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Guidelines for the Implementation of Risk Classification and Control for Safety in the Use of Fixed Pressure Vessels and the Establishment of a System for Identifying and Addressing Potential Accident Hazards 1 Scope These standards specify the terms and definitions, basic requirements, risk classification and control, identification and treatment of potential hazards, document management, and continuous improvement related to the implementation of such a system for safety in the use of fixed pressure vessels in Shandong Province. This standard applies to user entities in Shandong Province that utilize stationary pressure vessels, in their efforts to implement risk classification and control, as well as to establish a system for identifying and rectifying potential hazards. The hazard sources listed in this standard do not represent all the hazard sources of pressure vessels. 2 Normative reference documents The following documents are essential for the application of this document. For dated reference documents, only the version dated as specified applies to this document. For undated reference documents, the latest edition (including all amendments) applies to this document. TSG 03 Guidelines for the Reporting, Investigation, and Handling of Special Equipment Accidents; TSG 08 Rules for the Use and Management of Special Equipment; TSG 21 Safety Technical Inspection Regulations for Fixed Pressure Vessels; DB37/T 2882 General Provisions on the Risk Classification and Control System for Work Safety; DB37/T 2883 General Provisions on the System for Identifying and Addressing Potential Hazards in Work Safety Accidents; DB37/T 2971 Detailed Provisions on the Risk Classification and Control System for Work Safety in Chemical Enterprises; DB37/T 3010 Detailed Provisions on the System for Identifying and Addressing Potential Hazards in Work Safety Accidents in Chemical Enterprises; DB37/T 3078 Detailed Provisions on the Risk Classification and Control System for the Safety of Special Equipment; DB37/T 3079 Detailed Provisions on the System for Identifying and Addressing Potential Hazards Related to Special Equipment Accidents. 3 Terms and Definitions: The terms and definitions defined in TSG 08, TSG 21, DB37/T 2882, DB37/T 2883, DB37/T 3078, and DB37/T 3079, as well as the following terms and definitions, apply to this document. 3.1 Fixed Pressure Vessel A fixed pressure vessel (hereinafter referred to as a pressure vessel) is a pressure vessel that is installed in a fixed location for use. It is a sealed device used to hold gases or liquids under certain pressures. Such vessels are defined as those with a maximum operating pressure of 0.1 MPa (gauge pressure) or more for gases and liquefied gases, and for liquids whose maximum operating temperature is equal to or higher than their standard boiling point; they are also fixed vessels with a volume of 30 L or more and an inner diameter of 150 mm or more (for non-circular cross-sections, this refers to the largest geometric dimension of the cross-sectional boundary). 3.2 Rehabilitation The rehabilitation of pressure vessels refers to altering the structure of the main pressure-bearing components, or changing the operating parameters of the pressure vessel, the medium it contains, its purpose, etc. 3.3 Major Repairs Major repairs of pressure vessels refer to the replacement, reshaping, or patching of the main pressure-bearing components, as well as the rewelding of butt joint welds that meet the requirements of TSG 21 Section 3.2.2.1, or the repair of adhesive joints in non-metallic pressure vessels. 4 Basic Requirements 4.1 Risk Classification, Control, and Hazard Identification and Rectification 4.1.1 The user entity shall, in accordance with DB37/T 3078 and the standards for risk classification, control, as well as the risk assessment methods outlined in these implementation guidelines, carry out risk identification and assessment for pressure vessels, determine their risk levels, identify the departments and persons responsible for control measures at each risk level, implement such control measures, and establish a list of risk classification and control measures. 4.1.2 The user unit shall, based on the risk control list, and in accordance with the relevant laws, regulations, safety technical specifications for pressure vessels, as well as the requirements of DB37/T 3079, establish criteria for identifying potential hazards, determine the types and frequency of such hazard inspections, and carry out the inspections. 4.2 Principal Responsibilities 4.2.1 The user unit shall establish a special equipment safety management organization in accordance with the requirements of TSG 08, and organize the implementation of risk classification control and hazard identification and rectification for pressure vessels. 4.2.2 Responsibilities of the principal person in charge: 00001 – Bear overall responsibility for the safe use of pressure vessels employed by the unit ； 00002——Ensure the establishment, implementation, maintenance, and continuous improvement of a dual-prevention system for pressure vessels ； 00003—— Ensure that all personnel participate in the classification-based management and control of safety risks related to pressure vessels, as well as in the identification and rectification of potential hazards, and fulfill their respective responsibilities ； 00004— Ensure the allocation of resources for the development of the dual-prevention system; establish an evaluation, reward, and punishment mechanism; and regularly supervise and assess the progress of system development ； 00005——Urge the development and testing of emergency-specific plans ； 00006——Report accidents promptly and accurately, and organize rescue efforts for them. 4.2.3 Responsibilities of the person in charge of safety management: 00007 —— Assist the top management in fulfilling the leadership responsibilities for the establishment and implementation of a dual-prevention system for pressure vessels in the organization ； 00008——Organize the formulation of work plans and relevant documents for building a dual-prevention system for pressure vessels ； 00009——Organize the