In chemical plants, from equipment to production, from processes to maintenance, hazard identification

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①Equipment and Facilities
1. Reactors
1) Unusual noises from the reducer
2) Oil leakage from the reducer
3) Plastic fan blades of the reducer become deformed due to heat
4) Lack of oil in mechanical seals and reducers
5) Leakage from gaskets
6) Damaged or missing anti-static grounding wires
7) Safety valves not regularly inspected, leaking, or no records kept
8) Thermometers not regularly calibrated or damaged
9) Pressure gauges overdue for inspection, damaged, or blocked by materials
10) Rupture discs expired, broken, or no records kept
11) Valves beneath rupture discs not opened
12) Reactors posing explosion risks lacking rupture discs
13) Abnormal pressure increases or material overflow due to high temperatures or interrupted stirring
14) Bottom valves prone to blockage during discharging
15) Acidic corrosion on stainless steel or carbon steel reactors
16) Overloading due to filling beyond specified limits
17) Enamel-lined reactors used in corrosive, flammable, or explosive environments despite enamel damage
18) Erosion and damage to reactor inner linings near steam inlet ports
19) Pressure vessels exceeding service life, poorly manufactured, and still leaking despite multiple repairs
20) Pressure vessels lacking nameplates
21) Missing or unclear identification numbers
22) No safety checklists established for critical equipment
23) Critical equipment lacking spare parts or backup units

2. Storage tanks, tank farms, tank trucks
1) Obscured, damaged, or blocked level gauges
2) Loose or unconnected anti-static grounding wires
3) Leakage at flange gaskets
4) Elevated storage tanks such as small platforms not securely fixed
5) Safety liquid seal levels not meeting requirements
6) Atmospheric-pressure tanks operated under pressure
7) Filling beyond specified limits
8) Non-room-temperature tanks lacking thermometers
9) Cracked containers still in use
10) Frequent exposure to vacuum and nitrogen alternating loads causing tank damage
11) Low-boiling-point solvents or liquefied gas tanks exposed to sunlight without protective measures
12) Outdoor tanks at risk of being struck by transport vehicles
13) Unsealed openings in dikes surrounding hazardous chemical tank farms
14) Poorly sealed protective dikes in hazardous chemical tank farms with unauthorized drainage holes
15) Check valves leading to drains left open, creating unsafe conditions
16) Support structures for pipelines carrying flammable/corrosive materials lack spring compensation mechanisms or flexible connectors
17) No warning signs prohibiting mobile phone use, open flames, or limiting height/speed in hazardous chemical tank farms
18) No daily inspection records maintained for hazardous chemical tank farms
19) Motor vehicles entering hazardous chemical tank farms at will
20) Fire hazards present near hazardous chemical tank farms
21) Unauthorized use of electric stoves, kettles, or heating plates in control rooms
22) Tank trucks lacking grounding devices at loading/unloading sites
23) No measures to prevent operators from falling off tank trucks
24) Tank trucks lacking effective flame arresters or in poor condition (broken lights, faulty brakes) allowed into tank farms
25) Safety accessories (pressure gauges, thermometers, safety valves) on tank trucks lacking inspection dates or expired
26) No indication of next scheduled inspection date on tank truck containers
27) Absence of anti-static chains, protective gear, or leakage from valves on tanks
28) Failure to ground tank trucks for at least 10 minutes before/after unloading
29) Drivers and escorts leaving unloading sites without supervision
30) Use of open or splashing unloading methods
31) Overfilling or spillage beyond safe levels during unloading
32) Repeated transportation/unloading of partially filled tank trucks within facilities
33) Unloaded vehicles left running or handbrakes not engaged; vehicles restarted mid-unloading
34) Unloading operations conducted during intense lightning activity
35) Fewer than two grounding points for oil tanks
36) Operators handling gasoline, toluene, or other flammable solvents without anti-static clothing/shoes
37) No emergency dikes or dilution spray systems in areas storing liquid ammonia
38) No emergency showers or eyewash stations available
39) No measures to prevent misloading of materials
40) Cutting gasoline drums or welding tanks without prior cleaning
41) Overfilling of storage tanks
42) Blocking fire exits and obstructing pathways during tank truck unloading
43) Receiving personnel leaving unloading sites
44) Use of spark-generating tools like iron implements at loading/unloading sites
45) No operational records maintained for material transfer between tank farms and workshops

3. Condensers, reboilers
1) Leakage caused by corrosion or aged gaskets
2) No thermometer installed to monitor post-condensation material temperature
3) Heat exchange medium layers clogged by sludge/microorganisms
4) High-temperature surfaces lacking protection
5) Cooling water valves closed or insufficient flow when cooling high-temp liquids (e.g., 150°C); inadequate cooling capacity
6) Rapid temperature rise during initial operation of evaporators
7) Insufficient vibration dampening in heat exchangers, causing pipe connections to loosen/leak

