# Fermentation Heating Tube Anti-Corrosion Knowledge Base Construction, Case Inheritance & Experience Promotion Specification ## Preface This specification is the extended supporting document of the full anti-corrosion management system covering Doc.33 to Doc.120. It standardizes the classification collection, standardized sorting, review verification, internal sharing, hierarchical training application and cross-workshop replication promotion of all anti-corrosion typical failure cases, technical optimization schemes, mature maintenance experience, accident root cause analysis reports and verified process improvement achievements. It solves the problems of experience loss caused by personnel turnover, repeated recurrence of similar corrosion faults and uneven management levels among different production workshops, realizes the inheritance of on-site anti-corrosion practical experience, and provides rich data and case support for system annual review, document revision and staff competency training. ## 1. Classification and Archiving Rules of Anti-Corrosion Knowledge Base Materials All collected materials are divided into six core categories with unified coding and filing standards: 1. Typical Corrosion Failure Case Library: Including pitting corrosion, stress cracking, microbial under-deposit corrosion, galvanic corrosion, lining peeling, leakage and other fault records, each case must contain equipment number, failure phenomenon, inspection data, root cause analysis, rectification plan, post-repair verification data and preventive optimization measures. 2. Process & Parameter Optimization Case Library: Mature adjusted schemes of pickling passivation parameters, medium switching flushing procedures, static standby protection strategies, low-flow anti-corrosion control measures verified by long-term operation data. 3. Hardware Transformation & Material Matching Experience Library: Auxiliary pipeline dead-angle rectification, support anti-corrosion reconstruction, dissimilar metal isolation improvement, heating tube and sealing accessory material selection and spare parts application practical experience. 4. Accident Investigation & Accountability Archive Library: Safety leakage incidents, cross-medium contamination accidents, equipment scrapping caused by non-standard operation, together with closed-loop rectification and responsibility identification documents. 5. Third-Party Test & Data Analysis Library: Long-term trend data of medium ion detection, equipment wall thickness inspection, material performance test reports and seasonal corrosion statistical analysis results. 6. Excellent Incentive Improvement Achievement Library: Employee rationalization proposals, energy-saving and consumption-reducing optimization projects, anti-corrosion management innovation practices that have obtained factory reward recognition. All materials adopt dual electronic and paper archiving, with unified indexing labels of workshop, equipment type, fault category and occurrence time, to support fast retrieval during training, audit and system review. ## 2. Standardized Submission, Review and Access Management Mechanism Each workshop is required to submit no less than two typical anti-corrosion cases or practical optimization experiences to the equipment management department every quarter. Frontline operators, maintenance technicians and workshop supervisors can submit materials through the internal application system, and all submitted contents need to be attached with original inspection records, test data, on-site photos and implementation effect verification forms to avoid subjective and unsubstantiated experience summary. The equipment management department, together with the quality supervision department, conducts centralized review of all submitted materials: eliminate repetitive, inaccurate and unvalidated content, sort qualified cases into the official knowledge base, mark key high-risk typical faults as mandatory learning content for all posts. The knowledge base sets hierarchical access authority: basic case materials are open to all on-site employees; confidential cost analysis, major accident investigation and core optimization schemes can only be accessed by management and technical personnel after approval, complying with the data security requirements specified in Doc.108. ## 3. Internal Training & Post Competency Application of Knowledge Base The knowledge base is designated as the core teaching material for tiered anti-corrosion training in Doc.105: basic-level training selects common minor corrosion cases to help frontline operators identify hidden risks and standardize operation behaviors; intermediate training takes equipment failure and maintenance optimization cases as teaching carriers to improve maintenance personnel's fault diagnosis and process improvement capabilities; advanced training relies on major accident investigation and batch data analysis cases to strengthen supervisors' risk overall control and system optimization thinking. New employees, transferred post personnel and temporary replacement staff must complete the designated compulsory case learning and pass the corresponding theoretical assessment before taking up their posts. The learning records and test results are incorporated into personal competency archives, and supervisors shall regularly spot-check employees' mastery of typical fault disposal experience in daily on-site inquiries. ## 4. Cross-Workshop Experience Replication & Benchmark Promotion Mechanism Every six months, the equipment department sorts out mature, replicable excellent anti-corrosion optimization cases from the knowledge base, compiles standardized promotion implementation guidelines, and selects the workshop with the best implementation effect as the benchmark demonstration site to organize cross-workshop on-site exchange and observation activities. Before factory-wide popularization of any mature improvement scheme, a small-scale pilot verification shall be carried out in 1–2 workshops according to the dynamic revision requirements of Doc.120. After confirming that the scheme can effectively reduce the local corrosion failure rate and maintenance cost without inducing new safety risks, it shall be incorporated into the formal clauses of the corresponding anti-corrosion specification through the document revision approval process, and promoted to all production lines together with special interpretation training. ## 5. Regular Update, Screening and Elimination Mechanism of Knowledge Base The knowledge base undergoes centralized sorting, supplementing and invalid content cleaning every year in conjunction with the annual system review work: eliminate outdated cases that are no longer applicable due to equipment upgrading, process reform and document clause revision; supplement typical faults and innovative optimization achievements newly accumulated in the current year; classify and mark historical classic cases that still have reference value as long-term reserved learning materials. Combined with monthly corrosion failure statistical data, the management team regularly counts the recurrence rate of faults recorded in the knowledge base. If the same type of accident still occurs frequently after the case is included in the mandatory learning catalogue, it is necessary to check the loopholes in training implementation, on-site supervision and standard execution, and formulate supplementary rectification and strengthened publicity measures. ## 6. Archive and Long-Term Value Inheritance All case submission forms, expert review opinions, training learning records, cross-workshop promotion implementation reports and annual knowledge base sorting summary documents are permanently archived together with the full set of anti-corrosion system documents. The knowledge base serves as an important inheritance carrier of enterprise equipment management experience, effectively avoids experience loss caused by personnel mobility, continuously empowers the iterative upgrading of the whole anti-corrosion closed-loop management system, and consolidates the long-term operational soft guarantee for the safe and low-consumption service of fermentation heating tube equipment.
