This standard is formulated in order to strengthen the management of various inspection and maintenance projects, ensure the long-term safe operation of production devices and the safety of inspection and maintenance disassembly process, improve the quality of inspection and maintenance, and ensure safe production.
2 Scope of application
This standard is applicable to the management of operation, inspection, maintenance, dismantling and scrapping of all production facilities in the plant area of PVC project, as well as the management of technical measures and technical transformation projects implemented by the production technology department or relevant departments.
3 management responsibilities
3. 1 Responsibilities of Safety and Environmental Protection Department
3. 1. 1 Responsible for the overall safety supervision of the inspection and maintenance site.
3. 1.2 special operation ticket approval.
3.2 Responsibilities of Equipment Department
3.2. 1 Be responsible for the whole process management of the equipment of the inspection and maintenance project.
3.2.2 Prepare and report the annual maintenance plan and the plant shutdown maintenance construction plan.
3.2.3 Responsible for the implementation of materials required for inspection and maintenance.
3.3 Responsibilities of branches
3.3. 1 Cooperate with the equipment department to prepare the factory shutdown maintenance plan and construction plan.
3.3.2 Cooperate to manage the whole process of equipment maintenance.
3.3.3 Organize the daily maintenance of equipment.
4 Maintenance plan management
4. 1 All kinds of maintenance projects should be included in the plan management, go through the formalities of application for examination and approval, and arrange for implementation after being approved by the general manager of PVC project.
4.2 Annual Plan
The production technology department and various equipment use departments apply for the next year's factory shutdown maintenance plan and single equipment maintenance plan, complete the preparation of the annual maintenance plan and report it to the equipment department.
4.3 month plan
Before 20th of each month, the production technology department and the equipment department shall prepare the equipment maintenance plan for next month according to the annual plan and daily equipment operation.
4.4 Device Shutdown Maintenance Plan
Any equipment maintenance project plan included in the annual maintenance plan of that year shall be completed and reported to the Equipment Department before February of maintenance. If the scheduled maintenance time is delayed due to production and other reasons, the adjusted and confirmed equipment maintenance plan shall be submitted to the Equipment Department one week before the official shutdown.
4.5 The technical transformation project proposed by the plant and workshop must go through the process technical change procedures, and be submitted to the Equipment Department with the consent of the production technology department, and be included in the maintenance plan after the approval of the maintenance project review meeting.
4.6 45 days before the officially confirmed maintenance date, the workshop can make necessary supplements and adjustments to the maintenance project plan and complete the examination and approval procedures.
4.7 All equipment departments shall, according to the adjustment of the project, prepare and complete the implementation plan of factory shutdown and maintenance one month before the planned shutdown, and distribute it to relevant departments to implement the construction maintenance team and machines.
4.8 The outsourcing of equipment and equipment maintenance projects shall arrange the construction unit to carry out maintenance according to the Management Standards for Construction Contractors of PVC Projects and the approved maintenance business scope.
5 Maintenance and construction management
5. 1 Each branch factory should seriously prepare for the shutdown and maintenance of the device, and set up a maintenance headquarters to implement unified leadership, unified planning and unified command for the maintenance work, and its members should have a clear division of labor.
5.2 The shutdown maintenance project shall be determined from five aspects, namely, maintenance scheme, maintenance personnel, safety measures, maintenance quality and maintenance progress.
5.3 The person in charge of maintenance should carefully check and prepare the machines, materials and equipment for maintenance, and make arrangements for all kinds of machines, materials and equipment.
5.4 The parking, maintenance and start-up plan and its safety measures must be made for the parking and maintenance of the device. The overhaul scheme and safety measures of major projects shall be discussed by relevant departments, approved by the general manager, published in written form and strictly implemented.
5.5 Before the maintenance personnel enter the site, safety management measures for shutdown and maintenance shall be formulated. The maintenance headquarters shall hold a mobilization meeting to educate all personnel participating in the maintenance on the safety management system and safety operation procedures, raise safety awareness and implement safety measures for shutdown and maintenance.
5.6 When signing a contract for outsourced maintenance projects, a construction safety agreement must be signed at the same time, stipulating that the construction unit shall take full responsibility for the safety work of contracted maintenance projects, requiring the construction unit to strengthen its own safety management, strictly implement the safety management regulations for PVC projects, and accept the unified supervision and inspection by the safety and environmental protection department.
5.7 In the outsourcing construction project of equipment maintenance, the entrusting department must designate a special person to be responsible for the technical disclosure of the maintenance project to the construction unit, grasp the construction progress, quality and safety, and coordinate the work in time.
5.8 The external units and their personnel involved in maintenance must receive safety education from the safety and environmental protection department, and they can enter the maintenance site only after passing the examination.
5.9 The parking of the device shall be under the unified command of production scheduling, and the safe parking shall be ensured according to the parking plan.
