CN110874712A

CN110874712A - Modeling method of equipment integrity management system

Info

Publication number: CN110874712A
Application number: CN201811022554.6A
Authority: CN
Inventors: 许述剑; 刘小辉; 屈定荣; 孙德青; 邱志刚; 方煜
Original assignee: China Petroleum and Chemical Corp; Sinopec Qingdao Safety Engineering Institute
Current assignee: China Petroleum and Chemical Corp; Sinopec Qingdao Safety Engineering Institute
Priority date: 2018-09-03
Filing date: 2018-09-03
Publication date: 2020-03-10

Abstract

The invention relates to a modeling method of an equipment integrity management system, which mainly solves the problem that the equipment integrity management system in the prior art is incomplete. The invention adopts a modeling method of an equipment integrity management system, and adopts an equipment integrity management system structure model to carry out equipment integrity management, wherein the structure model comprises a primary element and a secondary element, and the primary element comprises an organization environment, a leader function, a plan, a support, an operation, a performance evaluation and an improvement; the secondary elements comprise technical schemes of laws and regulations, other requirements, initial condition review and planning of the equipment integrity management system and the like, the problems are well solved, and the method can be used in the equipment integrity management system.

Description

Modeling method of equipment integrity management system

Technical Field

The invention relates to a modeling method of an equipment integrity management system.

Background

In recent years, along with the upsizing of refining and chemical devices, the continuous deterioration of processing raw materials, the heavy production task, the rigor of equipment operation environment, the stricter requirements on safety and environmental protection, etc., the management work of Chinese petrochemical equipment shows many defects and problems, which affect the safe, stable and long-period operation of the devices, for example: the enterprise manages landslide in a 'three-base' manner; the management standard of the whole process of the equipment is not high, and the gate is not strict; the production device is not standard in maintenance management problems and maintenance cost; the investment for equipment operation maintenance and updating and reconstruction is insufficient; equipment corrosion, leakage, equipment accidents, unplanned shutdowns and even frequent occurrences of individual enterprises, etc.

At present, with the further deepening of the innovation of the petrochemical enterprise system, equipment management work faces new situation, new problems and new challenges, the active exploration and innovation of an equipment management mode is not only the situation requirement, but also the consensus of enterprises, the equipment management mode becomes a new normal state, the practical contradiction is solved through mode innovation, and the development of equipment management is promoted. The method has important significance in exploring and practicing the refining enterprise equipment integrity management mode by referring to the foreign integrity management concept and combining with the practical refining enterprise equipment management method because the equipment integrity management mode is carried out by the advanced petrochemical enterprises abroad, wherein the requirement of the improvement army to establish an equipment integrity management system is China petrochemical, and the 2006 year 07.

Disclosure of Invention

The technical problem to be solved by the invention is that the equipment integrity management system in the prior art is incomplete, and the invention provides a novel modeling method of the equipment integrity management system, which has the advantage of complete equipment integrity management system.

In order to solve the problems, the technical scheme adopted by the invention is as follows: a modeling method of an equipment integrity management system adopts an equipment integrity management system structure model to carry out equipment integrity management, wherein the structure model comprises a primary element and a secondary element, and the primary element comprises: organizing environment, leading function, planning, supporting, running, performance evaluation and improvement; the secondary elements include:

1) legal and other requirements;

2) evaluating and planning the initial condition of the equipment integrity management system;

3) risk management planning;

4) equipment selection and hierarchical management;

5) training;

6) managing risks;

7) ensuring the process;

8) professional management of equipment;

9) inspection, testing and preventive maintenance;

10) managing defects;

11) change management;

12) control of externally provided processes, products and services;

13) monitoring, measuring, analyzing and evaluating;

14) and (6) performing external auditing.

In the above technical solution, preferably, the elements are associated and interpenetrated with each other to form a benign and continuously improved PDCA management cycle, so as to ensure systematicness, uniformity, and normalization of the system, and achieve integrity and comprehensive optimization management of enterprise equipment.

In the above technical solution, preferably, the equipment selection and hierarchical management means that an enterprise makes a selection criterion according to a production and operation plan, an equipment management target or requirements of laws and regulations, and brings equipment into the scope of an integrity management system; meanwhile, according to the importance of the equipment in the device, the harmfulness of the equipment after an accident, the influence degree on safety and environmental protection and the influence severity degree on product quality, an enterprise establishes a definite equipment grading method and carries out grading management on the equipment, so that the equipment management is effectively carried out, and the equipment repair fund is reasonably used.

In the above technical solution, preferably, the risk management means that an enterprise should identify risks and evaluate influence factors, consequences and possibilities thereof at each stage of a full life cycle of the device, classify and grade the risks, and timely manage and control the identified risks to ensure that the identified risks are at an acceptable level.

In the above technical solution, preferably, the process assurance means that an enterprise establishes and maintains a corresponding quality control standard in order to identify and develop quality assurance activities of each process of the whole life cycle of the equipment, and takes effective or appropriate quality control measures to meet quality requirements of relevant laws, regulations, standards, technical specifications, and enterprise-specified documents, so as to realize control of the equipment process, and further effectively control performance, risk, and cost of the equipment system, and ensure that the equipment quality meets requirements of an equipment integrity management system.

In the above technical solution, preferably, the professional management of the device is a technical carrier of the integrity management of the device, and an enterprise should identify and determine professional management contents of the whole life cycle of the device, actively apply and optimize and improve related risk technologies, provide technical support for preventive maintenance of the device, and meet technical requirements required by management decisions, including professional management of static devices, professional management of dynamic devices, professional management of electrical devices, professional management of instrumentation devices, comprehensive professional management, and power management.

In the above technical solution, preferably, the checking, testing and preventive maintenance, referred to as ITPM for short, refers to systematic checking, detecting and active maintenance activities that are taken by an enterprise to ensure that equipment continuously conforms to its prescribed functional state, which is the core content of an equipment integrity management method, and aims to establish an ITPM management program, implement an equipment integrity plan in the process of making an ITPM plan and implementing an ITPM task, and implement and improve the reliability of the equipment.

In the above technical solution, preferably, the defect management means that an enterprise effectively identifies, responds, communicates, and eliminates the defects of the device at each stage of the life cycle of the device, so as to implement closed management of the defects, avoid failure and malfunction of the device, ensure the sound condition of the device, and ensure safe, stable, and long-term operation of the device.

In the above technical solution, preferably, the equipment change management means to manage and control the process of equipment change to enhance enterprise equipment change management, and ensure that the equipment change can be correctly applied, risk evaluated, approved, executed, accepted and notified, thereby eliminating risks and preventing new accident potential.

In the above technical solution, preferably, risk management and defect management are key, so that monitoring and discovery of equipment problems are core, inspection, testing and preventive maintenance are core, the equipment problems are addressed, failures and accidents are prevented, target planning, policy and resource support are continuously improved according to the reality of risk assessment and preventive maintenance, quality assurance is to ensure that all management activities reach the expected production management target and meet relevant laws, regulations and standards, and final performance assessment and corrective preventive measures, management review and continuous improvement are to check and feedback the effects of the management activities.

The method aims to solve the problems that equipment management of oil refining and chemical industry enterprises in China faces 'three-base' landslide management under a new situation, the overall process management standard of the equipment is not high, the customs is not strict, the quality of device inspection and maintenance is not high, the investment for equipment operation and maintenance is not sufficient, the use of maintenance cost is not standard, the investment for equipment updating and transformation is not sufficient, and the like, and promote long-period safe operation of the enterprises. Meanwhile, a unified equipment management system and standard of China petrochemical industry are formed, and a good method is shared and inherited; the transition from traditional experience-based and fragment-based equipment management to systematized risk-based equipment management is realized; the improvement of equipment management is promoted, and the improvement of equipment engineering technology and the optimization of an equipment management system are comprehensively considered. The invention provides an equipment integrity management system structure model, and enterprises can ensure that equipment meets the expected functions, improve the equipment management level, eliminate equipment hidden dangers, prevent equipment accidents, improve the safety, reliability and economic operation level of the equipment, ensure the safe, stable and long-term operation of the enterprises and obtain better technical effects by establishing and implementing an equipment integrity management system.

Drawings

Fig. 1 is a model of the device integrity management architecture of the present invention.

The present invention will be further illustrated by the following examples, but is not limited to these examples.