formulation of safety management systems and job responsibility systems for pressure vessels, and establish management organizations and managers ； 00010—Organize the review of the results of risk identification for pressure vessels; summarize, coordinate, supervise, and evaluate the risk points and their control measures; approve and issue the list of risk classification and control measures ； 00011——Organize the development of plans for identifying potential hazards, arrange or urge personnel at all levels to carry out hazard identification and mitigation activities in accordance with these plans, and supervise and inspect the implementation of measures taken to address such hazards ； 00012——Organize the development of special emergency plans for pressure vessels, and conduct regular drills ； 00013——Organize rescue efforts for pressure vessel accidents in accordance with the emergency response plan for such accidents ； 00014—Organize safety education and training on the dual prevention system for pressure vessels ； 00015——Regularly inspect the progress of the dual prevention system. 4.2.4 The safety manager, as the person responsible for the management of pressure vessel use within the using unit, has the following main responsibilities: 00016——Implementing the work plan for establishing a dual-prevention system for pressure vessels and related implementation documents ； 00017—Carry out inspections for potential hazards in pressure vessels, rectify such hazards, and implement corresponding measures ； 00018——Conduct safety education and training on the dual-prevention system for pressure vessels ； 00019——Develop special emergency plans for pressure vessels and conduct drills ； 00020——Report pressure vessel accidents as required, and assist in accident investigations and follow-up actions ； 00021 —— Upon detecting potential hazards related to pressure vessels, take immediate action to address them. In emergency situations, it is possible to decide to stop using the pressure vessel, and report this to the relevant person in charge of the unit ； 00022——Inspect the operators’ work performance, and promptly correct and prevent any violations of regulations. 4.2.5 Responsibilities of operators: 00023 – Full participation in the development of the dual-prevention system for pressure vessels ； 00024——Understand the risks and potential hazards associated with this position ； 00025——Carry out inspections for potential hazards in pressure vessels in accordance with the hazard identification plan ； 00026——Strictly implement the safety management regulations related to pressure vessels and operate in accordance with the operating procedures ； Fill out records regarding operations, shift handovers, etc., as required ； 00027——Participation in safety education and technical training for the dual-prevention system of pressure vessels ； 00028——Conduct routine maintenance, address any abnormalities that are detected promptly, and keep records of them ； 00029——If potential accident hazards or other safety issues are identified during operations, emergency measures must be taken immediately, and the relevant departments of the organization must be informed in a timely manner in accordance with the established procedures ； 00030——Participate in emergency drills to acquire the relevant basic rescue skills, and take part in the rescue of accidents involving pressure vessels. 4.3 Establishment of systems 4.3.1 Risk management system The using entity shall define the workflow for establishing a safety risk classification and management system for pressure vessels, and clarify the risk management responsibilities of each position ； Clarify aspects such as the identification of risk points, risk control measures, and safety risk communication, to ensure the standardized development of the organization’s risk control system. 4.3.2 Hazard identification system: The user unit shall establish a work process for building a system for identifying and addressing potential accidents related to pressure vessels, and clarify the responsibilities of each position regarding such identification and mitigation efforts ； It stipulates the measures for establishing, operating, and managing a system for identifying and addressing potential hazards in pressure vessels, clarifies the entities responsible for such inspections, the frequency and scope of these inspections as well as the implementation procedures, and defines the processes for rectifying these hazards and conducting inspections to verify that they have been resolved. 4.3.3 Reward and punishment assessment system: The operation of the dual-prevention system should be linked to the salaries of employees in various positions within the organization, so as to implement assessments and rewards or punishments accordingly. 4.4 Requirements for Training All Employees 4.4.1 Training Content The main contents of the training include: 00031——Laws, regulations, standards, systems, and operating procedures related to the dual-prevention system for pressure vessels ； 00032——Hazard identification and risk assessment methods ； 00033——Overview of risk point evaluation for pressure vessels ； 00034——Risk control measures ； 00035——Other risk information. 4.4.2 Training Records The entity responsible for training shall keep records of the training process; these records include: 00036——Training Plan ； 00037——Training materials or textbooks ； 00038——Training Sign-in Sheet ； 00039——Training assessment or performance evaluation records ； 00040——Other relevant materials. 4.4.3 Incentives and Penalties for Assessment: The entity in charge should establish an assessment and incentive/punishment system for the operation of the dual-prevention system for pressure vessels, linking the performance of this system to the earnings of employees in various positions within the organization, so as to apply appropriate incentives or penalties. 5 Risk Classification and Control 5.1 Identification and Investigation of Risk Points In accordance with the definition of risk points in DB37/T 3078, the using unit shall classify risk points by taking each individual pressure vessel in use and its associated operational activities as identification units, and establish a \"Risk Point Registration Table – Pressure Vessels\" that includes basic information such as the name and category of the risk point (pressure vessel), the equipment registration code, specifications, medium used, process tag/location, and safety level (see Appendix A.1). 