Research On Overhaul Project Quality Management Of Jilin Petrochemical Ethylene Factory

Within domestic petrochemical industry the overhaul of plant commonly used the“three-year overhaul” system, but each time from the organize maintenance to themanner of maintenance is very different. Its overhaul mode will be changed whenreplacing the maintenance organizer. Different overhaul methods can produce differentresults. So the overhaul quality risks can be brought. The Jilin Petrochemical Companyethylene factory overhaul project is for the first time to the company after four years ofcontinuous operation unit overhaul. The overhaul includes repair works involved546sets of equipments or machines,849common valves,1460electric devices,742instruments,467control valves; and inspection works involved343pressure vessels,2148pressure pipes which amount to191thousand meters,1049safety valves, and226leakage elimination works, etc. Jilin Petrochemical company ethylene factoryprepare in advance, improves overall program overhaul plan, process maintenanceoverhaul in the handover book and other overhaul documents preparation, forming359sets of construction program,699maintenance operating procedure files,9overhaulinstructions,26maintenance handover books. Those standardize equipment shutdownand returning materials, purge replacement, maintenance, repair and so on.The ethylene factory overhaul is the most important and the greatest risky task ofJilin Petrochemical Company "Culture Year",but also the rare downtime regionoverhaul opportunity of the factory during the "Twelve Five" period. So all the staffand the construction units attaché great importance to the significance and theopportunity of this overhaul. Because of Jilin Petrochemical Company ethylene factory equipments running continuously for four years, extending the conventional three-yearoverhaul to four years, many plants has run for a long time, equipments defects andhidden dangers occurring. Moreover, overhaul of2012is the first time four years ofcontinuous operation since ethylene plant Expansion, so useful experience is rare forlong periods of shutdown overhaul. Also because of tight maintenance schedule, moreoverhaul projects and higher maintenance goals, as well as external environmental andpolicy requirements and other factors, those factors put forward higher request foroverhaul. The overhaul project staff in line with the attitude of responsibility andimplementation, establish the full responsibility management system effectively; whilethey execute program and performing, strengthening the control and management ofthe whole process effectively. The entire staff of the ethylene factory overhaul workedtogether to finish the overhaul tasks safely and steadily.However, there are still some deficiencies of this Jilin Petrochemical Ethylenefactory shutdown overhaul project quality management. Based on the existing qualityproblems of ethylene factory overhaul project, this paper uses project qualitymanagement theories, from the personnel and organizational structure, equipment andmachinery, materials and spare parts, technique and environmental aspects of theproject,analyzing the impacts of the quality factors and reasons; And further this paperanalyzes the interaction, complementary and restrictive relationships between overhaulsafety, schedule, cost, and overhaul quality;Finally from maintenance work processes,quality control measures, overhaul safety, schedule, cost and other aspects, this paperputs forward quality control measures. Hope for providing a stable foundation for thefuture plants operation, and providing experience and learning for petrochemicalshutdown overhaul projects, having a certain practical significance.