditions for use and the unit safety interlock device is activated. During the start-up of large units, it is necessary to check parameters such as unit vibration, displacement and tile temperature, as well as check the tightness of each sealing part.

Article 90: Before starting the steam turbine, the warm-up tube must be qualified, and during the warm-up process, a mechanical inspection must be carried out and records must be made.

Article 91: Check whether the instrument interlock, safety monitor, visual security monitor and environmental monitoring instrument are working normally during the construction period, and organize joint schools of all specialties to confirm.

Article 92: Check if the test instruments and clamps are in a high temperature environment during the start-up period in a normal state.

Article 93: Check whether the automatic control system of the instrument and the temperature of the power supply are normal during the startup process. Check for overheating and overloading of electrical equipment such as circuit breakers, transformers and motors.

Article 94: Before starting a plant, an organization must look back on accidents in the past start-up process and learn from it.

Article 95: After the entire set of equipment is stopped for maintenance, technical transformation, technical measures, overhaul, renovation and other items completed during the maintenance period must be subject to subsequent evaluation.

Article 96. After three monthsFor maintenance and uptime, evaluate the operating condition of key equipment and key projects.

Article 97: Summarize the optimization of the overall plan for the overhaul, organization and arrangement of construction, general arrangement and process control.

Article 98: Assess the management of the contractor on site, the technical capabilities of the operation, the effect of the implementation of the operation, etc.

Article 99: Within one month after the overhaul, the construction and operation unit must submit the relevant data files to the production area in accordance with the requirements of the "Regulation on the management of technical documentation for the supply of oil refining and chemical construction projects" (Q/SY1476-2012) .

Article 100: The production area must submit original paper documents for equipment involved in major repairs, upgrades, technical measures and other elements of change (including equipment early management data), such as factory data (Drawings, manuals, certificates of conformity, quality certification documents, test and inspection reports, etc.), design, manufacture, installation, trial run and other relevant materials are archived, and the relevant information is entered into the comprehensive equipment management platform.