Sulfur Regulations

6. Safety Production Regulations 6.1 Daily Production Safety Regulations 6.1.1 It is necessary to ensure an adequate number of operators at their posts; those who have not received three levels of education and technical training are not allowed to operate the equipment. 6.1.2 On-duty personnel must remain at their posts and conscientiously abide by industrial discipline and operating rules. It is strictly prohibited to operate equipment under conditions of excessive temperature, pressure, or load. Unauthorized personnel are not allowed to tamper with any equipment or instruments at the post. 6.1.3 Before handling instruments, instrument technicians must contact the operators; work may proceed only after the operators have taken appropriate measures. When repairing critical instruments, a plan must be prepared, and the workshop personnel should address the issue only after arriving on site. 6.1.4 Before entering towers, containers, underground oil wells, and underground valve chambers, toxic and oxygen content analysis must be conducted first, an entry permit for equipment work must be obtained, and a dedicated person must be present to supervise the operation. 6.1.5 When sampling or turning on/off the sewage magnetic system, as well as in the event of an emergency, at least two people must be present at the site: one to supervise and one to carry out the work. 6.1.6 Implement the safety technical regulations issued by the manufacturer. 6.1.7 Control the height of the gas holder according to the process sheet to prevent over-height or deflation due to oil loss. 6.1.8 It is prohibited to discharge gas residues, acidic gases, and acidic water arbitrarily; they must be collected in a sealed manner. 6.1.9 All containers in the flare system should have their oil and water supply cut off in a timely manner to prevent rain of flammable liquids at the flare and pressure buildup within the flare system. 6.1.10 During winter production, it is necessary to strictly follow the safety regulations for preventing freezing and condensation to ensure the unobstructed flow of the flare line. 6.1.11 When entering the underground tank room to carry out operations, the exhaust fan must be started in advance to prevent the accumulation of harmful gases in low-lying areas; one person should act as a supervisor while another performs the operations. (Use an air respirator if necessary to prevent poisoning.) 6.1.12 Before starting the compressor, it must be rotated several times; the inlet and outlet pipelines should be drained of any residual liquid, and the liquid level in each separation tank should be less than 50%. 6.1.13 During compressor operation, the drain line between the first stage cylinder and the second stage cylinder must remain unobstructed. 6.1.14 The water seal tank of the flare line must maintain a certain water level in accordance with the process sheet. 6.1.15 When filling or draining the water seal tank, personnel on this post must not leave the site. 6.2 Safety Provisions for Commencing and Ceasing Operations 6.2.1 Safety Provisions for Commencing Operations 6.2.1.1 All employees shall be organized to conduct a thorough inspection of newly installed or repaired equipment; all planned maintenance tasks must be completed, and the quality must meet regulatory requirements. In particular, for newly installed equipment, relevant handover documents must be available. 6.2.1.2 Study the construction plan carefully; the details of the renovation project must be clearly explained to all employees so that everyone understands it. 6.2.1.3 Inspection and acceptance items: (1) All items specified in the maintenance plan must be completed fully, without any unfinished tasks, and the quality must be satisfactory. (2) The entire device is thoroughly cleaned, free of oil stains, waste, and debris. (3) Except for the machinery to be transported, which is placed in a safe location, all other machinery, equipment, scaffolding, etc. are removed from the installation. (4) All industrial equipment pipelines, valves, and instruments are properly insulated, have all necessary components, and are in normal condition. (5) Safety facilities are complete; safety valves, pressure gauges, level indicators, alarms, ventilation facilities, fire-fighting equipment, and lighting are all present and in good working condition. (6) The supply of water, electricity, steam, and air is normal, and all sewer manholes and ditch covers are properly closed. (7) All blind flanges that need to be removed have been removed, and all blind flanges that need to be installed have been put in place. Drainage at the low points of all valves has been carried out, and the vent valves are in a closed state. They will be gradually opened as needed after startup to prevent any leakage incidents. (8) The emergency venting equipment is in good working condition, and the equipment’s self-protection system is sensitive and functional. (9) All ladders, platforms, and railings are in good condition; the protective covers for operating equipment are complete; the equipment is properly grounded; and fire-fighting and gas masks are available. (10) Raw materials such as fuel, gas solvents, catalysts, and demulsifiers should be prepared, along with spare parts and specialized tools. (11) Arrange the shift workers properly to ensure adequate rest, and prepare the production supplies. 