Luoyang Wohong Petrochemical Equipment: Introduction to the Compilation of Operating Procedures and System Construction Project for Solvent Recovery Unit

When the solvent recovery device encounters operational issues, the root cause is often traced back to the following: there is no written basis for operation, relying solely on the memory and habits of experienced workers; record formats vary widely, changing with different record keepers; and when anomalies occur, there is no clear procedure to follow. The equipment is robust, but the management is weak. Without a solid foundation in management, the equipment cannot perform to its full potential. The compilation of operating procedures and institutional construction projects aim to help the user unit establish a solid foundation in this area.

What content should be included in the procedure

A complete set of operating procedures covers the entire operational scenario of the device: the sequence and confirmation items for normal startup and shutdown, the items and routes for daily inspections, the scope and authority for parameter adjustments, the judgment and handling steps for common abnormalities, the classification and actions for alarm responses, and the cycle and content of maintenance. Procedures do not simply copy the instructions, but clearly outline the actual operational requirements of the device under "this factory and these operating conditions" - the operational boundaries of the same model of device in different enterprises are not the same.

The language of the procedures is targeted at operational positions: the actions should be specific to "press which, look at which, and remember what", without writing such unenforceable phrases as "pay attention to observation and handle in a timely manner".

How to carry out the preparation

The preparation process is divided into four steps: the first step involves on-site research to understand the device configuration, operating conditions, personnel structure, and existing practices; the second step involves framework confirmation, where the chapter structure and granularity of the procedures are agreed upon with the enterprise, and the management's intentions are aligned in this step; the third step involves writing separate volumes, where procedures, record forms, and emergency plans are compiled into a complete set; the fourth step involves training and publicity, where the preparers explain on site, operators practice the actions in front of the equipment, and feedback is collected for revision and finalization.

The entire process of compilation emphasizes "user participation in writing": only when the opinions of operational positions are incorporated into the procedures can they be effective; procedures written behind closed doors will become mere decorations once issued.

What are the supporting systems

In addition to the procedures, there are three supporting elements: the record form is designed according to the inspection items in the procedures, with the filling items corresponding to each item in the procedures, making the record a trace of execution; job responsibilities assign the responsibilities of operation, inspection, maintenance, and recording to individuals, ensuring that interfaces do not overlap and leave gaps; the assessment method determines the inspection methods and reward and punishment standards for execution. Only when the system is enforced can it be taken seriously.

The lifeblood of a system lies in its revision: following equipment modifications, personnel changes, and adjustments to operating conditions, procedures and forms should be revised accordingly with a new version number, and a review should be conducted at least once a year.

deliverables

1. Operation procedures in separate volumes: startup and shutdown, inspection, adjustment, abnormality handling, maintenance;
2. Supporting record forms: inspection form, operation log, maintenance record, and shift handover record;
3. Abnormality Handling Card: A visual card displaying common phenomena and corresponding handling steps;
4. Text of job responsibilities and assessment methods;
5. Training publicity and implementation records, as well as assessment results;
6. Annual revision suggestions and version management agreements.

Frequently Asked Questions

The equipment is ready-made, so is it necessary to specially compile the procedures?

The instructions provide general requirements, but what is needed on site is specific actions under the factory's working conditions. For devices without procedures, the quality of operation depends on the personnel on duty. After personnel turnover, the status becomes unstable - procedures are the carrier that solidifies experience.

Can the enterprise itself compile it?

Yes, it is entirely feasible to develop a small device with high compatibility by oneself. The value of project services lies in bringing over operational experience, common abnormal scenarios, and mature form templates of similar devices. The development cycle is short, with fewer omissions, and the pitfalls of publicity and revision have been stepped over in advance.

Will the compiled procedures become outdated quickly?

It may become outdated, so the delivery includes an amendment agreement: revisions will be made simultaneously when the device and operating conditions change, and a fixed inventory will be conducted annually. Procedures are managed by version number, with old versions being recycled, and only the current version being retained on site to avoid mixing old and new versions.

This article is compiled by Luoyang Wohong Petrochemical Equipment Co., Ltd., which provides design, manufacturing, and operation and maintenance services for condensation recovery, membrane separation recovery, and complete solvent recovery equipment to chemical and pharmaceutical enterprises. If you need process evaluation or scheme configuration, please feel free to contact us for discussion.