Detailed Description

[ example 1 ]

A modeling method of a device integrity management system, as shown in fig. 1, provides a device integrity management system structure model, which includes a first-level element:

(1) organizing the environment

(2) Leadership function

(3) Plan for planning

(4) Support for

(5) Operation of

(6) Performance evaluation

(7) Improvements in or relating to

Meanwhile, secondary elements which embody the management characteristics of the integrity of the equipment are set, and the method comprises the following steps:

1) laws and regulations and other requirements

2) Device integrity management system initial condition review and planning

3) Risk management plans

4) Device selection and hierarchical management

5) Training

6) Risk management

7) Process assurance

8) Professional management of equipment

9) Inspection, testing and preventative maintenance

10) Defect management

11) Change management

12) Control of externally provided processes, products and services

13) Monitoring, measuring, analyzing and evaluating

14) External auditing

The elements are correlated and interpenetrated to form a benign and sustainable improved PDCA management cycle, as shown in the following figure, so as to ensure the systematicness, the uniformity and the normalization of the system, and realize the integrity and the comprehensive optimization management of enterprise equipment.

The equipment selection and hierarchical management means that enterprises make selection criteria according to production and management plans, equipment management targets or requirements of laws and regulations, and some equipment is brought into the scope of an integrity management system. Meanwhile, according to the importance of the equipment in the device, the harmfulness of the equipment after an accident, the influence degree on safety and environmental protection and the influence severity degree on product quality, an enterprise establishes a definite equipment grading method and carries out grading management on the equipment, so that the equipment management is effectively carried out, and the equipment repair fund is reasonably used.

Risk management means that an enterprise identifies risks at each stage of the whole life cycle of equipment, evaluates influence factors, consequences and possibility of the risks, classifies and grades the risks, and timely manages and controls the identified risks to ensure that the identified risks are at an acceptable level.

Process assurance refers to establishing and maintaining corresponding quality control standards for enterprises to identify and develop quality assurance activities of each process of the whole life cycle of equipment, taking effective or appropriate quality control measures to meet the quality requirements of relevant laws, regulations, standards, technical specifications, enterprise regulations and other documents, realizing the control of the equipment process, further effectively controlling the system performance (efficiency), risks and cost of the equipment, and ensuring that the equipment quality meets the requirements of an equipment integrity management system.

The professional management of the equipment is a technical carrier for the integrity management of the equipment, and enterprises need to identify and determine professional management contents of the whole life cycle of the equipment, actively apply, optimize and improve related risk technologies, provide technical support for preventive maintenance of the equipment and meet technical requirements required by management decisions. The method generally comprises static equipment professional management, dynamic equipment professional management, electrical equipment professional management, instrument equipment professional management, comprehensive professional management, power management and the like.

Inspection, testing and preventive maintenance (ITPM for short) refers to systematic inspection, detection and active maintenance activities that an enterprise takes to ensure that equipment continuously conforms to its prescribed functional state. The method is the core content of the equipment integrity management method, and aims to establish an ITPM management program, implement the equipment integrity plan and realize and improve the reliability of equipment in the processes of preparing the ITPM plan and implementing the ITPM task.

The defect management means that an enterprise effectively identifies, responds, communicates and eliminates the defects of the equipment at each stage of the service life cycle of the equipment, so that the closed management of the defects is realized, the faults and the failures of the equipment are avoided, the sound state of the equipment is ensured, and the safe, stable and long-period operation of the device is ensured.

The equipment change management is to manage and control the process of equipment change to enhance the enterprise equipment change management, ensure that the equipment change can be correctly applied, risk evaluated, approved, executed, accepted and informed, eliminate the risk and prevent new accident hidden dangers.

The risk management and defect management are key, so that equipment problems are monitored and discovered, inspection, testing and preventive maintenance are core, the equipment problems are addressed, faults and accidents are prevented, target plans, policy strategies, resource guarantee support and the like can be continuously improved according to the actual risk assessment and preventive maintenance, quality assurance is to ensure that all management activities reach the expected production management target and meet related laws, regulations and standards, and final performance assessment and correction preventive measures, management evaluation and continuous improvement are to check and feed back the effects of the management activities.

[ example 2 ]

The method of example 1 is used in the martian petrochemical plant integrity management architecture.

I, Wuhan petrochemical equipment integrity management system test point construction

In order to improve the safety and reliability of long-period operation of the device, the China petrochemical oil refining division determines that the Wuhan petrochemical industry is a pilot unit to carry out an 'oil refining enterprise equipment integrity management system', and carries out equipment management innovation work. The establishment and implementation work plan of the equipment integrity management system is divided into five stages:

the first stage is as follows: status quoting

And a second stage: overall plan

And a third stage: system document authoring and review

A fourth stage: device integrity management architecture implementation

The fifth stage: review and management review

1. Presence assessment

The evaluation aims to know the current situation of equipment management of Wuhan petrochemical industry, find out differences by comparing 'equipment integrity management system specifications' and 'implementation guidelines', and obtain strategic improvement suggestions, determine improvement directions and promote targets on the basis of difference analysis. Meanwhile, the method is also used for inspecting and perfecting the applicability of system elements through current situation evaluation, and provides a basis for revising and perfecting the 'specification' and 'guide'.

(1) Device management Presence overview

The equipment management work in the present stage of the martian industry obtains abundant results in system construction, tool application, resource management, index assessment, system construction (HSE system and quality system and equipment related parts) or other aspects. In the aspect of system, the system not only follows the relevant equipment management system of headquarters, but also is enriched and perfected according to the actual situation of martial and petrochemical industry, covers each life cycle of design, manufacture, operation, maintenance and inspection and repair, and has more comprehensive existing management system and program files. The use of information-based work and risk management tools, such as development and use of equipment information management platforms, use of EM, and pilot work of DRBPM, RCM, RBI, etc., is also actively promoted in tool application.

The Wuhan petrochemical industry also defines the equipment management target at the present stage:

1) no report on headquarter equipment accidents;

2) no unplanned shutdowns due to equipment;

3) no large-area power failure accident;

4) the equipment fault intensity is reduced by 10% on a same scale;

5) the rate of equipment burst faults is less than 10%;

6) the failure rate of the large unit is less than 0.18 percent;

7) the leakage rate of the static sealing point is less than 0.01 percent;

8) the instrument control rate is more than 95 percent;

9) the thermal efficiency of the heating furnace is more than 92.2%;

10) the cost accuracy of the equipment maintenance plan is 80% -120%.

Technical indexes which can be achieved by the equipment management work at the present stage are as follows (reference is made to the statistical results in 2012 and 2013):

table 12012 years wuhan petrochemical equipment technical index completion statistical table

Table 22013 years equipment technical index completion statistics table

The static equipment is monitored, detected and managed in five aspects of process corrosion prevention, water quality monitoring, special equipment detection, heating furnace monitoring, pressurized plugging and heat preservation general investigation in daily life. And a corresponding annual and monthly inspection plan is made, and corresponding indexes are tracked and monitored. And (4) collaboratively making a detection and maintenance plan by the laboratory workshop, the equipment monitoring center and the workshop, and specifically implementing the inspection and maintenance work in the workshop. Meanwhile, RBI trial work is also carried out in the aspect of quiet equipment management, and a risk management tool is introduced.

The movable equipment mainly focuses on the indexes of the completeness rate, the first-time overhaul qualification rate, the service rate, the equipment fault strength and the like of the examination equipment, and is analyzed and summarized month by month to form a technical monthly report. Meanwhile, the dynamic state of maintenance is checked, the sealing leakage is concerned, the statistical analysis and summary are carried out on fault accidents, and the technical attack and the technical clearance are carried out on the reason analysis and the processing of certain accidents. The equipment monitoring center practically carries out vibration state monitoring, lubricating oil monitoring, maintenance of an air compressor and the like, and a workshop carries out daily inspection and monthly post inspection according to a plan. In addition, the active device management also actively pushes the DRBPM and RCM application work.

The electrical equipment mainly focuses on equipment availability factor, relay protection action rate, illumination availability factor and the like, the instrument equipment mainly focuses on availability factor, utilization rate, control rate, leakage rate and the like, the treatment of equipment problems is promoted through a plurality of inspection activities such as company post inspection, headquarter safety major inspection, professional monthly inspection and the like, some equipment problems are radically treated through preventive maintenance work, and the three rates of the electrical equipment and the instrument equipment can basically reach established targets. The electrical instrumentation aspect introduces no risk assessment or management tools for a while.