6.2.1.4 After the start-up order is given, the plant shall begin operation in accordance with the steps outlined in the start-up plan. 6.2.1.5 During the start-up period, the following points must be observed: (1) Command for starting up operations shall be issued uniformly by the workshop leaders who are familiar with production processes and the shift supervisors; under no normal circumstances should other personnel give direct instructions to the operators on the job. (2) Attention should be paid to removing air from the system during feeding. (3) Prevent bumping and oil leakage during the constant-temperature dehydration process of the device. (4) When the temperature is raised to 200–300°C, the equipment should be heat-tightened at a constant temperature; when tightening the bolts, appropriate and even force should be applied. (5) When activating equipment and opening valves, do so slowly to prevent leaks or water accumulation caused by sudden temperature changes. For heat exchangers, ensure that the pressure difference between the tube side and shell side is not excessive, so as to avoid overpressure damage to the equipment. (6) Due to the frequent opening and closing of valves, operators on duty should pay attention to confirming and rechecking them, especially the high/low temperature connection valves as well as the valves connecting the oil line to the air line, in order to prevent mistakes in operation that could lead to accidents. (7) It is not allowed to replace gaskets or add packing under pressure. (8) The valve downstream of the safety valve must be fully open. (9) Before putting equipment into use, it is necessary to rely on analytical data rather than experience; this is especially important before putting gas cabinets into operation. (10) The torch must be purged with steam before ignition to prevent flash explosions. (11) The safety accessories of each device must be complete and in working condition. (12) The supply of water, electricity, steam, and air shall meet the process requirements. (13) The equipment’s automatic protection system must be flexible and easy to use, such as the cylinder valve at the inlet of the gas tank, the oil pressure of the compressor, the temperature at the secondary outlet, and the exhaust pressure at the secondary outlet. 6.2.1.6 Strengthen communication with the dispatch team to ensure a balanced supply of raw materials, as well as water, electricity, gas, and air; all maintenance personnel shall carry out their tasks to maintain operational continuity. 6.2.1.7 After the commissioning of newly built, renovated, or expanded facilities following their completion and acceptance, various rules and regulations shall be established. Commissioning shall be carried out in accordance with the requirements set forth in these regulations. Workers must undergo training and pass assessments; functional departments within the plant shall form a commissioning team to assist in the process, ensuring a successful first-time commissioning. 6.2.2 Safety regulations for plant shutdowns 6.2.2.1 Except in cases of emergency shutdown due to accidents, plant shutdowns should be carried out in accordance with a predetermined shutdown plan. A shutdown plan must be established for the plant to be shut down, and this plan should be thoroughly explained to all employees so that everyone is aware of it. During winter shutdowns, measures to prevent freezing and condensation must be taken. 6.2.2.2 During short-term shutdowns without maintenance or minor repairs, in addition to taking measures to prevent freezing and condensation, thorough cleaning may be omitted with the approval of the relevant departments. 6.2.2.3 For units that are shut down for a long period or undergoing major/minor repairs, operations must be carried out in accordance with operating procedures or the shutdown plan; thorough purging is required to meet the conditions for hot work. 6.2.2.4 The following points should be noted when shutting down the equipment: (1) The shutdown must be ordered under the unified command of the workshop supervisor and the shift leader, with close coordination with relevant units. (2) There should be a proper purging procedure; a purging record must be filled out, specifying the purging process, timing, and responsible person, to prevent any omissions or oil cross-contamination. (3) It is strictly prohibited to use compressed air for direct purging; only after the purging is complete can air be used to remove any remaining water, in order to prevent explosions and fires. (4) It is prohibited to discharge acidic gases, ammonia, and gas into the ground, sewers, or atmosphere to prevent poisoning or explosions and fires. Any oil remaining in the equipment must be drained, and gases should be sent to a flare; any trace amounts of oil and gas that cannot be processed must be vented after the heating furnace has been completely shut down. (5) During the shutdown purging process, there should be no sources of fire around the facility. (6) After the equipment has been purged, the raw materials, fuel, gas, and solvents supplied to the device, as well as the finished products, semi-finished products, and gas exiting the device, must be cut off. All pipelines should be fitted with blind flanges, and a person designated to oversee these blind flanges should be assigned to keep track of them through numbering and labeling, in order to prevent omissions when installing them or failures to remove them before starting up the device, which could lead to accidents. (7) During winter shutdown, all equipment pipelines should be shut down; low-point drains and vents must be fully opened to remove accumulated water. In the absence of vent valves, the lowest flanges, plugs, blind plates, or covers should be removed, and regular inspections during duty shifts are necessary. (8) After the plant is shut down, experienced personnel should be assigned to duty to conduct regular inspections of various stations, paying special attention to abnormal situations such as the spontaneous combustion of iron sulfide in open equipment. (9) There must be test and analysis data for the medium replaced in the equipment. (10) It is strictly prohibited to use compressed air to clean gas lines and oil lines; air can be used for cleaning only after they have been cleaned with steam. (11) During the shutdown period, it is strictly prohibited to discharge gas, residues, acidic gases, and oils onto the ground, into open ditches, floor drains, or septic tanks. Oils must be recovered and removed, harmful gases should be burned in flares, and residual liquids as well as acidic water must be recovered and treated. 6.3 Safety regulations for equipment maintenance The characteristics of equipment maintenance include tight deadlines, heavy workload, limited space, a large number of personnel, concurrent operations, extensive use of fire, and a high risk of various accidents. These regulations are formulated to ensure safety during maintenance work and to prevent accidents such as personal injuries, fires, and explosions. 6.3.1 Preparatory work before equipment maintenance