4. Pipelines and fittings
1) Welding residues/debris remaining inside pipelines post-installation
2) Dirty or damaged sight glass panels
3) Inappropriate selection of sight tube materials; improper installation
4) Sight tubes cracked or used under pressure for extended periods
5) Anti-static grounding wires or flanges lacking electrical bonding
6) Severe corrosion/ruptures in pipes, flanges, or bolts
7) High-temperature pipelines lacking insulation
8) Explosion relief pipes fabricated as bends
9) Unclear labeling of pipeline contents/direction
10) Faded pipeline color codes
11) Interconnecting valves for different materials left unblocked during testing
12) Abandoned pipelines not removed promptly
13) Low-mounted valves/pipes causing head injuries or operational difficulties
14) No protective measures at leak-prone locations for corrosive material pipelines/flanges
15) Risk of water, nitrogen, air, or steam infiltrating material pipelines
16) Flammable/explosive materials stored near high-temperature pipes in metal/plastic containers
17) Unsuitable material selection for pipelines/fittings, prone to corrosion
18) Glass tube level gauges lacking protective covers
19) No protective metal mesh installed around potentially explosive sight glass areas
20) Check valves non-functional or ineffective
21) Electric valves losing power; pneumatic valves losing compressed air
22) Pressure pipelines transporting hydrogen lacking regular maintenance or operating while defective
23) Untrained/unlicensed personnel operating pressure pipelines
24) Maintenance staff unqualified to repair/modify pressure pipelines
25) Poor welding quality in pressure pipelines (undercutting, porosity, slag inclusion, incomplete fusion)
26) Missing safety accessories or expired inspections on pressure pipelines
27) No documentation/procedures established for pressure pipelines
28) Enamel-coated pipelines damaged by impacts from steel pipes
29) Existing pipeline valves used despite incompatible material properties after process changes
30) Nitrogen and air pipelines interconnected
31) Brine and cooling water pipelines interconnected

5. Transfer pumps, vacuum pumps
1) Pump leakage
2) Unusual noises
3) Couplings lacking protective covers
4) No pressure gauges or check valves at pump outlets
5) Residual liquid in pumps/pipelines after prolonged inactivity, causing corrosion/sealing issues
6) Positive displacement pumps operated with outlet valves closed or no safety return valves
7) Small inlet diameters, lengthy winding pipelines
8) Centrifugal pumps installed above suction height limits
9) Anti-static belts unused

6. Centrifuges
1) Solvent removal without nitrogen purging; blocked nitrogen lines or absent flow meters
2) Oxygen detectors/alarm systems omitted when removing solvents via centrifuges in drying ovens
3) Emergency braking using auxiliary tools (e.g., iron rods)
4) Centrifuges inadequately grounded
5) Anti-static belts unused in explosion-proof zones
6) Excessive vibration during operation

7. Double-cone dryers
1) Absence of guardrails/safety interlocks
2) Personnel climbing into double-cone interiors to replace vacuum bags
3) Drive belts lacking protection
4) Shaft seal leakage
5) Vacuum lines blocked or valves unopened during operation

8. Gas cylinders
1) Cylinders lacking caps/shock rings
2) Steel cylinders exposed to direct sunlight during summer transport/storage
3) Some cylinders past annual inspection deadlines
4) Acetylene and oxygen cylinders placed <5m apart during simultaneous use
5) Hydrogen cylinder valves operated while wearing catalyst-contaminated gloves
6) Impacting/knocking cylinders
7) Cylinder pressure dropping below 0.05 Mpa post-use
8) Damaged cylinder clusters/pipeline connections/valves
9) Anti-static devices absent/defective on hydrogen cylinders
10) No anti-toppling measures for gas cylinders
11) Drains/tunnels present in storage areas
12) Poor ventilation or corrosive gases entering storage areas
13) Insufficient fire extinguishers
14) Acetylene cylinders used horizontally
15) Faded cylinder color codes

② Electrical instruments
1. Non-explosion-proof electrical equipment/control cabinets installed in explosion-proof zones
2. Broken window glass in electrical rooms
3. Excessive clutter in electrical rooms
4. Steam, material pipes, dust, and corrosive substances accelerating electrical equipment degradation, causing short circuits
5. Acid mist corrosion, solvent infiltration, or excessive dust affecting outdoor transformers
6. Clothing/debris present behind control or substation cabinets
7. Aging electrical cabinets prone to short circuits
8. Cables positioned near high-temperature pipes
9) Corrosive materials leaking from nearby material/ sewage pipes into cable trays
10) Underground cables corroded by groundwater
11) Severe sewage infiltration into cable trenches
12) Heavily corroded cable trays
13) Aging/ruptured cable protective sleeves
14) Non-combustible materials unused to seal pipe penetrations through walls/floors
15) Improper exhaust duct installations causing cable disconnections/electric leakage
16) Unclear labeling linking switches/buttons to equipment IDs
17) Disorganized/unlabeled cables within workshops
18) Missing or defective emergency lighting
19) Outdoor motors lacking adequate protection ratings
20) Insufficient illumination at operational sites
21) Mismatched equipment sizing causing overheating/fire risks
22) Water sprayed onto electrical equipment/cable trays
23) Loose screws on explosion-proof lighting fixtures causing light leakage

③ Static electricity
1. In flammable/explosive areas, reactors, pipelines, tanks, condensers, pumps, flanges, and valves lack grounding or have poor grounding
2. Powder feed hoppers ungrounded in flammable/explosive areas
3. Flow rates exceeding safe limits (v2