(2) Status quoting

1) The Wuhan petrochemical industry has acquired abundant experience and achievements in the aspects of system construction, tool application, resource management, index assessment, system construction (HSE system, quality system and relevant parts of equipment) and the like in equipment management. In the aspect of system, not only all equipment management systems of headquarters are well executed, but also the improvement is carried out according to the Wu petrochemical industry reality, and all life cycles of design, manufacture, operation, maintenance and inspection and maintenance are covered. The use of information-based and risk management tools, such as development and use of equipment information management platforms, EM, DRBPM (reliability-based equipment dynamic preventive maintenance platform), RCM, and RBI, is also actively promoted in the application of management tools.

2) Through equipment management current situation evaluation, the 'equipment integrity system standard of an oil refining enterprise' is verified to cover the existing equipment management content of the enterprise, and 10 sub-elements reflect the characteristics of equipment management in the petrochemical industry, absorb risk concepts and integrity management requirements and accord with the direction of continuous improvement of an equipment management system of the enterprise.

3) In a table of 'Wuhan petrochemical equipment integrity status assessment summary', qualitative risk analysis is carried out on the found conditions, and a risk matrix is as follows:

TABLE 3 Risk matrix

"degree of difference" refers to the difference in the described problem against the elements of the "specification" of the device integrity management system:

a-a program is established and meets the requirements of system elements;

b-establishing corresponding management program and system files, and effectively implementing the management program and the system files in actual work, but further improving the technical level by contrasting with the gap of advanced practice;

c-building corresponding management programs and system files, but having defects in program execution in actual work;

d-has no related management program and system.

"importance" refers to the degree of importance of the impact of the problem on system operation and equipment safety:

high-direct impact on equipment safety risk or equipment reliability;

the device security risk or device reliability is influenced by a medium-indirect method;

low-with less impact on the device security risk or device reliability.

Analysis of 34 records according to the above criteria, total:

high risk of 6 items;

6 items with medium to high risk;

there are 14 items at risk;

low risk of 8 items.

The results show that the above risks are the majority, and the evaluation work aims to find the difference between the current management practice and the requirement of the equipment integrity management system specification and provide direction and support for the next system planning. Therefore, some good practices and rich experiences in the management of martial arts petrochemical equipment are not described, and the emphasis is placed on the difference description of 10 elements.

4) Analysis of the 34 items evaluated is to find the gap required by current management and "system specifications". According to the aspects of 'whether a management program is established, field implementation content and technical means' and the like, brief statistics is carried out on 10 elements, and specific evaluation conditions are shown in '2 and evaluation conditions and suggestions of all elements'. Among them, the several elements with large differences are:

4.3 organizational organization and responsibility, personnel training and document control C

4.4 Risk management D

4.7 Defect management D

4.8 Change management C

4.9 Performance assessment and corrective precautions C

Therefore, the next stage will mainly work around the required contents of these several elements, including the work of programming and standardization.

TABLE 4 element difference comparison Table

2. System plans

(1) Analyzing and summarizing important activities and key processes of equipment management of oil refining enterprises, and identifying the key processes which have great influence on the integrity of the equipment. The method specifically comprises the following steps:

4.3 organizational organization and responsibility, personnel training and documentation control

4.4 Risk management

4.7 Defect management

4.8 Change management

4.9 Performance assessment and corrective precautions

(2) Aiming at the comparison between the current enterprise equipment management content and an equipment integrity management system, the method covers the actual working key points of equipment management and forms a Wuhan petrochemical equipment integrity management element and enterprise actual working key point comparison file.

(3) Related system files are managed by the Wuhan petrochemical equipment, and a Wuhan petrochemical integrity system file directory, a newly added management program and a management method are formed.

3. Three-level architecture file creation

The establishment of the system file is an important stage of the construction process of the equipment integrity management system, and a special writing group is established by combining the actual requirements of an enterprise and the requirements of the system file in the documentation process. In the process of compiling the Wuhan division system files, reference is made to the data of a medium petrochemical equipment management system catalog, a TUV integrity file catalog, a Qingdao refining equipment management system catalog, a Jinan refining equipment management catalog, a Fujian united petrochemical equipment management catalog, CCPS related files and the like. The authoring team should perform a survey analysis on the relevant documents before starting the authoring task, in which process the following tables can be referenced.

TABLE 5 File Compare sheet

Elements of management manual	Program file	System of events	Operating files	System of group company	Remarks for note
						1
1.1
						…
2
						2.1
…

The documentation process mainly comprises the following basic steps: (1) collecting task information; (2) drafting a file; (3) draft document examination; (4) verifying the file; (5) modifying the file; (6) approval and release; (7) a periodic review piece; (8) and (4) updating periodically.

In the writing process of the system files, three-level file architectures of manuals, program files and operation files are generally included, the manuals mainly cover the contents of guidelines, targets, commitments and the like respectively aiming at the highest management layer, the middle management layer and the production operation layer, the program files mainly include management system programs and operation control programs, and the operation files may include operation guide files and basic management related files.

In the martian petrochemical system documentation process, according to the previous state evaluation result and system plan files, the files are compiled aiming at the aspects of equipment inspection, test and preventive maintenance management, defect management, quality assurance, risk management and the like, and the method mainly comprises an equipment inspection, test and preventive maintenance management program, an equipment defect management program, an equipment inspection maintenance plan cost management program, an equipment integrity performance management program, an equipment quality assurance management program, 5 equipment integrity management programs, an equipment risk evaluation management method, an equipment fault root cause analysis management method and an equipment change management rule 3 management systems.

4. Operation of the system

In the operation of the equipment integrity management system of the martian petrochemical industry, firstly, the construction of an operation framework is carried out aiming at the equipment integrity system, and according to the actual management condition of an enterprise, the equipment integrity system framework is considered from 3 latitudes: the 1 st latitude is a device integrity management element, the 2 nd latitude is device professional management, and the 3 rd latitude is a device management hierarchy. The system and the method realize the whole period, the whole process and the all-round integrity management of equipment management through three dimensions, and realize the integration and implementation of the integrity management and the real equipment management work through system files, work flows, work forms and information subsystems established by modules of a framework structure, namely, the existing equipment management system, the existing flow and the existing forms are applied to a three-dimensional management framework according to the requirement of the equipment integrity management.

Secondly, establishing an equipment integrity technical support center, and performing test points, wherein the test points are divided into three parts: the first part is used for testing in a united workshop, so that problems are exposed, and improvement is perfect; the second part is to take the united workshop and the united three workshops as a film area for trial, expose problems and improve the quality; and in the third part, the trial experience of the tablet areas of the united workshop and the united three workshops is popularized to the coking tablet area, the experience is summarized, and the method is comprehensively popularized in Wuhan division.

And developing a series of propagative training of equipment integrity management. The revised and newly compiled programs and operation files are used for training relevant workers, the training work is divided into 3 levels of a management layer, a technical layer and an operation layer, the training of the management layer is focused on a manual, a system and a flow, and the management layer is responsible for a management department and a maneuvering department; the application of the training professional management and management technology and method of the technical layer is responsible for equipment professional teams and Qingdao security institutes; the operation layer side is focused on training of operation instruction, form application and the like and is responsible for professional teams and workshops of all equipment. The training content generally includes risk assessment methods, risk-based inspection, testing and preventive maintenance, quality assurance, defect management, change management, critical equipment control measures, and the like.

The implementation of management elements and professional elements is realized by selecting change management elements and field management sub-elements, implementing the change management elements and the field management sub-elements in each professional management, finding out difficulties and accumulating experiences, and popularizing the implementation of other elements in each professional management. And secondly, selecting the professional of the rotating equipment from 10 major elements of equipment integrity management, comprehensively implementing according to 3 levels of the professional, the area and the device, carving out a sample plate, and then stably following other 8 major industries for management. On the basis of element implementation, research and test point application of equipment management KPI indexes are carried out, and the method is used for promoting continuous improvement of an equipment integrity management system.