6.3.1.1 Prior to shutting down the equipment, a plan for shutdown and purging must be formulated.
6.3.1.2 When cleaning the equipment pipelines during purging, it is necessary to coordinate with relevant areas beforehand to adjust the process flow, thereby preventing issues such as pressure buildup, tank overflow, or improper airflow direction. 6.3.1.3 After shutting down, the pipelines connected to other production units must be disconnected or blind flanges must be installed. During maintenance, the person in charge of blind flanges is responsible for installing and removing them, and proper registration numbers must be kept; all locations of blind flanges should be clearly marked. 6.3.1.4 When cleaning the lines, be careful to turn on the water first; gradually increase the gasoline flow to prevent water hammer from damaging the pipelines and equipment. 6.3.1.5 The tower and containers may be opened only after 24 hours of steaming; it is necessary to ensure that the internal pressure has been completely released before opening them. The manhole covers of the tower should be opened after the temperature has dropped. The opening process should be carried out from top to bottom. After ventilation for more than one day, the plant personnel shall conduct inspections, and entry is permitted only upon confirmation that all conditions are satisfactory. Before entering the tower or containers, samples must be taken to analyze combustible, toxic, harmful gases as well as oxygen levels. Once these tests show satisfactory results, an operation permit for entering the equipment must be obtained. At least two people must be present when entering the tower. 6.3.1.6 For septic tanks and sewers containing oil and gas, they should be flushed clean with water; a water seal can also be used to prevent explosions. Gullies and drains should be cleaned thoroughly and sealed properly. 6.3.1.7 Fuel and steam lines must be isolated with blind flanges to ensure the safety of personnel entering the furnace. 6.3.1.8 During shutdown for maintenance, water, electricity, gas, and air supply are under the unified control of the production scheduler; no one is allowed to supply or stop these services without permission. 6.3.1.9 During equipment maintenance, the workshop supervisor and the full-time safety officer are responsible for inspecting the area where work is being carried out, for proposing and implementing fire prevention measures, and for approving the fire permits. 6.3.2 Preparation for maintenance work 6.3.2.1 Before the maintenance begins, the factory headquarters forms a maintenance command team, and the workshops establish leading groups to establish \"five fixed\" measures for each maintenance task, namely: fixing the project scope, safety measures, quality requirements, completion time, and the person in charge of the project. 6.3.2.2 Each inspection and leadership group must adhere to the principle of “safety first” during maintenance activities, ensuring the “six simultaneities”; that is, while planning, arranging, inspecting, contracting, summarizing, and evaluating production work, they must also plan, arrange, inspect, contract, summarize, and evaluate safety work. 6.3.2.3 The workshop maintenance leadership team shall designate safety officers for each independent maintenance team, who are responsible for monitoring and supervising safety measures during maintenance work. In the event of any accident, whether large or small, the principle of \"four no-lets-go\" must be adhered to. 6.3.2.4 Before carrying out any maintenance work, a work plan must be prepared in accordance with safety regulations; larger plans should be submitted to the maintenance command center for review or approval. 6.3.2.5 Before maintenance, all equipment must be carefully inspected, especially welding and lifting tools; those that do not meet the requirements must not be used. 6.3.2.6 Each scaffold must be inspected to ensure it is sturdy and secure; it can only be put into use after approval by the person in charge on site. 6.3.3 Safety regulations during maintenance work 6.3.3.1 A strict and scientific approach should be adopted, with emphasis on carrying out maintenance work in a civilized manner. When there is a conflict between maintenance work and safety, safety must take precedence. Carelessness and lax attitudes should be avoided. 6.3.3.2 Personnel involved in maintenance work must attend daily pre-shift safety meetings and post-shift safety reviews. 6.3.3.3 All individuals entering the maintenance area must wear their protective equipment properly, including safety helmets; slippers are not allowed, and those working at heights must wear safety belts. 6.3.3.4 Fire prevention measures must be implemented, and an appropriate number of fire-fighting equipment items should be available on site. 6.3.3.5 New workers (including interns and trainees) as well as those who come to the maintenance area to work should operate under the supervision of experienced workers, who shall inform them of safety precautions to prevent problems arising from a lack of experience. 6.3.3.6 Strictly enforce labor discipline in the maintenance yard; fighting is prohibited, as is wandering around indiscriminately. One must concentrate during work, adhere to traffic safety rules, and must not climb on vehicles or force one’s way onto them. 6.3.3.7 Try to avoid concurrent operations at different levels; when such operations do take place, rope nets should be used as a barrier between the levels. 6.3.3.8 Cranes and lifting equipment must be operated under the unified command of a designated person; unauthorized personnel are not allowed to use them. The area where heavy objects are lifted should be enclosed with ropes and nets, and signs prohibiting access should be posted. Thorough arrangements must be made to ensure safety. 6.3.3.9 Workers performing work at heights shall have tool bags, which must be hung in a secure location to prevent tools from falling and causing injury. 6.3.3.10 When working at heights, no one shall stand under objects that are being installed or removed, as well as under furnaces, towers, containers, and heat exchange equipment, to prevent injury from falling objects. 6.3.3.11 The distance between the oxygen cylinder and the acetylene cylinder used for gas welding should be more than 3 meters; the acetylene cylinder must also be at a distance of more than 10 meters from any open flames. It is necessary to prevent sparks from falling from heights, and care must be taken to avoid backfire or improper operation that could cause the acetylene cylinder to explode and injure people. 