1.     Replay of the emergency repair process

At 8: 00 a.m. on 9^th January, the deputy director Xiong Yongxiang of the No.3 FCC workshops detected the abnormal vibration of the flue gas turbine.

The Run & Maintain workshop made a quick response, and arranged a shift team to cooperate with the No.3 FCC workshop to stop the steam turbine and then start the reciprocating compressor.

At 8:06 a.m., the standby main fan started up normally. The Run & Maintain workshop conducted investigation, test and recorded all data of the air inlet valve, air exhaust valve and oil injection system of the compressor, and arrange the personnel on duty to inspect it from time to time to ensure the normal operation of the standby main fan.

After the standby main fan was started, the Run & Maintain workshop immediately put the emergency repair task of the faulty flue gas turbine on the schedule and made deployment, and then arranged workshop team 1 as the main force responsible for this emergency repair. Meanwhile they picked one technician from other shift team to support this task.

At 9:00 a.m., the main fan is shut down and turned off. At 9:30 a.m., the installation team disassembled the inlet for short insulation, and the temperature reaches 600 ° c, waiting for cooling (more than 10 hours). At 16:00 p.m., the installation team ready to remove the flue gas turbine concentric reducer.

During cooling period, the Run & Maintain workshop convened technical backbones and made full and detailed preliminary preparations for maintenance, including discussion and determination of maintenance plan, preparation of equipment and tools, etc., all works started at 10th January.

On 10^th January

8:00 a.m.to 12:00 a.m., the instrument team remove the instrument probe, and the locksmith team remove the concentric reducer and the intake cone.

At 13:00 p.m., the fitter team remove bearing box volute, and then the air intake cone to repair the individual screw hole, handle the instrument thermocouple and other operations in the county industrial park machinery factory. In order to supervise the progress, the workshop arranged a fitter and an instrument professional to follow up the whole process until the air intake cone was repaired and transported back to the site of No.3 FCC maintenance site.

At 14:00 p.m., the fitter professional pump the rotor and clean the inside of the rotor.

On 11st January

At 8:00 a.m., clean and test parts.

At 10:00 a.m., the rotor is installed.

At 12:00 a.m., the installation is completed and the installation requires accurate positioning.

At 13:00 p.m., install the bearing box.

At 15:00 p.m., send the air inlet cone back to factory, and install it.

At18:30 p.m., the installation is completed.

At 18:30 p.m., the electric instrument personnel install instrument probe. The installation requirements of the probe are relatively strict, if the installation precision is not good enough, or the accuracy is not high enough, it would affect the measurement, and cause the chain shutdown. Personnel overcome the low temperature at night, bad light condition and other difficulties, dedicated to the operation and strive for excellence.

At 20:00 p.m., the installation is completed.

It is the coldest time in China, when there is an emergency in the flue gas turbine. In order to repair the unit and put into operation a short time, the repair personnel overcome all the difficulties and cooperate closely. It only takes 2 days from having the qualified the maintenance condition to the completion of the maintenance. This refreshes the shortest time record of replacing the rotor in our company.

During the rush repair period, the company manager Ma Chuanbo came to the scene many times to supervise and guide; Production management department, equipment management department, 3^rd catalytic workshop and other departments also give full support and close cooperation, which provides guarantee for accelerating the repair progress. By 8:00 pm on January 11, the whole maintenance task was successfully completed, and the three units start the work successfully.

2.     An “accident” in the emergency repair process

At 5:00 p.m., on 9^th January, during the maintenance hoisting operation, the aerial crane broke down and not working functionally. The Run & Maintain workshop emergency electrical professionals Duan Wendong and Li Chongliang rushed into to the site for inspection and maintenance. As the height is higher than 13m, after authorized by the equipment management department, the two men climbed the 13m aerial crane and checked the distribution box and circuit. At 19:00 p.m., they defined that there was a problem with the control loop cable, and 4 of the 12 core control cables were short circuited, and it was not worthy to fix. After the cause of the fault was defined, these two men quickly communicated with the workshop. Considering that if not repair in time, it woukd seriously affect the maintenance progress of the flue gas turbine, thus the workshop decided to change the control cable. At 19:30 p.m., Duan Wendong and Qi Yongxue climbed the aerial crane for operation. At 23:00 p.m., all the wires (more than 20 meters) have been replaced and the loop circuit is normal. Hence valuable time is gained for maintenance later.

3.     Influence and evaluation (provided by production management department)

In the morning of 9^th January, the vibration numerical value of the flue gas turbine of the 3^rd catalytic workshop suddenly increased. According to the judgment of the abnormity, the 3^rd catalytic workshops decided to switch the standby unit and the flue gas turbine shutdown after the report. Meanwhile, the centrifugal turbine unit was shut down and the reciprocating machine was switched for operation, and the processing load of the unit was greatly adjusted. The shutdown of the flue gas turbine also has a great impact on the public system and material balance: insufficient steam consumption, imbalance of upstream and downstream materials etc. At the same time, the outage of the two units will increase the power consumption by nearly 200 thousand degrees every day. Put it into use as soon as possible is balanced stability and it brings economic benefit, so time cannot be wasted. During this critical period, the Run & Maintain workshop and the installation company carry out emergency repair method. The equipment management department and the 3^rd catalytic workshop actively cooperate to determine the solution and allocate the material. Finally, it was starting up successfully at 19:00 p.m. on 12th January, and it was effectively ensured the balance and stability of production. It shows the spirit of unity of the company and the good work style.

4.     The power of example

The rush repair of the flue gas turbine is the first tough battle that the Run & Maintain workshop has encountered since the company's institutional reform and functional reorganization. Through the unremitting efforts, the original 5-6 days maintenance task has been shortened to 2 days. This is another nice battle that the Run & Maintain workshop has won. From this we can see:

1.     The rush repair process is well-organized, reasonably deployed and strongly executed, which gained time for the quick overhaul of the flue gas turbine;

2.     The rush repair work is highly valued by the top managers of the company, and is strongly supported and fully cooperated by the relevant departments, which provides a great help to shorten the rush repair time;

3.     The combination of the company's institutions makes the integration of resources and the strengthening of functions, which is favorable for the improvement of workshop efficiency and execution;

4.     After the establishment of the Run & Maintain workshop, the management promotion and cultural remold achieved good results. The workshop culture connotation of "simple, harmonious, hard and dedicated" and the work concept of "self-discipline and hard work" make the staff's ideological cognition and behavior standard more unified, and the workshop's mental outlook and comprehensive guarantee strength reached a new level.

The company is in a special and critical period of trying to promote upgrading and transformation, and further promoting the opening pattern. It needs this kind of work spirit of concerted efforts, dedication and hard work, more cadres and employees who are brave to bear the heavy burden and overcome all kinds of difficulties. This spirit of dare to challenge is what we need to accelerate the healthy and sustainable development of Hengyuan!