And performing informatization construction on the summary experience. Device management informatization is an important support for the effective implementation of device integrity management. Based on the traditional equipment management information system of the Wuhan petrochemical industry, enrichment and improvement are carried out according to the requirement of equipment integrity management and the requirement of professional management, on the basis, system integration is carried out according to an equipment integrity management framework, and an equipment integrity management platform is specially developed and used for supporting system operation.

5. Review and management review

The main content of the stage is to train auditors, implement enterprise integrity management audit and perform equipment management review. The training content of the auditor comprises equipment integrity system specification and implementation guidance, enterprise risk-based management theory and auditing method. The management and review needs to perform trend analysis and review of related contents on the basis of collecting the performance indexes of the equipment. And (4) correcting the disagreement found in the auditing and management review, making preventive measures, simultaneously proposing continuous improvement measures and compiling a management review report.

Different from the auditing of other systems, the equipment auditor requires to master the auditing knowledge of the system and also has the professional skill of the equipment. The equipment management department and auditors of all units can master the auditing knowledge of the system, and master the auditing skill by participating in the on-site auditing, thereby continuously improving the equipment integrity management system. The training content may include: standard knowledge related to equipment, system auditing knowledge, management and review related knowledge, auditing methods and skills and the like.

6. Application effects

The pilot test work obtains good effect, and the application condition of the integrity system is as follows:

(1) according to the oil refining enterprise equipment integrity management system specification and the oil refining enterprise equipment integrity management system specification implementation guide, according to ten element requirements of the specification, the management status of the Wuhan petrochemical equipment is firstly evaluated, the elements are compared one by one, the difference between the management and integrity management requirements of the Wuhan petrochemical equipment is found, meanwhile, the existing equipment management content of an enterprise can be covered by verifying the 'oil refining enterprise equipment integrity system specification', 10 sub-elements not only reflect the characteristics of equipment management in the petrochemical industry, but also absorb the risk concept and the integrity management requirements, and accord with the direction of continuous improvement of an enterprise equipment management system.

(2) In the aspects of integrity management responsibility, corresponding organization and architecture, risk management, use of risk tools, training and resource guarantee, defect management, root cause analysis, equipment change management programs, quality assurance, equipment reliability management, maintenance contractor management and the like, corresponding improvement and improvement suggestions are provided for the existing equipment management of Wuhan petrochemical industry according to the requirements of each element of the integrity system, beneficial references are provided for supplementing and perfecting corresponding systems and programs, and the Wuhan petrochemical industry comprehensively improves and perfects related weak items according to the corresponding suggestions.

(3) Deep combing research is carried out aiming at two elements of change management and defect management, the Wuhan petrochemical change management has the defect of insufficient hierarchical management, the defect management needs to be further streamlined, and root cause analysis is enhanced. The two elements are used as breakthrough ports to plan the integrity management system of the Wuhan petrochemical equipment.

(4) In the trial work, the improvement and perfection work of the integrity management of Wuhan petrochemical equipment in many aspects is gradually developed through the current situation assessment, trial planning and management system file carding: an equipment support center is set up, and powerful support and guarantee are provided for realizing equipment integrity management on the basis of an organization architecture; in the aspect of equipment management, the authority and the practice are more implemented to corresponding departments such as maneuvering departments, and the management efficiency is improved; modifying the original management system of some dynamic equipment and static equipment; , the management contents in the aspects of risk identification, registration, evaluation and the like are further refined in the aspect of risk management consensus; further introducing risk management tools such as DRBPM; beneficial attempts are made on equipment change management, management key points of different changes are defined clearly, responsibility of each department on equipment change management is defined clearly, particularly coordination of production process departments and maneuvering departments on change management is avoided, and careless omission is avoided; for defect management, related management processes and information systems are combed, and root cause analysis of defects and failure failures is further enhanced; the method is characterized in that equipment data management is enhanced, particularly data circulation among different information systems and effective utilization of the equipment information data are achieved, and Wuhan petrochemical industry systematically combs and performs resource utilization on related equipment information data by means of defect management and subsequent system development. With each party's efforts, the management elements of the system are running step by step and some expected good results have been achieved.

By integrating the above, the implementation of the equipment integrity management system of the oil refining enterprise achieves a better effect, wuhan petrochemical industry introduces the integrity management system, formulates related program files and management systems, introduces the preventive maintenance system of the mobile equipment, establishes an equipment monitoring and protection technical center and other specific measures, modifies 5 management elements, and manages, improves and promotes the related elements. The integrity management system of the Wuhan petrochemical equipment is established, the management weakness is strengthened, and the equipment management level is improved.

The equipment failure intensity situation of whole factory is the decline trend, and 2012-2015 year equipment failure intensity month average deduction trend respectively is: 50.75, 57.5,29.2, 22.9;

the rotating equipment carries out a state monitoring and amplitude early warning mechanism, and no shaft holding fault of a pump bearing occurs in a main production device;

along with the development of state monitoring work, the service lives of a pump bearing and a mechanical seal are increased year by year, the average service life of the pump bearing commonly used in the main device is prolonged from 20500 hours in 2010 to 28200 hours in 2015, and the average service life of the mechanical seal is prolonged from 12600 hours to 20400 hours;

the failure intensity of the equipment is in a remarkable descending trend, and the non-planned shutdown of a headquarters is not reported since 2012. Particularly, 4 sets of newly-built devices of the second-stage project of oil refining reconstruction in 2014 to 2015 are all normally operated, and the fault strength of an electromechanical instrument is not obviously increased;

the equipment failure rate of the whole plant mechanical and electrical apparatus is obviously reduced, and the equipment failure rates in 2010-2015 are respectively as follows: 90%, 55%, 18%, 15%, 13%, 10%;

a plant operating for four years has no significant risk before shutdown.

At present, the concept of martian petrochemical equipment managers is greatly changed, risk awareness and systematized thinking are enhanced, and measures are actively taken to comprehensively implement an integrity management system.

[ example 3 ]

The method is used in the integrity management system of Qingdao refining equipment according to the method described in the embodiment 1:

evaluation of integrity management initial condition of Qingdao refining equipment

The evaluation work is completed through two times of centralized data consultation, personnel interview, field inspection and the like on the basis of collecting data and establishing a current situation evaluation table (comprising 814 access items). The main evaluation results are as follows:

1. device management system current situation positive highlighting

(1) Organizational policy level

a) The production safety management of the leadership is determined and the equipment management strategy is definite.

b) The manpower of the equipment management unit is simplified, the production capacity can be maximized besides the requirement of equipment management can be met, and the achievement of 'simplified personnel determination, high post determination and high efficiency' is achieved.

c) The equipment management does a large amount of solid and effective work, and the equipment management level is continuously improved.

(2) Management system level

a) The equipment management system is basically sound, and has the advantages of the traditional management mode, and related system files are prepared.

b) The cost control method for the equipment maintenance subcontractor has a considerable effect.

c) Equipment management encounters technical difficulties seeking support assistance from external professional units.

d) The process technology has high maturity and strict organization and management, and can show the process technology control capability at different levels.

e) The production operation program and system file are complete and the operability is high, so that the execution force and the implementation degree are improved.

f) The performance indexes of various equipment management are popularized and practical, and a good performance management foundation is laid.

(3) Operation execution layer

a) The environmental protection and safety during the operation maintenance of the equipment are in compliance, and the execution and management are highly perforative.

b) Various devices actively adopt new technologies and pay attention to technical transformation and development.

c) The equipment safety inspection work scale is large, and the inspection records are complete.

d) Various equipment information management platforms are actively used, and particularly the integration application of an EM system is well used.

e) Pay attention to the equipment management of the boiler and the heating furnace, and actively monitor the energy-saving effect of the heating furnace.

f) The overhaul quality and stability of key instruments and equipment such as DCS and SIS control systems are emphasized.

g) The HSE management of the equipment contractor is specific and careless, and particularly, the factory safety training content is complete and impressive.

2. Statistical analysis of comprehensive evaluation results

TABLE 6 statistical table of systematic degree of evaluation of present situation of equipment integrity management system

The current situation evaluation systematization degree distribution result of the Qingdao refining equipment integrity management system is as follows:

280 items in total, 35%, of A-level (unit owned, and systematized) question items

254 terms in total, 31%, between the B-level (unit owned but not systematized) question terms

198 total questions from level C (not fully populated and not systematized unit), accounting for 24%

82 questions in class D (unit not owned), accounting for 10%

According to the importance of the evaluation questions, the evaluation results are distributed as follows:

table 7 statistical table for evaluation importance of present situation of equipment integrity management system

The current situation evaluation importance distribution result of the Qingdao refining equipment integrity management system is as follows:

274 items of high importance, 34%

393 items of intermediate importance, 48%

147 terms of Low importance, 18%

And performing matrix intersection according to the systematization degree and the importance of each question item to form a risk matrix evaluation result and distribution.