6.3.3.12 Whenever electrical equipment is to be maintained, the power supply must be disconnected and a warning sign must be placed; the “three, three, two, five” rules for electrical work must be strictly followed. 6.3.3.13 In addition to strictly following the welding procedures, welders must adhere to the principle of \"no welding without three conditions\": no welding without a valid welding permit, no welding unless preventive measures have been implemented, and no welding without a supervisor present. When working inside equipment, samples must be taken for analysis before welding can proceed; a test with an open flame must also be conducted before personnel enter the equipment, and a work permit for entering the equipment must be issued. 6.3.3.14 Management of the maintenance of critical equipment and vital parts must be strengthened; entry by unauthorized personnel is prohibited. Removed components must be properly stored to prevent loss or damage. 6.3.3.15 Minimize night-time operations; where work is necessary, adequate lighting must be provided. The voltage of temporary lighting fixtures used within equipment shall not exceed 36V. When working in narrow containers or humid areas, the voltage of handheld lamps must not exceed 12V, and such lamps must be equipped with protective covers. 6.3.3.16 After maintenance of equipment such as towers and vessels is completed, prior to sealing the manholes, both the plant and the maintenance workshop shall conduct a joint inspection and acceptance. Only after confirming that no items have been left behind shall both parties seal the manholes on the spot. 6.3.3.17 After the maintenance is completed, it is necessary to adhere to the rule of \"four conditions under which work may not commence\": work shall not start if the quality of the maintenance is poor, if leaks have not been completely sealed, if safety facilities are incomplete, or if the hygiene conditions are unsatisfactory. 6.3.3.18 Setting pressure of the safety valve. The workshop should assign a specific person to be responsible for inspection and acceptance, and keep records; the Mechanical Department shall be in charge of applying seals. 6.3.3.19 When carrying out maintenance work inside a container, or working in narrow and concealed areas, deep ditches, fire shafts, etc., a dedicated person must be assigned to supervise from the outside. 6.3.3.20 The use of gasoline to clean equipment and components is prohibited during maintenance. If gasoline must be used, it must be done with the approval of the safety officer in charge of the site, and at a designated safe location. Since the medium stored in the gas tank is flammable, explosive, and toxic refinery gas, all operators must exercise high levels of responsibility during operations, strictly adhere to the operating procedures, take good care of the equipment’s maintenance, and comply with relevant rules and regulations. In case of any problems, effective measures must be taken to resolve them. It is necessary to uphold the production principle of \"safety first, prevention foremost\" in order to minimize the risk of accidents such as poisoning, fires, and explosions. 6.3.3.21 During the commissioning, operation, and maintenance of the gas holder system, it is necessary to purge the gas pipelines with nitrogen or steam before taking any other actions; working with fire is strictly prohibited when gas is still present. Operators should enhance their awareness of poison prevention; when working in toxic environments, they must take necessary preventive measures against poisoning. 6.3.3.22 The compressor is strictly prohibited from being started when the height of the gas tank is ≤ 2.5 meters. When the compressor is in operation, it must be stopped if the height of the gas tank is ≤ 1.5 meters. 6.3.3.23 The gas holder must not exceed the upper limit or fall below the lower limit; it should be controlled in accordance with the process requirements. 6.3.3.24 Before starting the compressor, rotate it 3 times to remove all the condensate from the cylinder; ensure that the condensate is completely drained from the inlet and outlet pipelines. Check that the liquid level in each separator tank does not exceed the limit, to prevent liquid slugging incidents. 6.3.3.25 During compressor operation, the drain line between the first cylinder and the second cylinder must remain unobstructed to prevent condensate from entering the second cylinder. 6.3.3.26 The liquid level in the separator tanks at each inlet and outlet of the compressor must not be allowed to rise too high, to prevent liquid from entering the compressor cylinders. 6.3.3.27 It is strictly prohibited to start the compressor under pressure; the startup procedures must be followed rigorously. 6.3.3.28 When shutting down the compressor after removing the load (except in special circumstances), the shutdown procedures must be strictly followed. 6.3.3.29 When putting equipment into operation or starting it up, all safety accessories must be activated first. 6.3.3.30 When pressurizing each container with oil or water, the pressure level must be strictly controlled to prevent overpressure or water hammer effects. 6.3.3.31 When the valve is fully open, loosen it by one or two turns. When closing the valve completely, do not apply excessive force to prevent damage to the valve sealing surface and subsequent leakage. 6.3.3.32 When maintenance is required on a piece of equipment during the production process, the equipment must be shut down in advance. The media inside the equipment should be completely removed, and blind flanges should be installed to isolate it from other equipment and pipelines before disassembly for maintenance. In addition, a maintenance work permit must be obtained. 6.3.3.33 A flame arrester must be activated before igniting the torch to prevent backflow. 6.3.3.34 When purging cold exchange equipment, during one stage of purging, there must be a vent in the other stage to prevent overpressure damage to the equipment caused by liquid vaporization. 6.3.3.35 When introducing steam into pipelines and equipment, the steam must be dried of water before it is fed into these pipelines and equipment, in order to prevent water hammer. 6.3.3.36 It is strictly prohibited to use air to purge gas lines and oil lines with a flash point below 130°C. 6.4 Safety regulations for fire and explosion prevention