5. When the10 device is stopped, all materials entering and leaving the device shall be cut off according to the stopping plan and process requirements, and the device area shall be withdrawn as required. The recovery, neutralization, detoxification and discharge of chemically contaminated water with inflammable, explosive, toxic and corrosive substances shall strictly implement the national industrial hygiene discharge standards and shall not be discharged at will. The pressurized evacuation of flammable and explosive gases should be carried out slowly, and the pressure should be gradually reduced. Fire prevention measures must be taken at the end of the venting pipeline.
5. 1 1 Equipment, containers and pipelines containing toxic, flammable and corrosive substances should be thoroughly purged with steam, neutralized with acid and alkali, replaced with nitrogen and replaced with air within the specified time, so that there is no residue or residual gas in them, and sampling analysis should meet the safety technical requirements. After the analysis is qualified, plug it with a blind plate that meets the requirements of its process pressure grade to isolate it from the corresponding equipment, pipelines and systems. Adding blind plates shall be carried out in strict accordance with the shutdown plan and blind plate diagram (table), and marked, and designated personnel shall be assigned for unified numbering management to prevent leakage, blockage and pumping.
5. 12 During shutdown and maintenance, if there are flammable, explosive, toxic and harmful substances remaining in tanks, tanks, towers, pipelines and other equipment, a blind plate with the same process grade should be added at the exit, entrance or the connection with the equipment system, and a warning sign "Materials are available, pay attention to fire prevention or gas prevention" should be hung, and a special person should be appointed to take care of it.
5. 13 Before opening the equipment manhole, the internal temperature and pressure should be reduced to a safe state and opened from top to bottom. When opening the bottom manhole, first open the bottom discharge vent valve, and then enter the manhole after confirming that there is no blockage or residual material inside. Before loosening the manhole cover, remember not to disassemble all the screws to avoid scalding people.
5. 14 clean up the open ditches, pits (including other drainage wells), the ground, platforms and equipment, and the oil stains and materials outside the pipeline in the device area to avoid fire and explosion.
5. 15 There should be clear handover procedures and procedures for production and maintenance. All technical treatments must be checked and confirmed by relevant personnel before maintenance and construction can be carried out.
5. 16 All maintenance personnel must wear personal protective equipment as required when entering the construction site.
5. 17 Anyone who enters toxic and harmful parts (including equipment, trenches and underground wells) should be tested first, and then can enter the equipment for operation after passing the test. The operation sheet requires indoor operation, and special protective articles such as gas masks, oxygen respirators and air respirator should be selected to prevent poisoning and suffocation.
5. 18 During the maintenance operation, the prohibitions and regulations on safety in production must be strictly observed, and it is strictly forbidden to implement the ticket management system for safety operation and the general safety management regulations for entering the production device.
5. 19 Special operators must hold valid operation certificates to work at their posts.
5.20 At the maintenance site for interchange operation, the units involved in maintenance and construction must have specific safety assurance measures and schemes.
5.2 1 During the maintenance period, it is necessary to strengthen the security work, assign special personnel to patrol and inspect 24 hours, maintain key parts of key equipment, and control irrelevant personnel to enter and leave at will.
5.22 During the maintenance period, it is necessary to ensure that the fire-fighting roads in the factory are unblocked, the fire-fighting water pressure is sufficient, and all kinds of fire-fighting equipment are complete and easy to use.
5.23 The safety management personnel of the maintenance headquarters shall conduct a comprehensive inspection of the construction site, strengthen safety supervision and inspection, and have the right to stop and assist in the formulation of safety measures if any operation or violator that endangers safety is found.
5.24 After equipment maintenance, there should be obvious handover procedures between maintenance and production. The construction site must be finished, the material is clean and the site is clear. Toxic and harmful scrap metal, equipment and pipelines should be handled safely by special personnel to prevent future troubles. After overhaul, the equipment and pipelines must be cleaned and sealed after careful inspection, with inspection records and signatures of maintenance personnel.
5.25 After the equipment is overhauled, the overhaul unit shall organize relevant departments to check and accept the overhaul items and startup scheme of shutdown device item by item, and sign for confirmation.
5.26 Before driving, conduct a comprehensive inspection of all safety facilities such as ventilation, communication, fire fighting, ladders, platform railings and lighting, and keep them in good condition.
5.27 Before the start of the plant, the system diagram and operation procedures must be revised in time according to the changes of technology and equipment, instruments and electricity, and strict training should be given to the post workers. After passing the examination, you can operate at your post.
5.28 After maintenance, pressure vessels, pressure pipes and other facilities must be tested for pressure resistance, leakage and air tightness according to regulations, transmission equipment should be tested by single machine, and safety devices should be debugged and reset. Equipment, pipelines, instruments and interlocks that fail the pressure test cannot be put into production to ensure the successful start-up.
5.29 The closed equipment and pipelines with inflammable and explosive substances as the medium must be replaced by gas according to the technological requirements before feeding. After the analysis is qualified (an analysis sheet must be issued), blind plates shall be drawn and blocked one by one according to the blind plate number according to the contents specified in the blind plate drawing and blocking flow chart, and no omission shall be allowed. The person in charge of maintenance must review and confirm.
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