TABLE 8 evaluation result chart of risk matrix for evaluating the current situation of equipment integrity management system

The 4 color results of the risk matrix are distributed as follows:

the total number of green questions is 280, which accounts for 34%, and is completely possessed and systematized in the equipment integrity management system, the risk is well controlled, and the residual risk degree is low. Continuous refinement is recommended.

The blue question is 213 items, accounting for 26%, which are possessed but not systematized in the equipment integrity management system, the risk is controlled considerably, and the residual risk degree is high. Alternative improvements are suggested.

The yellow question items account for 191 items, account for 23%, are not completely provided and systematized in the device integrity management system, the risk is not effectively controlled, and the residual risk degree is high. It is recommended to improve as soon as possible.

130 red questions, accounting for 16%, which are not possessed in the device integrity management system, risk is not controlled, and residual risk degree is high. Immediate improvement is recommended.

3. Equipment integrity management system opinion evaluation abstract

(1) And (3) organizing strategy level evaluation opinion abstract:

a) integrity is a primary task with security: and a method for managing the integrity of the equipment of the oil refining enterprise is proposed and referred to, the management system takes the safety of the whole life cycle of the equipment as a primary target, and establishes a systematic 'specification of the equipment integrity management system of the oil refining enterprise' by emphasizing the aspects of the quality, reliability, performance efficiency, energy conservation, emission reduction, economic benefit and the like of the equipment.

b) Integrity is by means of risk management: the oil refining petrochemical plant belongs to a high-risk dangerous chemical working unit, so an equipment integrity management system needs to take risk management as a means and closely combine all elements of 'safe production standardization work'. Although the factory follows the risk management system of the medium and petrochemical group, factory personnel lack a complete and professional risk management concept. The method is based on the chemical process risk management, strengthens a comprehensive and systematic risk management system, covers the aspects of process risk, equipment risk, operating personnel risk, ecological environment risk, economic risk and the like, defines the risk identification range, method, frequency and responsible person, specifies the requirements of risk analysis result application and improvement measure implementation, and performs risk identification analysis on the whole production process. The risk identification and analysis are carried out on the production and storage device which relates to key supervision dangerous chemicals, key supervision dangerous chemical process and major dangerous sources (namely two major points and one major point) of the dangerous chemicals, besides Quantitative Risk Assessment (QRA), danger and operability analysis (HAZOP) technology and protective layer analysis (LOPA), the risk-based inspection (RBI) assessment technology can be applied to static equipment and movable equipment, and according to different complexity degrees of the device, methods such as working hazard analysis, pre-hazard analysis, fault type and influence hazard analysis (FMECA) technology and the like or a combination of multiple methods are selected, and a re-assessment period is set, so that the continuous and effective risk assessment and management are ensured.

c) Setting an integrity manager: in order to promote the work of the equipment integrity management system, an 'integrity manager' is suggested to be considered (1) in the mobile engineering department, or (2) at the same level of the mobile engineering department and the HSE department, or (3) at a higher level, so as to facilitate the related work of organizing, planning, coordinating, approving, supervising and examining the equipment integrity management system. It is suggested that "integrity manager" should consider the professional ability of having a background of equipment management expertise and process risk management (QRA, hazo, LOPA, RBI, FMECA, etc.).

d) Setting a technical expert database: it is recommended that each professional department organize a task group "technical expert library (AI personnel)" to assist the integrity manager in processing the related research, analysis and approval of the high risk equipment. If necessary, external expert support and assistance should also be considered.

e) Adjusting the in-plant manpower and outsourcing strategy: the staff of the oil refinery arranges about 670 personnel, only for the arrangement manpower of half of the general oil refinery, and most of the frequent maintenance work adopts a high-proportion outsourcing system, so the property of the contractor, the management of the contractor, the maneuverability of the contractor, the compliance, the contract stability, the business monopoly and the like are potential operation risks of the equipment integrity management system. Therefore, the organization structure and the human resource management strategy of the plant are suggested to be considered again, and the outsourcing system proportion and the derived risks are reduced.

f) Proxy mechanism and handover: because the factory organization is labor-saving, each post personnel, especially the middle-layer supervisor, should establish a perfect and reasonable agent handover system to respond to the system operation during the period of the personnel leave. The contractor also needs to establish the same agent handover system and replace the transition period in the contract period to make the handover work earlier and reduce the risk impact of organization change.

g) The equipment integrity management system information management platform comprises: this opinion will be analyzed and explained in the summary report.

h) Equipment integrity management performance index: this opinion will be analyzed and explained in the summary report.

(2) And (3) evaluating the abstract of the opinion in the management system level:

in the management system level, the following 10 units of management systems were adopted for evaluation and analysis.

TABLE 9 statistical table of evaluation results of management system units

In the management system plane of the equipment integrity management system of Qingdao refining:

the overall average score was 60.2% above the typical refinery-petrochemical level of 50%.

The highest degree of systematization of the two units, i.e., the operation program (score of 77.8%) and the job license (score of 77%).

The degree of systematization of the two units, contractor management (score 69%), pre-departure safety review (score 69.6%), and the like.

Three units centered between management responsibility (score 61%), training (score 59%), and mechanical integrity (score 57%).

However, the systematization of process safety information (score 47.6%), alteration management (score 39.5%) and process hazard analysis (score 30.7%) is the weakest, and comprehensive reinforcement is urgently needed.

1) Mechanical integrity

(1) Static equipment:

a) RBI inspection plan: after the first overhaul test in 2011, the atmospheric and vacuum distillation unit and the catalytic cracking unit obtain quite abundant static equipment degradation mechanisms and thinning basic data, and begin RBI evaluation work in 2013. However, the RBI report only adopts a qualitative risk assessment method for the pressure vessel instead of API RP 581:2008 edition quantitative risk assessment (the qualitative method loses technical support and cannot upgrade or update RBI assessment), and does not completely analyze damage mechanisms and parameters according to the requirement of API 571 new edition, the pipeline does not mark corrosion loop analysis conditions, or external corrosion such as corrosion under an insulating layer is not specifically discussed. This RBI report is more focused on adjusting or extending the tank opening inspection date, and does not specify the equipment pipeline inspection strategy and inspection plan. In addition, the heat exchanger tube bundle maintenance treatment is too simple, or the maintenance record is not fed back to correct the RBI analysis. Therefore, it is recommended that the next overhaul should re-analyze the first overhaul test results, daily test results and EM maintenance records, and re-plan the second overhaul 2015 with reference to API 510 (equipment) and API 570 (pipeline) standards, in addition to the RBI analysis report. The general findings of the aforementioned Qingdao refining RBI report are described in detail in appendix 4.

b) And (3) detecting effectiveness of overhaul corrosion: the 'overhaul corrosion investigation report' of the pressure vessel shows that most of corrosion detection works only carry out visual inspection and thickness measurement aiming at a thinning damage mode, evaluation and detection of stress corrosion cracking, material degradation or mechanical damage are not considered, the thickness measurement data do not mark relative positions on equipment drawings, trend tracking is not carried out, thickness limit comparison is not carried out, and the corrosion detection effectiveness is insufficient. It is recommended that corrosion detection plans be implemented in accordance with the practical and effective specifications of the API 581 standard.

c) Corrosion loop analysis: the detection plans of the first overhaul and the second overhaul in the future are not evaluated by adopting the concept of systemic or looping corrosion loop, so that the real risk cannot be completely mastered, and particularly the risk of the pipeline cannot be effectively reduced. It is suggested that the concept of corrosion loop should be adopted to re-plan the overhaul inspection plan.

d) And (3) major repair detection plan: the plan of the first overhaul detection plan still has room for improvement, the future second overhaul detection plan is planned according to RBI evaluation report, but the overhaul/detection period is set according to the theoretical corrosion rate, and under the condition of lacking multiple measurement data, the four-year once overhaul period is actually over optimistic.