6.4.1 It is strictly prohibited to stack flammable and explosive materials around production equipment. There should be no flammable substances in the vicinity of heating units. Flame arresters must be installed on gas pipelines, which must also be leak-proof. Gas pipelines must be regularly drained of oil and moisture. Fire-extinguishing steam lines and emergency vent lines must be kept unobstructed. 6.4.2 Pipelines, trenches, cable ducts, sewers, etc., that need to be moved during the production process must be properly isolated at points of entry/exit from units, buildings, substations, instrument rooms, and living facilities. 6.4.3 In light oil pump rooms, liquefied gas pump rooms, combustible gas compressor pump rooms, and areas where flammable and explosive materials are present, fire-extinguishing steam lines must be installed and kept in good working condition at all times. Additionally, natural ventilation and mechanical ventilation should be enhanced; any hammering or impact that could generate sparks is prohibited indoors. 6.4.4 There should be a recovery system for the discharge of residual liquids, gases, light oils, contaminated oil, etc., within production facilities. Under no circumstances, whether during production or maintenance, should these substances be discharged into sewers or onto the ground. 6.4.5 During production, before performing maintenance on high-temperature equipment, fitters must inform relevant personnel at the post and the shift supervisor. The inlet and outlet valves must be tightly closed to prevent any leakage; the temperature inside the equipment must not exceed 70°C, and it must be ensured that there is no pressure within the equipment before any maintenance can be carried out. 6.4.6 The multi-layer piping layout of the production units (high-temperature hot pipelines, corrosive pipelines, and flammable liquid pipelines) shall meet fire and explosion prevention requirements and be properly insulated. 6.4.7 Transmission lines in areas with flammable gases and oil vapors must be installed within pipes, and the lighting and electrical equipment in such areas shall comply with the explosion-proof specifications for electrical equipment issued by the Ministry of Petroleum. 6.4.8 All grounding devices shall be kept in good condition. 6.4.9 Insulation of high-temperature equipment and pipelines, with no flammable materials in the vicinity. Gauges on high-temperature pipelines and equipment should be brazed or silver-welded and equipped with isolation devices. 6.4.10 Solvents and flammable or explosive chemical raw materials required for device production should not be stored in large quantities; only the amount needed should be taken as it is used, and they must be kept properly stored. 6.4.11 When filling, placing, and transporting materials with a flash point of 45°C or lower, the following rules must be followed: Filling should be done slowly, not too quickly, and the outlet flow rate should be less than 4 meters per second. 6.4.11.1 Leave a 5-cm margin when filling oil drums or other containers. 6.4.11.2 When stored outdoors, a shelter should be used to protect it from direct sunlight. 6.4.11.3 Use wooden planks as rollers to prevent collisions during handling. 6.4.12 When operating the production equipment, it is necessary to strictly adhere to all process parameters and operating procedures; no changes should be made arbitrarily. Operating under conditions of excessive temperature, pressure, speed, or load is strictly prohibited, and the equipment must not be used when it is malfunctioning. It is also forbidden to disassemble any components while the equipment is in operation. 6.4.13 For equipment and containers used for transporting, storing flammable, explosive, and toxic substances, the discharge valves or open-type safety valves on such equipment and pipelines shall not be installed in a position facing high-temperature equipment or high-temperature pipelines. 6.4.14 During major overhauls of production units, the \"Safety Regulations for Major Unit Overhauls\" must be followed. 6.4.15 Within the production facility, a specified number of fire-fighting equipment must be installed, depending on the type of flammable materials present. 6.4.16 Each production unit shall, based on its own production processes and characteristics, and in accordance with relevant fire and explosion prevention regulations, formulate its own rules for fire and explosion prevention, anti-freezing and anti-condensation measures, as well as safety production protocols. 6.4.17 For new installations, new processes, new technologies, as well as processes and equipment in newly expanded or renovated installations, a complete set of safety measures must be in place, including operating procedures, process parameters, and start-up and shutdown plans; otherwise, operation is not permitted. 6.4.18 Before putting the production unit into operation, blind flanges must be installed at the connections of the air lines and high-temperature steam lines. 6.4.19 Under no circumstances shall liquid hydrocarbons be used to clean the gasoline pipeline. 6.5 Safety regulations for preventing freezing and condensation 6.5.1 Blind flanges should be installed at the connections between the shut-down equipment pipelines and the production system; any accumulated water should be drained and the areas cleaned thoroughly. For equipment that is left outdoors or has open sections, measures should be taken to prevent accumulated water and snow from damaging the equipment. 6.5.2 Equipment, water pipes, air pipes, and control valves that are in operation or temporarily shut down must have anti-freezing and insulation measures; alternatively, a method of maintaining a small flow of water or minimizing steam flow can be used to achieve both cost savings and protection against freezing. After the steam supply is stopped, these components should be thoroughly cleaned. 6.5.3 In valve chambers at low temperatures, water in fire hydrants must be drained, and measures such as anti-freezing protection should be taken. 6.5.4 For motor vehicles parked outdoors in winter, the water accumulated in the radiator should be drained completely. For precision instruments and chemical substances, a dedicated person should be assigned to regulate the room temperature to prevent freezing. 6.5.5 It is strictly prohibited to use high-pressure steam for heating; care must be taken to prevent high-pressure steam from entering the low-pressure steam system. The return pipes for high-pressure and low-pressure steam must not be connected to each other. Pressure valves and gauges installed on the pipelines of steam heating systems must be properly calibrated. Each heating element must be tested for leaks before it can be used. 6.5.6 Frozen cast iron valves and similar items should be thawed using warm water, with a small amount of steam used to heat them gradually, in order to prevent damage caused by sudden heating. 