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On October 30th, Ningxia Petrochemical's fertilizer plant entered the 318th day of long-term operation of Category A.
This means that the device has not stopped for one minute and has been running for 7,632 hours continuously.
It has established a 30-year historical record of the factory and ranks among the best in the national fertilizer industry.
The Ningxia Petrochemical fertilizer plant is one of the 22 key industrial development projects during the country’s "Seventh Five-Year Plan" period.
The plant was introduced in Japan and was one of the only three sets of residue ammonia plant in China at that time.
The process of the chemical fertilizer plant is complicated, and the key moving equipment is a single series.
Some minor changes may cause the entire system to stop, and the direct loss of more than 2 million yuan per start and stop.
Large-scale fertilizer manufacturers at home and abroad all regard continuous operation for 100 days as the primary goal of long-term production.
How to prevent the "classic car" from stopping for 30 years of overdue service? At the beginning of 2014, in the face of as many as 12 unplanned shutdowns of the installations in the previous year, Ningxia Petrochemical launched a two-year long-term operation of fertilizer installations.
In the past two years, five special research teams including production and operation, equipment guarantee, electrical instrumentation, environmental protection, and basic management have worked together to face the production site, face up to difficulties, weaknesses, blind spots and stubborn points, and carry out lasting and in-depth rectification of hidden dangers and elimination of bottlenecks.
In the past, the number of device shutdowns caused by water vapor and electrical instruments exceeded 50% of the total accidents.
During the research period, for common accidents such as high boiler tube burst, boiler coking, and chain malfunction, the boiler and electrical instrument system set off an upsurge of refined management.
Established a competitive induction mechanism, adopted a series of measures such as gas system technological transformation, low-standard elimination, key equipment pipeline monitoring, predictive maintenance, anti-shake electricity research, and chain special management, etc.
, to achieve continuous long-term steam supply for high-pressure boilers for 438 days, A major breakthrough in the zero accident of the electrical instrument system.
As the main unit of the plant, the No.
1 Chemical Fertilizer Plant carried forward the hard work spirit of the “Hundred-faced Red Flag Unit” of the group company, incorporated "abnormal production management" into the management of unplanned shutdowns, and strictly assessed and fulfilled it.
A total of 317 key production hazards and 60 abnormal conditions were discovered.
, All were dealt with in time, the equipment stability rate reached over 99%, and the equipment maintained high-load running for long-distance running.
In the two years since the implementation of the special project, the unplanned shutdown of Ningxia Petrochemical's fertilizer plant has decreased by 78%, and a direct loss of 60 million yuan has been reduced.
The key equipment No.
1 gasifier burner has achieved a breakthrough of 230 days of continuous operation since the establishment of the plant.
The energy saving and emission reduction and environmental protection management of the device have been improved simultaneously, and the "three rates" of the device have reached more than 90%.
The fertilizer plant has also become the only plant with the longest operating cycle of the current "Three Oils" system since 2010 by virtue of its continuous operation for 318 days.
This means that the device has not stopped for one minute and has been running for 7,632 hours continuously.
It has established a 30-year historical record of the factory and ranks among the best in the national fertilizer industry.
The Ningxia Petrochemical fertilizer plant is one of the 22 key industrial development projects during the country’s "Seventh Five-Year Plan" period.
The plant was introduced in Japan and was one of the only three sets of residue ammonia plant in China at that time.
The process of the chemical fertilizer plant is complicated, and the key moving equipment is a single series.
Some minor changes may cause the entire system to stop, and the direct loss of more than 2 million yuan per start and stop.
Large-scale fertilizer manufacturers at home and abroad all regard continuous operation for 100 days as the primary goal of long-term production.
How to prevent the "classic car" from stopping for 30 years of overdue service? At the beginning of 2014, in the face of as many as 12 unplanned shutdowns of the installations in the previous year, Ningxia Petrochemical launched a two-year long-term operation of fertilizer installations.
In the past two years, five special research teams including production and operation, equipment guarantee, electrical instrumentation, environmental protection, and basic management have worked together to face the production site, face up to difficulties, weaknesses, blind spots and stubborn points, and carry out lasting and in-depth rectification of hidden dangers and elimination of bottlenecks.
In the past, the number of device shutdowns caused by water vapor and electrical instruments exceeded 50% of the total accidents.
During the research period, for common accidents such as high boiler tube burst, boiler coking, and chain malfunction, the boiler and electrical instrument system set off an upsurge of refined management.
Established a competitive induction mechanism, adopted a series of measures such as gas system technological transformation, low-standard elimination, key equipment pipeline monitoring, predictive maintenance, anti-shake electricity research, and chain special management, etc.
, to achieve continuous long-term steam supply for high-pressure boilers for 438 days, A major breakthrough in the zero accident of the electrical instrument system.
As the main unit of the plant, the No.
1 Chemical Fertilizer Plant carried forward the hard work spirit of the “Hundred-faced Red Flag Unit” of the group company, incorporated "abnormal production management" into the management of unplanned shutdowns, and strictly assessed and fulfilled it.
A total of 317 key production hazards and 60 abnormal conditions were discovered.
, All were dealt with in time, the equipment stability rate reached over 99%, and the equipment maintained high-load running for long-distance running.
In the two years since the implementation of the special project, the unplanned shutdown of Ningxia Petrochemical's fertilizer plant has decreased by 78%, and a direct loss of 60 million yuan has been reduced.
The key equipment No.
1 gasifier burner has achieved a breakthrough of 230 days of continuous operation since the establishment of the plant.
The energy saving and emission reduction and environmental protection management of the device have been improved simultaneously, and the "three rates" of the device have reached more than 90%.
The fertilizer plant has also become the only plant with the longest operating cycle of the current "Three Oils" system since 2010 by virtue of its continuous operation for 318 days.