e) Construction specification content: at present, the management system files of various types of equipment in the factory are relatively simple, the requirement of actual construction is quite different, the current various types of specifications of other foreign enterprises are recommended to be referred, and the relevant specifications of purchase, design, construction, detection, acceptance and the like are compiled by taking the equipment types as the core.

f) And (3) improving a maintenance work order: the current auditing procedures of the maintenance work order and the work ticket are complicated, and the processing timeliness of the emergency can not be mastered. The proposal is that an emergency work ticket system is additionally established, field personnel are authorized to carry out emergency repair under the condition of orally informing a supervisor of approval, and then a maintenance work order is additionally provided, so as to strive for time effectiveness and maintain the level-to-level auditing spirit of the existing system.

g) Root cause analysis project system: and (3) performing fixed statistical analysis on the maintenance projects with faults in the last year, selecting the projects with the highest frequency and the highest risk of damage to perform deep Root Cause Analysis (RCA), entrusting an external expert to perform project analysis improvement if necessary, and continuously tracking the improvement effect. Once this program is continuously driven, the most frequent failure problem is improved year by year, and it is expected that the failure occurrence frequency will be greatly reduced while the operational risk is reduced.

h) An exception management system: the integrity manager is suggested to establish more systematic abnormal condition risk management, integrate the supervision work of abnormal possible conditions such as equipment state deviation, safety violation condition, gas/liquid/dust leakage, design condition change, non-compliance maintenance program and the like, clearly order control classification and standard limit values, and perform trend tracking, root cause analysis and performance indexes so as to predict early improvement of risks and prevent equipment damage.

(2) Instrumentation and control equipment:

a) SIS safety life cycle management system: the factory Safety instrument system is started in 2013, only the management and control work of hardware failure of part of production devices is concerned, the Safety life cycle management of the Safety instrument system is not implemented, and even an SIF Safety Requirement Specification (SRS) is not established, so most of the system failure causes still exist. Therefore, the method proposes the rapid training and invites a third party unit to examine the LOPA analysis process above SIL 2 and the SIS checking result so as to effectively connect with the equipment integrity management system.

(3) Moving equipment:

a) and (3) dynamic equipment management strategy: it is suggested to add a system structured dynamic equipment management strategy architecture diagram or flow chart according to the current dynamic equipment management system file.

b) Unscheduled shutdown pipelining principle: for an unplanned shutdown or a failed power plant, the tube management principle is suggested.

c) And (3) mobile equipment risk assessment: it is proposed to use FMECA method to evaluate the risk of mobile equipment and clear the potential risks and weaknesses of equipment and its components to facilitate the improvement of solutions and safeguards.

(4) Electrical management:

a) risk assessment and classification of electrical equipment: the hidden danger grade division of the electrical equipment in the whole plant is not carried out, and the FMECA method is recommended to be used for risk evaluation, so that the potential risks and the weaknesses of the electrical equipment are cleared and graded.

b) Monitoring the state of the electrical equipment: the state maintenance concept of the electrical equipment or the disposal plan of the fault emergency mechanism of the electrical equipment are not introduced yet. The passive reaction is only taken when the equipment fails or needs forced repair and replacement. The method is suggested to adopt a new technology and intelligent online monitoring equipment to carry out online real-time monitoring on the insulation condition of main electrical equipment, and is combined with a conventional test means to ensure the safe and reliable operation of the equipment and ensure the safety of the electricity utilization of the whole plant.

(5) Managing the spare parts:

a) safe stock of spare parts: and suggesting and strengthening the setting management and optimization of the safety stock of the spare parts, and particularly suggesting and making a spare part plan for the condition that the key safety valves have no safety stock at present.

b) Warehousing and self-checking: at present, the procedures and regulations of warehousing self-inspection are simple, and the development of inspection procedures, authority units, inspection tools, inspection flow charts and inspection and acceptance standards of various material stocks is suggested.

c) Connecting with an EM management platform: the EM management platform is connected with the procurement spare management platform, so that convenience and continuity of maintenance operation flow are facilitated, and fault risk of an operation interface is reduced.

d) And (3) carrying out change management and control of spare part linkage: for machine part spare parts of changed materials or OEMs in the change management process, the method proposes to add spare part linkage purchase management and control in the last procedure of change management.

e) And (3) leftover recycling management and control: leftover bits and pieces after the ex-warehouse material is cut again are not marked or controlled, risk holes are formed on the condition of recycling, and identification, flow tracking, balance calculation, use condition setting and examination and approval control are suggested to be carried out on the leftover bits and pieces.

f) And (3) managing performance indexes of the spare parts: it is suggested to set up the performance index of the spare parts management according to the risk factors such as the quality, speed, stock, and availability of various supplies in the spare parts supply process, so as to ensure the integrity of the equipment management system.

(6) Defect management

a) And (4) defect classification: at present, the defect management method for Qingdao refining is too simplified, the defects of the equipment are not clearly classified, and the technical conditions of the heavy equipment (A type and B type) and the general equipment (C type) are only analyzed and evaluated. It is recommended to refer to foreign practice, and classify seven key devices according to the severity of defect nature and the influence degree on the safety and normal operation of the device system, for example:

(i) major defect (type a defect): namely, the defects are very technical, and can be solved only by carrying out larger equipment improvement, spending larger fund or combining unit maintenance.

(ii) Critical defect (class B defect): defects which endanger the safe operation of human bodies and equipment are not immediately processed, or the defects which can be eliminated only by stopping the operation of main equipment or stopping the operation of auxiliary equipment to influence the operation of key equipment are eliminated, and the defects that the standby defect elimination time exceeds 24 hours although the output of a main machine is not influenced.

(iii) General defects (type C defects): and the defect that the defect can be eliminated in the operation of the equipment or the operation of the auxiliary equipment needs to be stopped without influencing the operation of the key equipment is overcome, and the defect that the defect elimination time is not more than 24 hours after the defect is removed from the standby mode.

(iv) Device exception (class D defect): the equipment operating conditions occasionally deviate from normal state ranges or normal functions, but the equipment safety or personnel hazards are not yet compromised, and defects can be temporarily observed.

(v) Civilized production type defects (type E defects): the defects do not directly influence the safe operation of equipment, mainly refer to the defects related to civilized sanitation, life and production facilities, and mainly comprise the defects of damaged door and window glass, unlighted bulbs, accumulated water, accumulated oil, accumulated dust, accumulated powder, footpath, platform, railing and the like.

b) Leakage defect: and (4) implementing management and control aiming at leakage defects of equipment and a system, including defects of chemical leakage, oil leakage, water leakage, air leakage, powder leakage, ash leakage and steam leakage. The severity of the leakage defect is mainly divided into a seepage point (the sealing point has medium seepage), a general leakage point (the sealing point has medium leakage), and a serious leakage point (for example, oil drops by 1 drop per minute or more; steam leaks in a linear or planar shape, etc.).

c) And (3) equipment defect management:

(i) equipment defect management process (different defect management processes should be established for equipment defects of different classification levels)

(ii) Defect work order processing flow

(iii) Discovering and logging in defect work orders

(iv) Work order planning and defect elimination preparation

(v) Carry out defect elimination work

(vi) Handling of abnormal situations

(vii) Limitations for Temporary Repairs (Temporary Repairs)

(viii) Quality acceptance

(ix) Equipment defect analysis

Number of defects and defect elimination rate

Summary analysis of causes of defects

Analysis of the occurrence and cause of overdue defects

Frequent defect analysis

Other typical defect cases

Repetitive defect cases

Analysis of important defects

Delayed defect situation

Analysis and countermeasures for delay defects

Analysis of deferred defect status without scheduled removal

(x) Equipment state analysis and evaluation (for example, static equipment adopts service-adaptability (ASMEFFS-1/API-579) or residual life evaluation method, principle and execution time)

d) Equipment defect management examination and penalty rules: the elimination rate is proposed to be set for the equipment defect as an assessment method, for example:

(i) the defect eliminating rate of key equipment: is the percentage of the total number of critical equipment defects that can be eliminated over a period of time.

(ii) And (3) eliminating the defect rate of auxiliary equipment: means the percentage of total number of auxiliary equipment defects that can be eliminated over a period of time.

(iii) The defect elimination completion rate of key equipment: is the percentage of the number of the key equipment defects eliminated in a certain period of time to the total number of the main equipment defects.