6.5.7 Water used for construction and production should be discharged into gutters or areas that do not interfere with traffic. Ice accumulations on overhead pipelines and under eaves where people walk must be removed at all times, and platforms, stairs, and tank tops covered with ice or snow must be cleaned before they can be used. 6.5.8 Each unit shall identify the frost prevention areas, establish and improve a system for regular frost prevention inspections, and implement appropriate frost prevention measures. 6.5.9 Strengthen the dehydration of purified and unpurified air to prevent moisture from being carried in the air, which could cause instrument signals to be interrupted due to freezing and lead to incorrect operation of the actuators. 6.5.10 Anti-freezing procedures should be implemented when the temperature is close to 0°C; anti-solidification measures are required when the oil temperature is 10°C above its freezing point. 6.5.11 When the temperature is 10°C, use air to blow out the water contained in the fire suppression bag; if it cannot be completely emptied, steam should be vented regularly. 6.5.12 During the use of the gas holder, it is necessary to ensure that there is no liquid inside the tank. Attention must be paid to the quality of the gas; if liquefied gas is present, the cause must be identified promptly, and the gas supplied to the gas holder should be diverted to a flare instead. If the inlet pipelines freeze, steam should be used to thaw them in order to ensure proper gas collection by the gas holder. 6.5.13 Carefully control the height of the gas tank in accordance with its upper limit to prevent it from reaching excessive heights, which could affect on-site operations. 6.5.14 The supply and return water for compressor cooling must be unobstructed to prevent freezing and damage to equipment and pipelines. 6.5.15 When the compressor is shut down, the inlet and outlet pipelines must be regularly drained of condensate, especially the drain line between the first and second cylinders. This line must remain unobstructed whether the compressor is running or not. 6.5.16 If there is condensate or water in the liquid separation tanks at the inlet and outlet of the compressor, it should be removed promptly to prevent freezing at the bottom of the tanks. 6.5.17 All heat tracing steam lines must maintain unobstructed traps; if blockages occur, the steam supply should be stopped promptly for disassembly and repair. 6.5.18 The vent at the air line should be slightly opened to drain the cooling water. 6.5.19 The degassing systems of each liquid separation tank in the flare system should be operated more intensively, with the liquid level to be maintained at ≤30%. 6.5.20 Without turning off the flare, it is strictly prohibited to stop the steam used for flare protection; it should be kept at a level sufficient to prevent freezing. 6.5.21 It is strictly prohibited to use such a small amount of protection steam that condensate accumulates at the torch outlet and freezes, thereby causing pressure buildup in the torch system. 6.5.22 To ensure the proper functioning of the flare system, a pilot light test should be conducted once a week. 6.5.23 All heat tracing lines must be in operation, and the traps must remain unobstructed; any blockages detected should be promptly removed and repaired. 6.5.24 When the residue pump is not in use, the inlet and outlet valves should be opened to maintain circulation and prevent the equipment from freezing; the doors and windows of the pump room must be closed. 6.6 Provisions for Preventing Hydrogen Sulfide Poisoning 6.6.1 These provisions are formulated in order to strengthen the safety management of our factory’s employees and to effectively ensure their safety and health. 6.6.2 All new employees must receive safety training at the factory, workshop, and team levels, and only after passing the examinations may they proceed to work on production positions or start learning. 6.6.3 All personnel participating in maintenance work must undergo two levels of safety training at the factory and the workshop level before entering the maintenance site; they must also pass an examination before being allowed to carry out maintenance tasks there. 6.6.4 The content of safety education and training is as follows: (1) Education on industrial hygiene knowledge related to the prevention of hydrogen sulfide poisoning and first aid, as well as the acquisition of basic skills for self-rescue and mutual rescue in case of poisoning. (2) Have a thorough grasp of safety operating procedures and relevant management regulations. (3) Have a thorough understanding of the requirements regarding the use, maintenance, and storage of special protective equipment. (4) Understand the distribution of hydrogen sulfide in this device and at this position. 6.6.5 The safety and health facilities for new construction, renovation, and maintenance projects shall be \"designed, constructed, and put into use simultaneously\" with the main project. Ensure that the hydrogen sulfide level in the working environment meets **health standards**. 6.6.6 The Production Department must keep track of the types and proportions of crude oil processed, and inform the Quality Inspection Center of any changes in sulfur content. It is also necessary to promptly notify the relevant workshops of any changes in the sulfur content of the materials used, so that preventive measures can be taken in advance. 6.6.7 The Production Department shall, in light of the different characteristics of production positions and working environments, provide appropriate hydrogen sulfide protection equipment, conduct regular inspections to ensure its effectiveness and proper use, and strengthen management accordingly. 6.6.8 The Production Department shall equip hydrogen sulfide detection alarms in devices or areas where there is a risk of hydrogen sulfide leakage causing poisoning, and install warning signs at sites where hazardous operations are carried out, so as to detect problems promptly and take timely measures to prevent poisoning incidents. 6.6.9 All units are required to strictly implement the relevant regulations regarding protective equipment and testing. 6.6.10 According to the Health Technical Specifications for the Petrochemical Industry, hydrogen sulfide is classified as a toxic substance of category 2; workers exposed to hydrogen sulfide must undergo medical examinations every two years. 6.6.11 The Technology Development Department must vigorously promote technological progress, accelerate the innovation and improvement of process technologies, and achieve closed-system production, so as to keep the hydrogen sulfide concentration in the production area at **standard levels and ensure intrinsic safety. 