化工集团公司工艺、设备管理制度汇编

XXXXXXXX化工集团公司工艺、设化工集团公司工艺、设化工集团公司工艺、设化工集团公司工艺、设备管理制度汇编备管理制度汇编备管理制度汇编备管理制度汇编化工企业管理制度•工艺篇-1-编制说明工艺管理、设备管理是化工企业实现安全生产的管理基础，通过建立、健全工艺、设备管理制度，明确分工、明确职责、明确管理流程，有利于提高企业的整体管理水平，确保生产系统实现“安、稳、长、满、优”安全运行，提高生产效率，实现节能降耗，降本增效。由于历史原因，集团公司化工企业在生产规模、工艺技术和设备的先进性、人员的业务技能等方面存在较大差异，各单位的管理水平、管理标准参差不齐，尤其是部分小企业，建厂早、工艺落后、设备老化，工艺管理和设备管理工作非常薄弱。因此，为充分发挥大集团的整体优势，提升化工企业的整体管理水平，全面实行规范化、标准化、科学化管理，化工事业部组织中原大化、煤气化公司、安化公司和龙宇煤化工等单位的专业技术管理人员，依据国家、行业标准和规范，对各单位现有的企业标准深入研究，博采众长，编写了14项主要工艺管理制度和18项主要设备管理制度，作为化工企业的统一管理制度。同时为了促进各单位加强工艺、设备管理力度，还制定了《化工工艺管理考核标准》和《化工设备管理考核标准》。由于本次编写的管理制度要兼顾不同的企业，制度的深度和广度仍需完善，要求各单位在本制度的基础上，结合本单位的管理结构和技术特点，进一步细化、充实制度内容。本次未制定的其它相关管理制度，由各单位自行制定。今后各单位的制度格式要与本制度统一。化工事业部将按照考核标准定期对各单位的工艺、设备管理工作进行监督、检查和考核。由于时间仓促，本制度存在的不足之处，请各单位及时提出宝贵意见，化工事业部将组织人员进行修订。化工企业管理制度•工艺篇-2-XX化工集团化工事业部二〇一〇年三月化工企业管理制度•工艺篇-3-目录工艺篇工艺管理责任制··············································································-6-化工岗位责任制············································································-11-化工岗位操作人员巡回检查制度··················································-14-化工岗位交接班制度·····································································-17-生产调度管理制度········································································-20-工艺指标及分析频率管理制度······················································-28-工艺操作规程管理制度·································································-32-岗位记录及工艺台帐管理制度······················································-36-开停车方案管理制度·····································································-42-系统及主要设备开停车确认制度··················································-47-工艺联锁、报警管理制度·····························································-51-技术改造管理制度········································································-53-工艺月报管理制度········································································-60-工艺操作事故管理制度·································································-62-设备篇设备管理责任制············································································-67-设备技术基础管理制度·································································-71-化工企业管理制度•工艺篇-4-设备维护保养管理制度·································································-76-设备密封管理制度········································································-80-设备润滑管理制度········································································-86-设备巡检/包机理制度···································································-93-备机管理制度················································································-96-特种设备管理制度········································································-98-设备检修管理制度········································································-98-供用电管理制度··········································································-115-仪表管理制度··············································································-120-计量分级管理制度······································································-126-设备防腐蚀管理制度···································································-131-备品备件制度··············································································-134-修旧利废管理制度······································································-138-设备事故管理制度······································································-141-设备更新改造和报废管理制度····················································-146-建(构)筑物、设备基础管理制度·················································-150-附件一：设备检查评级管理标准---------------------------------------150-附件二：工艺管理考核标准------------------------------------------150-附件三：设备管理考核标准------------------------------------------150-化工企业管理制度•工艺篇-5-工艺管理责任制1111范围本制度规定了生产过程工艺管理的范围。本制度适用于XX化工集团各化工企业产品生产过程中各工序的控制。2222规范性引用文件GB/T1.1—2000标准化工作导则第一部分标准结构与编写规则GB/T15498—2003企业标准体系管理标准与工作标准体系。3333职责3.1生产工艺管理部门制定本制度，并组织执行本制度。3.2安全管理部门负责对生产过程的环境状况进行监督检测和组织制定产品生产过程中的安全规程并组织实施。3.3劳动人事部门负责组织对生产过程及产品质量有关人员的培训、考核工作。4管理内容与要求4.1工序控制点的设置及控制方法和要求4.1.1生产管理部门根据工艺流程的实际情况确定各生产装置的主要控制指标，并列出《一级控制工艺指标一览表》及《分析项目频率一览表》。化工企业管理制度•工艺篇-6-4.1.2各生产单位的工艺操作人员根据工艺指标对工艺状态实施控制，并根据仪表显示和检验监测数据调整工艺状况，填写“岗位记录日报表”。4.1.3各化验室对所辖范围内工序控制点的项目按《分析项目及频率一览表》及“分析规程”进行检验，及时将结果报工艺操作人员。4.1.4生产管理部门按照《一级控制工艺指标一览表》对生产过程中关键工序主要控制指标的监督抽查。4.2工序检查4.2.1工艺操作人员根据本岗位操作规程的内容规定频率和要求对所在岗位进行巡回检查，发现问题要及时采取措施进行处理，并将检查情况及处理结果记入“岗位交接班日志”中，处理不了的问题向值班长汇报。4.2.2值班长每班对现场主要岗位及重要设备每班巡检不少于两次，发现或接到工艺人员汇报的问题及时联系有关人员并组织处理；对外界有影响或与外界有联系的问题要向值班调度汇报，并根据值班调度指令组织处理；当班无法处理时向本单位值班领导汇报，根据值班领导的指令组织处理。处理过程及结果记入相应岗位记录。4.2.3各工序（装置）的工艺技术员在工作日内每日要到现场进行巡检，全面检查工艺指标执行情况，装置运行情况，将巡检中发现的问题通知当班值班长组织处理，如果问题较为严重时向主化工企业管理制度•工艺篇-7-管领导汇报，并按要求填写“工艺检查台帐”。4.2.4生产管理部门每周组织一次生产过程工艺管理执行情况抽查，抽查结果及时通知有关单位。4.3工艺指标偏离规定要求的处理4.3.1岗位工艺操作人员根据仪表显示数据和检验结果，发现工艺状况偏离“操作规程”及有关技术标准要求时，立即进行调整处理，并向值班长汇报，填写“岗位日志”。4.3.2工艺值班长要组织、协调对偏离控制要求的工艺指标进行调整。如果是由于工艺操作以外的原因要及时联系有关人员或调度室进行处理，并将处理结果记入各自的岗位日志。4.3.3如果调整后仍达不到要求或问题重大时，生产单位主管领导或值班领导要直接参与组织进行处理。4.3.4当由于工艺指标偏离影响到其它工序时要立即向调度汇报，调度要向相关单位通报有关情况，积极协调，避免影响扩大，并填写“调度日志”。4.4紧急故障及事故的应急措施4.4.1各岗位操作人员必须掌握“操作规程”中紧急故障及事故处理的应急措施，以便在出现紧急故障或事故的情况下，按规定的程序进行处理。4.4.2紧急故障或事故的影响范围只局限于本岗位时，岗位操作人员及时进行处理，向值班长汇报，由值班长负责协调处理。4.4.3紧急故障或事故的影响范围波及到其它工序时，岗位操作