(iv) The auxiliary equipment defect elimination completion rate: is the percentage of the number of the defects of the auxiliary equipment to be eliminated in a certain period of time to the total number of the defects of the auxiliary equipment.

2) Process safety information and process hazard analysis

(1) Quality of major hazard assessment: the assessment implemented in the hazard identification, risk evaluation and control measure determination control program is JHA and SCL, emphasizes on operation safety and inspection points, and does not finish all process hazard analysis. The concern for critical hazard source assessment reports is not ideal. In addition, the analysis conclusion only makes emergency measures aiming at major hazard sources; chapter five security management measures, security technologies and monitoring measures, such as corrosion prevention, detection, alarm, etc., lack pertinence, and therefore, it is not possible to apply information of systematic risk assessment to the equipment integrity management scheme planning.

(2) The process hazard analysis work progress: HAZOP analysis is not carried out in the factory building period, HAZOP analysis of an atmospheric and vacuum distillation unit and a catalytic cracking unit is not completed until 2013, LOPA analysis work of the catalytic cracking unit is just started, and the atmospheric and vacuum distillation unit is processed with HAZOP and is not closed; the catalytic cracking device is made into HAZOP and LOPA; delayed coking completes SIL rating analysis, but does not perform hazard analysis risk assessment with HAZOP; the sulfur recovery unit completes the SIL grade check and evaluation report. And related improvement measures are not closed or enter the equipment side for modification. In other words, the risk of potential process hazards from the design time of the plant, which is a significant risk upstream of the plant's full life cycle, has not been eliminated since now in the production process equipment. It is therefore recommended to complete HAZOP analysis, LOPA analysis, safety instrumentation system setup and other related corrective work for all production plants as quickly as possible.

(3) HAZOP assay validity: the HAZOP reports of the catalytic cracking unit and the atmospheric and vacuum unit show that the basic logic of possible hazard reasons and consequences is identified by process deviation guide words, but the analysis of protective measures is incomplete, and the risk possibility evaluation is lack of systematization, and only indexes are subjectively given by evaluators, so that the real risk cannot be evaluated or the risk is underestimated. The HAZOP contribution to risk control is very limited, to the HAZOP improvement recommendations of the catalytic cracker, is to increase the alarm? Advising external professional units for training and review.

3) Operating procedure

(1) The operation program book reflects the hidden danger of updating: three emergency shutdowns have occurred with the potential safety hazard of oil and gas leakage due to hot spots possibly membrane breakthrough in the cold wall lining of the catalytic unit reactor, and this phenomenon and the response to the solution have not been reminded in the operating procedure book.

(2) Health safety considerations for the operating procedure: safety and health considerations have not been fully considered in the catalytic device operating program book, including: necessary measures for preventing exposure of chemicals used in the manufacturing process, control measures to be taken when physical contact or air form exposure occurs, quality control of raw materials, inventory control of hazardous chemicals, and the like.

(3) Exception management of running reports: some of the records or reports of the deviation from the index are not interpreted or accounted for by the associated corrective measures. For example, the actual measured values 137.60 ℃, 139.99 ℃ and 137.74 ℃ of all three times of the key process operating parameter 27 item fractionation tower top temperature (TIC20101) of the catalytic device in section 7.1 of the 'monthly report on operating device production technology of operation device' in 2013 year 5 are all out of the range of the control index of 100-130 ℃, but related corrective measures are not explained or explained, so that a hidden danger is formed. Suggesting enhanced exception logging and reporting review quality.

4) Training

(1) Developing a training plan: the training of maintenance contractor personnel is lacking in process safety and equipment integrity related training, in addition to the safety and health insights into the factory and post, including the requirements of basic work permit regimes. The advices are with the human or personnel department, and take into account the laws, standards/norms, professional qualification requirements, process risks, events/accidents, safety performance and other factors to develop systematic Training requirement analysis (Training requirements measures), and develop Training plans related to process safety and equipment integrity, JCC (Job Cycle check) or Training success evaluation plans according to the requirements of the third item of 29CFR 1910.119(j) MI aiming at the actual needs of various workers of maintenance contractor personnel.

(2) Factory personnel supervision training: since all items such as MI maintenance and inspection belong to professional items, although the maintenance company and the special inspection yard are completely relied on to assist in executing related tasks, the personnel in the factory area lack sufficient qualification and training plans for quality monitoring, and problems can form experience faults along with the change of experienced qualified and leadership duties, thereby causing problems. It is recommended to perform technical expert (AI accountant) training, following other companies.

(3) Technical expert (AI staff) system: it is proposed to select appropriate personnel from the engineering project, and to receive various professional training to engage in the work items of quality monitoring, and any change management items must be checked continuously by the AI personnel to identify the identity of the person. When the professional ability of AI personnel is not enough to judge, the expert inside or outside is required to consult after the leading response, so as to ensure that the change of important engineering projects can effectively reduce the risk.

(4) API in-service inspection Engineers: the factory has the inspection performed by pressure container and pressure pipeline inspectors approved by national statutory, but API active inspection teachers and quality personnel and corresponding training are not available, and the API 510 pressure container, the API 570 process pipeline, the API 653 ground storage tank and the API 580 engineering technicians in the aspects of risk-based inspection and API 571 damage mechanism are recommended to be trained as soon as possible so as to supplement and deepen ideas which are not related to national statutory inspection, and internationally identical, mature and advanced inspection experiences are adopted as references for major repair and daily maintenance.

(5) Continuously training electrical personnel: the factory can not continuously and regularly train the electrical operators according to the electrical regulations, the training and examination of the maintenance unit personnel has obvious walking form and walking phenomenon, and the recommendation is improved and implemented.

5) Contractor management

(1) Contract content of contractors: and a reasonable contract pricing mode is proposed to be newly ordered, so that the situation that a contractor does not actively process maintenance projects is avoided, for example, different pricing standards are respectively ordered according to the heat preservation maintenance area and the construction height, otherwise, the condition of poor heat preservation maintenance at present cannot be effectively improved.

(2) And (3) continuing skill training of contractors: the management ability degree and the working quality of contractors are different, some contractors only provide personnel qualification and testimony in contracts, but lack systematic training plans, only depend on teachers to exercise professional skills, work program books are similar to the nominal ones, and no change management concept is added, so the serious hidden danger of MI is caused. The Jinling Jianan company is suggested as a standard pole, other contractors are required to imitate continuous skill training, and transverse skill and management evaluation, reward and punishment and jig change are carried out.

(3) Contractor work program: although each task is provided with a working program book, interviews find that the actual condition is not executed according to the execution, and the construction is still implemented according to personal working experience of teachers, so the program book is not used. Related circumstances also occur in pre-job security check projects. And if the daily routing inspection record is obviously lost, the quick modification and correction are recommended.

(4) The working environment is as follows: the manufacturer and subcontractor have high consensus on the safety requirements, but the environmental impact is still to be further improved. The continuous VOC detection in factories is limited by the fact that the detection frequency of human factors is still low, and the method is suggested to be perfect.

6) Safety examination before driving

(1) Clearly making a safety examination system file before vehicle opening: although the notice of the regulatory regulation of the "san jie" construction project of issue No. 2007,288 of Zhongshimian has been provided with a safety review system before driving, the manufacturer has not implemented it but has simply adopted the "device maintenance and delivery confirmation table" to form a risk hole. It is suggested to review the reasonability and operability of the system document or independently and clearly make the safety inspection system document before the vehicle is opened and implement the method.

(2) Safety examination range before driving: for new and extension projects, the notice of the administrative regulation on the "three-in-one" construction project of Zhongshijinian [2007]288 ] does not cover the audit part of the manufacturing completion document of the equipment, and suggests to supplement the content of the part.

(3) Safety examination range before driving: notification of the management regulation on the construction project 'Sanshima' from the question No. 2007,288 of Zhongshidian (China petrochemical industry Security Association) does not cover the safety protection measures of the computer and system and the safety examination table before driving such as the fault resetting of the controller, and suggests to supplement the contents.

7) Job approval

(1) Fire-activating license: fire permits have been listed which require the removal of the surrounding combustible material from the fire, but have not been listed as covering the combustible material with a fire-resistant covering when it is not removable. It is recommended to add the contents of the checklist to the fire permit.