6.6.12 The quality inspection center must organize the measurement and evaluation of the hydrogen sulfide concentration at the end of the production process in accordance with the regulations set by the Technical Development Department, and shall notify the Technical Development Department of the measurement results. 6.6.13 In accordance with the requirements of the \"Technical Specifications for Health Monitoring in the Petrochemical Industry,\" the Safety and Environment Department must conduct regular measurements and evaluations of the hydrogen sulfide level in the working environment every two months, and the results of these measurements shall be communicated to the relevant departments and workshops. 6.6.14 In the event that the hydrogen sulfide concentration exceeds normal levels due to changes in materials, modifications to the equipment, or variations in operating conditions, the workshop must take appropriate protective measures and promptly inform the relevant teams or personnel to prevent poisoning incidents. 6.6.15 Operating regulations: 6.6.15.1 For Class A and Class B oil tanks, operations on the tank top such as sampling for measurement, temperature testing, replacing or inspecting safety accessories are prohibited during oil filling, oil discharge, and blending. Such operations may be carried out only after the liquid level in the tank has remained stationary for 30 minutes. 6.6.15.2 When carrying out the following tasks, respirators should be selected based on the actual hydrogen sulfide levels present in the respective work areas; two persons must be present at the site, standing upwind, with one person carrying out the work and the other acting as a supervisor. (1) Sampling, gauging, and dewatering operations for crude gasoline tanks and light contaminated oil tanks; sampling of toxic substances such as acidic gases, gas, and liquid hydrocarbons, as well as dewatering and condensate removal from system pipelines or containers and other equipment. (2) Inspection operations for leaks of toxic substances in systems, pipelines, containers, pumps, etc., that contain acidic gases, gas, and liquid hydrocarbons. (3) Tank top operations such as the disassembly and inspection of gasoline tanks, light crude oil tanks, etc., as well as the replacement of safety accessories. (4) Wellhead operations involving oil-containing, acid-containing, alkali-containing, and sulfur-containing sewage wells, industrial wastewater, etc. 6.6.15.3 For any work performed inside equipment or containers containing hydrogen sulfide, it is necessary to, in accordance with relevant regulations, cut off all material supplies, thoroughly flush and purge the container, install blind flanges, conduct sampling and analysis to ensure compliance with safety standards, implement appropriate safety measures, and only after having two supervisors present and obtaining an “Equipment Entry Permit” can personnel enter to carry out the work. 6.6.15.4 In principle, work in hazardous areas such as sewers and sealed containers is prohibited. If entry is necessary, the production unit and the construction unit must establish practical safety measures; work may only be carried out under supervision, with the use of air respirators or other non-filtering respirators, and after obtaining an \"Entry Permit for Equipment Work\". 6.6.15.5 When working in hydrogen sulfide-contaminated areas while wearing special protective equipment, it is strictly prohibited to remove such equipment before leaving the hazardous area to prevent poisoning. 6.6.16 In the event of a poisoning incident, in addition to immediately organizing rescue efforts, the workshop shall promptly report to the Safety and Environment Department to coordinate the rescue operations. 7. HSE control procedures for operational tasks in direct operations
7.1 Disassembly, assembly, and cleaning of flame arresters
7.1.1 When the temperature inside the furnace F3502 cannot be maintained within the specified range and it is determined that this is caused by a clogged flame arrester, the flame arrester must be disassembled, assembled, and cleaned. The specific steps are as follows: The operators both inside and outside the plant should communicate via walkie-talkies; the standby flame arrester should then be put into service. The operator inside the plant must control the gas pressure to prevent overheating at the furnace outlet. Next, the operator outside the plant closes the valves upstream and downstream of the flame arrester and opens the bottom vent valve to relieve pressure. It is important to stand on the upwind side and wear a gas mask. Once no more gas is discharged from the vent, steam should be used to disperse any remaining gas odor. Only then should contact be made with the company for the actual disassembly of the flame arrester. 7.1.2 Cleaning of the flame arrestor mesh: Wash the flame arrestor mesh with steam or water, remove any debris that has accumulated there, and once the mesh is clean, contact the company to have a flame arrestor installed. 7.1.3 Commissioning: After the flame arrester is installed, close the bottom drain valve, slowly open the valve upstream of the flame arrester, and check for any leaks at the flanges of the flame arrester. If a leak is detected, close the upstream valve immediately and contact the company for further handling ； Ensure no leaks; after fully opening the upstream and downstream valves, close the bypass valve. Coordinate well between the indoor and outdoor operators to prevent overheating at the furnace outlet. Note: The same procedures can be used for the installation and removal of other filters, etc. If wire cleaning is required, carry out that first; once completed, relieve the pressure. After confirmation by the workshop, contact the company to handle the installation, cleaning, and commissioning. Acidic gas flame arresters must be shut down and cleaned thoroughly before they can be disassembled and maintained. 7.2 Operating procedures for oil and water removal from gas tank cabinets 7.2.1 Wear anti-static clothing and protective gloves; be careful to avoid slipping in rainy or snowy weather. 7.2.2 When climbing the ladder, hold onto the handrail and discharge any static electricity in your body; if the lighting is insufficient at night, carry an explosion-proof flashlight. 7.2.3 When sampling, be sure to stand upwind and use the specified sampling tools. 