The integrity rate of equipment reached 99.67%, the integrity rate of major equipment reached 99.76%, and the application rate of instrument interlocks reached 99.8%. The device accident rate reported to China National Petroleum Corporation was zero. This is a set of latest data obtained by reporters in early March at Daqing Petrochemical Company. As an old petrochemical enterprise with a 47-year development history, and as a super-large petrochemical conglomerate engaged in refining, ethylene, plastics, rubber, chemical processing, liquid chemicals, fertilizers, and fiber production, while undertaking engineering technical services, production technical services, mechanical processing and manufacturing, and mining area services, how did Daqing Petrochemical achieve three near-100% rates and a zero target for equipment accidents? Wang Bin, vice president of Daqing Petrochemical Company, revealed the secret: implementing "four modernizations" in equipment management, namely, layer-by-layer responsibility in management, skillfulness in management personnel, standardization in management technology, and refinement in the management process.
Layer-by-Layer Responsibility in Management: Fully Implementing Equipment Package Mechanism
Responsibility outweighs capability. To ensure the achievement of equipment standards and create complete equipment packages, the Mobile Equipment Department of Daqing Petrochemical Company organized the compilation of the "Daqing Petrochemical Company Package Machine Package Area Implementation Details" and the "Equipment Inspection Technology Manual", standardizing inspection items, content, standards, cycles, and record formats for equipment inspections, providing guidance and demonstration for equipment package areas. Each unit under the company, combined with the work of achieving equipment standards, actively explored equipment package modes suitable for their own situations, widely mobilized grassroots equipment managers and operators to participate, highlighted the role of operators and maintenance personnel in the equipment package area work, and strengthened the responsibilities and supervisory functions of grassroots equipment managers.
This company also formulated and improved the "Daqing Petrochemical Company Equipment Inspection Details", quantified standards, and regularly organized inspection and evaluation work. Each grassroots unit inventoried the equipment under its jurisdiction, clarified the inventory, especially for key equipment and components that might affect system operation, combined with equipment hazard investigation, ensuring knowledge and control of critical areas, striving to reduce potential hazards in the equipment and maintain its safe and reliable state.
After efforts, the equipment failure rate of this company significantly decreased, the service life of bearings and mechanical seals in rotating equipment greatly increased; the number of unplanned shutdowns due to pressure vessels and pressure pipelines with pressure leaks obviously reduced; the situation of leaks significantly improved, the site appearance greatly improved, and some low-standard and chronic problems were addressed.
Skillfulness in Management Personnel: Vigorously Enhancing Management Level
In recent years, Daqing Petrochemical has consistently focused on improving the comprehensive quality of all levels of equipment management staff, continuously strengthening their professional training in equipment management, and significantly enhancing the professional level of equipment management.
This company targeted equipment managers, following the annual professional training plan, conducting business training in several specialties including dynamic equipment, static equipment, instrument automation, and water quality management. In recent years, the company successively held training sessions on lubrication management, condition monitoring and fault diagnosis, water quality analysis technology, corrosion prevention technology, special equipment, etc., providing "fuel", "brain supplements", and "charging" for various levels of equipment managers. Meanwhile, the company invited scholars and experts from within the industry or equipment manufacturers, hosting lectures and conducting business exchanges targeting practical issues, broadening the horizons and thinking of equipment technicians, and enhancing their ability to study and solve problems.
On this basis, this company promoted self-study of professional technology among all levels of equipment managers through organizing equipment technology competitions. In 2008, Daqing Petrochemical's Production Technology Sports Meeting first added a "Equipment Management Zone", where a batch of skilled technicians and model workers emerged. In the equipment management personnel skills competition held by China National Petroleum Corporation the same year, this company achieved excellent results.
Standardization in Management Technology: Actively Promoting and Applying New Technologies
Modern management technology is the primary management force. Daqing Petrochemical Company achieves high efficiency and high benefits in production through the modernization of equipment management work. The company inherits traditional equipment management experience and methods, actively explores, promotes, and applies advanced management methods and means, gradually moving equipment management from post-event maintenance to modernization.
This company comprehensively conducts condition monitoring and predictive maintenance, establishing and improving a complete equipment condition monitoring organization and diagnostic network with the company's equipment monitoring diagnosis center as the key monitor and each secondary unit as the general monitor. By integrating resources, focusing on priorities, and effectively playing the role of condition monitoring, it ensures early awareness of faults and early treatment of hidden dangers, making condition monitoring serve predictive maintenance. RBI technology helps recognize dangerous points and defect forms existing in the equipment, comprehensively improving the safety risk assessment level of equipment, truly ensuring the reliability of equipment operation and the safety and economy of facility production. Daqing Petrochemical widely promotes and applies RBI risk detection evaluation technology, organizing equipment management personnel to seriously study, scientifically solving the technical points of equipment detection, and clarifying which defects need to be checked for the equipment.
Meanwhile, this company continuously improves the informatization system construction of equipment management thldl.org.cn, providing strong support for equipment management information transmission, equipment file management, professional technical management, data statistics and analysis, etc.
Refinement in the Management Process: Striving for Perfection in Every Link
Refinement in the management process becomes increasingly important for the long-term reliable operation of equipment. To overcome the contradiction between tight repair costs and increasingly severe safety production situations, all units of this company strictly control project approval from the start of various equipment repairs and major overhaul updates, adhering to the principle of "repair when necessary, repair well," striving not to miss any equipment隐患and defects, nor conduct excessive repairs. The company shifts the focus of work to daily basic management, strengthens archive and document management, and enters fault repair information, ensuring the accuracy of plans through strengthening pre-repair data collection and accumulation of daily basic documents.
In construction management, this company proposes the requirements of "four non-dos" for construction personnel and "five non-dos" for project construction parties, extending process control over equipment to every detail, adopting comprehensive control measures, greatly avoiding risks brought by construction. At the same time, this company fully utilizes the maintenance construction forecast system, allowing relevant personnel to fully understand construction tasks, ensuring clarity.
To control the entry of raw materials and parts into the factory, this company guarantees reliable equipment operation from the source. The mobile department and material supply units closely cooperate, formulating related management details, strictly limiting the access threshold of manufacturers, laying a foundation for reducing equipment failures.