Daqing Zhonglan has strengthened its equipment management, real-time database auxiliary equipment operation analysis, large-unit operation monitoring and risk assessment as well as special equipment daily checks, online testing, overhaul and maintenance. The company aims to achieve long and steady equipment operations. As of now, all of the company’s major equipment is in good condition. More than 96 percent of general equipment is up and running as well. Its DCC and FCC units have been running smoothly for 11 months. The company has also taken the initiative in implementing preventative maintenance to achieve the goal of having an overhaul every two years.
Since the overhaul last year, the company has improved management in more than 30 fields, including equipment information, use, maintenance and accidents. It also upgraded the production and testing records for pressure vessels, pipes, hoisting machinery and vehicles. It concluded 25 total productive management (TPM) projects, which raised the equipment running efficiency. As of now, the company’s equipment failure rate dropped to 1.09 percent, down 28 percent year-on-year.
Since the real-time database was put into service, the company has actively applied MES and AF tools to monitor and analyze equipment operations. It strengthened the monitoring of pump flow, the temperature of high-temperature equipment and energy conservation equipment efficiency. Through database analysis, the company can find problems at an early stage and take preventive measures to ensure the equipment is always in good running condition. Since the second quarter of this year, the MTBE pump load had stayed below 60 percent due to raw material reasons. The company found the problem very quickly through monitoring the database, and solved the problem by adjusting the process parameters in time and increasing back flow. In addition, the company has also performed regular tests on the temperature of high-temperature equipment, the vibration of rotating equipment and the thickness of corrosion equipment. It has also conducted regular analysis and maintenance.
The company conducts weekly monitoring and analysis of five large pieces of equipment, including the main air blower and centrifuges. It also invites professionals to do comprehensive testing and analysis on a quarterly or random basis. It takes corresponding measures to ensure the equipment is in good running condition. The company follows the required protocol for special equipment, such as the pressure vessel, does checks regularly and strengthens on-line detection to find problems and resolve them in time. It also checks corrosion equipment and analyzes condensate water at tower top to adjust corrosion prevention measures and avoid non-planned shutdown.
Planned and preventive maintenance plays a key role in steady and long-term equipment operations. Therefore, the company has continued to improve equipment tests and upgrade its management on maintenance materials, risk control and quality monitoring. At the moment, the company has been running analysis on its large equipment and will conduct preventive maintenance on key equipment, such as the gas turbine, to smoothen equipment operations.