7.2.4 This unit is a tank for light oil with high sulfur content; it must be operated in strict accordance with the operating procedures. When working, make sure to stand in the upwind direction. After sampling, carry the tools back, being careful not to leave anything behind ； 7.2.5 For tanks that require dehydration and degreasing, first check whether the liquid level and temperature in the tank are within the normal range. When carrying out dehydration and degreasing, stand upwind and make sure to stay in place to prevent the oil inside the tank from flowing into the drain due to prolonged dehydration, which could result in oil loss. Open the dehydration valve slowly, ensuring that no oil is carried away during the process, and close the valve promptly once dehydration is complete. 7.3 Maintenance procedures for pumps and motors: Upon receiving notification that the pumps and motors in the company’s facility require maintenance, the procedures to be followed in our facility are as follows: 7.3.1 Close the relevant inlet and outlet valves of the pump and motor unit, stop the cooling water supply, drain all the fluid from the pump unit, and make sure to recycle it. 7.3.2 Contact the electrician to cut off the power to the pump that needs repair; once it is confirmed that the power has been disconnected, inform the workshop that the conditions for maintenance are met. After the workshop confirms this, it will issue a valid disassembly work order, which is then handed over to the company for the pump’s repair. 7.3.3 After the maintenance of the pump is completed, thoroughly check that all vents are closed. Contact the electrician to supply power, then start the pump by rotating its shaft with oil; once there are no issues, introduce cooling water. The hot oil pump should also be preheated to bring it into standby condition. 7.4 Procedure for replacing pressure gauges and thermometers 7.4.1 Close the manual valve in front of the pressure gauge; once the gauge pointer returns to zero, use two adjustable wrenches to remove the old pressure gauge. After installing a new gauge that has been calibrated and comes with a valid calibration label, mark the red line indicating the operating range ； 7.4.2 The thermometers in this device are generally of the sleeve-type and can be removed directly; new thermometers that have been calibrated and come with valid calibration labels should be installed, with red lines marking the operating range ； 7.4.3 When it is not possible to determine whether there is a hazard using the pressure gauges and thermometers in high-temperature areas, seek guidance from the workshop before replacing them. 7.5 Line cleaning 7.5.1 Close the valves at the connections of the pipelines to be cleaned, direct the flow to a safe location for cleaning, and assign a dedicated person to monitor the area where the flanges are removed, in order to prevent other people from being burned during the cleaning process. 7.5.2 Steam dehydration should be carried out before cleaning the pipeline to prevent water hammer incidents during steam cleaning. Steam should be introduced slowly, with the amount of steam gradually increased. After the pipeline is cleared, pressure should be applied and then released repeatedly to ensure the quality of the cleaning process. During cleaning, it is necessary to check along the flow path for any signs of pressure buildup, blockages, or leaks, and to address such issues promptly. 7.6 Procedure for starting and stopping the heat tracing system of the unit 7.6.1 Carefully read the heat tracing diagram to identify clearly the steam supply points for pipeline heat tracing and the corresponding drain points. 7.6.2 When introducing heat tracing, first ensure that the drainage path is unobstructed, then slowly open the steam supply valve. Once it can be confirmed by touch that the steam supply point and the drainage point are functioning properly, the heat tracing wire can be used normally. 7.6.3 To stop the heat tracing, the opposite is done: after closing the valve at the steam supply point and the corresponding drain point, the drain valve at that drain point is opened to allow drainage. 7.7 Procedures for Removing and Installing Safety Valves 7.7.1 When a team detects internal leakage in a safety valve during inspections, it first analyzes and determines the cause of the leakage. 7.7.2 If the safety valve does not return to its normal position after activating, the operator inside and the one outside should communicate via walkie-talkie. The operator inside should operate the equipment carefully to prevent overheating and overpressure. The operator outside should close the valves located before and after the safety valve, and then reopen them once the safety valve has returned to its normal position. 7.7.3 If it fails to return to its normal position even after being opened, close the upstream and downstream valves promptly, inform the crew on duty, and arrange for the safety valve to be removed for inspection. If the leakage is caused by a problem with the safety valve itself, close the upstream and downstream valves again, inform the crew on duty, and arrange for the safety valve to be removed for inspection; if possible, replace it with a spare safety valve and put it into use immediately. 7.7.4 During the period when the safety valve is not in use, the operator must operate with care to prevent the equipment from experiencing excessive temperature or pressure. 7.7.5 After the safety valve has been calibrated and installed, it shall be put into use in accordance with the workshop’s arrangements. First, open the upstream and downstream valves slowly to check for any leaks at the flanges; if there are no leaks, open the valves fully. If leaks are detected, close the valves immediately and contact company personnel to handle the issue. Once the safety valve is operating properly, operators should check whether there is still any leakage in the pipelines leading out from the safety valve. 7.8 For valves below DN50, replace the valve or replace the gasket. 7.8.1 Disconnect the connection at the location where the valve or gasket needs to be replaced, and ensure that all air is drained. 7.8.2 When dealing with toxic substances, wear an air respirator; use special wrenches to remove the flanges at the parts that need to be replaced, install new gaskets, and then tighten the bolts. 7.8.3 When putting it into use after replacement, open the valve slowly to check for any leaks. 7.9 Sampling control program 7.9.1 Sampling is a routine operation, but since acidic gases contain high levels of hydrogen sulfide, it is essential to follow safety procedures during the sampling process. 7.9.2 When sampling, two people must go together, both wearing air respirators, and stand on the upwind side. 7.9.3 One person for supervision, one person for operation. 7.9.4 After sampling is complete, close the sampling valve and verify that it has no internal leaks, in order to reduce environmental pollution; random discharge is prohibited. 7.9.5 For collecting liquid samples, follow the steps above.