(2) And (4) shift recording: the record shows one shift for 24 hours, while no shift record for the refinery's night shift is found. For the authorized permission operator or the non-record display controller which is not completed in the night shift, the management system of the shift switching and the control of the permission operation are recommended to be enhanced.

8) Change management

(1) Change management classification and threshold: the factory uses the cost amount as a classification principle of change management, when the amount exceeds a set value (limited items), the factory uses an investment management system to examine and approve instead, and when the amount is lower than the limited amount, the factory enters an equipment change management system to examine and approve. Setting a basis for money is not likely to be the most reasonable basis for differentiation, and changes that have a large impact on security but a lower amount of money may occur to accept a complete (external) professional assessment due to the large difference between the review procedures and the professional consultations. At present, the column management condition threshold of change management is too low or unreasonable, the change management classification and classification system is recommended to be revised from the hazard risk angle, and the change condition checking table is obviously revised to comprise the change condition threshold, the hazard degree, the influence degree, the hazard risk grade and the like.

(2) Temporary change: at present, a deep temporary change management system is lacked, and the situation that the temporary change is more likely to cause direct cheap operation of basic-level operators cannot be effectively avoided. Current practice has affected equipment integrity and system risks. Before the MOC regime has not been changed, it is recommended to fully check whether temporary changes that have been made in the past are still present in the existing equipment, and to re-make MOC evaluations if necessary.

(3) Changing the management mode: at present, the equipment change mode is managed by each equipment department, and an integrity manager is proposed to uniformly control the change management operation flow of each department through an information management platform so as to avoid the risk of system loophole. For example:

2013/10/26 the facility for injecting alkali into crude oil after the atmospheric and vacuum distillation unit is technically improved by the motor engineering department, and the process comprises standing cards, design instructions, operating rules, adding alkali injection and alkali distribution cautions, work notification (training), summary, lack risk assessment and safety examination and record before driving.

The improvement of the catalytic cracking unit waste heat boiler economizer is guided by the development planning department and is subject to scientific research, design review and other procedures. The increase and decrease of the equipment pipeline are not brought into change management.

Such as a steam scavenging line 2 at 20802 position of a double-stripping C201 top PDV of an equipment maintenance work order 210005691, a sulfur transfer agent filling tank added to a 210005730 catalytic unit, and the like.

The pump 1101-P-108 leaks for many times in the normal pressure and reduced pressure device, the mechanical seal of the corrugated pipe is replaced by a large-spring mechanical seal, the type of the components of the equipment is changed without executing change management,

advising the concept of reinforcing personnel's knowledge of change management and its scope, and equipment risk control.

(4) Change management flow: the safety examination system before driving is only implemented in scientific research programs and large-scale technical improvement, and the safety examination before driving is not implemented before all MOCs are started after being changed. The proposal combines the change management with the three-in-one management implementation rule of occupational health, earthquake resistance and disaster reduction. The key points of the change management process and the safety examination before driving are as follows:

a) confirming that all changed or newly set equipment facilities are installed and debugged according to the standard, specification, commonly Accepted Good Engineering Practice (RAGAGEP) or the recommendation of suppliers;

b) confirming that relevant operation, maintenance and safety regulations are established;

c) confirming that the relevant personnel finish training;

d) confirm that hazard analysis or HAZOP recommendations have been tracked and turned off.

(3) Comprehensive evaluation abstract of mechanical integrity operation execution layer

1) In the mechanical integrity unit, seven key devices complete 381 evaluations. The scoring results and distributions are as follows:

TABLE 10 statistical distribution of critical equipment evaluation results of mechanical integrity unit

Class of devices	Score of
		General matters (GL)	61.5％
Pressure container (PV)	50.5％
		Process Pipe (PP)	51.8％
Pressure relief discharge system device (RV)	69.2％
		Emergency shutdown system (ES)	30.2％
Control system (CI)	78.2％
		Transfer machine equipment (RM)	57.3％
Electrical Equipment (EE)	64.8％
		Mean value of	60.2％

Claims

1. A modeling method of an equipment integrity management system adopts an equipment integrity management system structure model to carry out equipment integrity management, wherein the structure model comprises a primary element and a secondary element, and the primary element comprises: organizing environment, leading function, planning, supporting, running, performance evaluation and improvement; the secondary elements include:

1) legal and other requirements;

3) risk management planning;

4) equipment selection and hierarchical management;

5) training;

6) managing risks;

7) ensuring the process;

8) professional management of equipment;

9) inspection, testing and preventive maintenance;

10) managing defects;

11) change management;

12) control of externally provided processes, products and services;

13) monitoring, measuring, analyzing and evaluating;

14) and (6) performing external auditing.

2. The modeling method of the equipment integrity management system according to claim 1, wherein the elements are related and interpenetrated to form a benign continuously improved PDCA management cycle to ensure systematicness, uniformity, and normalization of the system, and to achieve the integrity and comprehensive optimization management of enterprise equipment.

3. The modeling method of the equipment integrity management system according to claim 1, wherein the equipment selection and hierarchical management means that an enterprise makes a selection criterion according to a production operation plan, an equipment management target or requirements of laws and regulations, and brings the equipment into the scope of the integrity management system; meanwhile, according to the importance of the equipment in the device, the harmfulness of the equipment after an accident, the influence degree on safety and environmental protection and the influence severity degree on product quality, an enterprise establishes a definite equipment grading method and carries out grading management on the equipment, so that the equipment management is effectively carried out, and the equipment repair fund is reasonably used.

4. The modeling method of the equipment integrity management system according to claim 1, wherein the risk management means that an enterprise should identify risks and evaluate their influencing factors, consequences and possibilities at each stage of the equipment life cycle, classify and grade the risks, and manage and control the identified risks in time to ensure that they are at an acceptable level.

5. The modeling method of the equipment integrity management system according to claim 1, wherein the process assurance refers to that an enterprise establishes and maintains a corresponding quality control standard in order to identify and develop quality assurance activities of each process of the equipment in a full life cycle, and takes effective or appropriate quality control measures to meet quality requirements of related laws, regulations, standards, technical specifications, and enterprise-specified documents, so as to realize control of the equipment process, and further effectively control the performance, risk, and cost of the equipment system, and ensure that the equipment quality meets the requirements of the equipment integrity management system.

6. The modeling method of the equipment integrity management system according to claim 1, wherein the professional management of the equipment is a technical carrier of the equipment integrity management, and enterprises should identify and determine professional management contents of the whole life cycle of the equipment, actively apply and optimize related risk technologies, provide technical support for preventive maintenance of the equipment, and meet technical requirements required by management decisions, including professional management of static equipment, professional management of dynamic equipment, professional management of electrical equipment, professional management of instrumentation equipment, comprehensive professional management, and power management.

7. The modeling method of the device integrity management system according to claim 1, wherein the inspection, testing and preventive maintenance, referred to as ITPM, refers to systematic inspection, detection and proactive maintenance activities that an enterprise takes to ensure that a device continuously conforms to its prescribed functional status, which is the core content of the device integrity management method, and aims to establish an ITPM management program, implement a device integrity plan, and achieve and improve device reliability in the processes of making the ITPM plan and implementing ITPM tasks.

8. The modeling method of the equipment integrity management system according to claim 1, wherein the defect management means that an enterprise effectively identifies, responds, communicates and eliminates the defects of the equipment at each stage of the equipment life cycle, so as to realize closed management of the defects, avoid equipment failure and invalidation, ensure the sound condition of the equipment, and ensure the safe, stable and long-term operation of the device.

9. The modeling method of the equipment integrity management system according to claim 1, wherein the equipment change management means managing and controlling the process of the equipment change to enhance the enterprise equipment change management, and ensuring that the equipment change can be correctly applied, risk assessed, approved, executed, accepted and informed, thereby eliminating risks and preventing new accident potential.

10. The modeling method of the equipment integrity management system according to claim 1, wherein risk management and defect management are key, so that monitoring and finding equipment problems, inspection, testing, preventive maintenance are core, the equipment problems are addressed, failures and accidents are prevented, target planning, policy and resource support are continuously improved according to the actual risk assessment and preventive maintenance, quality assurance is to ensure that all management activities reach the expected production management target and meet the relevant laws and regulations and standards, and final performance assessment and corrective preventive measures and management review and continuous improvement are to check and feedback the management activities.