5.2 Hazard Identification and Analysis 5.2.1 Contents of Hazard Identification When identifying hazards, the user unit shall implement the requirements for pressure vessel safety management, namely \"three implementations, two certifications, one inspection, and one emergency plan\", as well as the requirements for operation and maintenance. It is necessary to identify the potential dangerous and harmful factors associated with the pressure vessels and their operational processes, in accordance with the accident characteristics listed in TSG 03. The scope of identification should take into account four aspects: human factors, physical factors, environmental factors, and management factors. Among these: 00041 – Human factors include the person in charge of safety management at the pressure vessel user unit, safety management personnel, the certification status of operators, safety training, staffing levels, operational skills, and working behaviors ； 00042— The material factors should include the inherent safety conditions of pressure vessels (such as procurement, manufacturing, acceptance, corrosion, etc.), safety accessories or protective devices, equipment attachments and tools, inspection and testing, usage markings, protective devices, vibration risks, operating media (low temperature, high temperature, toxic, harmful, corrosive, etc.) ； 00043——Environmental factors should include the conditions of the facility where the pressure vessel is located, the site foundation, water supply and drainage systems, the working environment, and natural conditions (temperature, humidity, air pressure), etc ； 00044——Management factors should include the safety management organization for pressure vessels, safety management systems, training systems, usage registration, change management, regular inspections, maintenance, handling of abnormal situations, operating procedures, safety technical records, emergency rescue plans, etc. 5.2.2 Characteristics and consequences of accidents caused by hazard sources The characteristics of accidents caused by hazard sources refer to the failure modes or ways in which pressure vessel equipment fails, which correspond to the most severe consequences of those accidents. It usually manifests as explosions, deflagrations, leaks, deformation, fractures, damage, uncontrolled falling, or failures. The consequences caused by hazard sources include personal injuries, people being trapped, property damage, shutdowns, violations of the law, damage to reputation, deterioration of the working environment, and environmental pollution. 5.2.3 Procedure for identifying hazard sources The using unit may refer to the following process for identifying hazard sources: 00045 – A identification team is formed consisting of the person in charge of special equipment safety management, special equipment safety supervisors, special equipment operators, and other professionals ； 00046——Collect relevant information on laws and regulations, safety technical specifications, procedures, standards, systems, etc., related to the safety of pressure vessels ； 00047——Analysis of accidents or failures that have occurred and may occur in pressure vessels ； 00048——Classify and identify hazard sources (hazardous factors) in light of the actual conditions of the unit. 5.2.4 Methods for identifying hazard sources: Hazard sources can be identified using the following methods: 00049 – In accordance with relevant laws, regulations, rules, safety technical specifications, and standards related to pressure vessels, it is necessary to identify safety risks existing in aspects such as production processes, equipment and facilities, working environments, personnel behavior, and management on a comprehensive and thorough basis, ensuring a systematic and complete approach without any omissions ； 00050——Pressure vessels should be broken down into various specific inspection items; based on relevant standards, specifications, and management experience, inspection criteria for the proper condition of each item should be established, and any instances where an item fails to meet these criteria along with the possible consequences thereof should be identified ； 00051——For pressure vessels, it is advisable to use the safety checklist method (abbreviated as SCL) for identification; the using entity may also choose other effective and feasible methods based on its actual circumstances. 5.3 Risk Assessment 5.3.1 Risk Assessment Methods For the identified hazard sources, it is advisable to use the risk matrix (LS) method to assess their level of risk; based on the assessment results, a classification is determined, and the \"Safety Inspection Form Analysis and Assessment Record\" should be filled out (see Appendix A.2). The using entity may also adopt other risk assessment methods based on its own actual circumstances. 5.3.2 Principles for determining risk levels The risk level of a single pressure vessel is determined based on the highest risk level identified among all the hazard sources associated with that vessel. The risk level is divided into 5 categories from highest to lowest: 1, 2, 3, 4, 5, with level 1 representing the highest risk and level 5 representing the lowest risk. 5.3.3 Risk control measures 5.3.3.1 Engineering and technical measures include: 00052——Installation of safety accessories for pressure vessels ； 00053——Install safety interlock devices for pressure vessels ； 00054——Set up the automatic control system ； 00055——Pressure vessel safety relief valves are equipped with sealed recovery devices ； 00056——Installation of on-site monitoring and control equipment as well as alarm systems (for flammable, explosive, and toxic substances) ； 00057——Seal off the pressure vessel areas where hazards are generated or caused ； 00058——Separate people from hazardous areas through isolation ； 00059——Repair of defects identified during regular inspections of pressure vessels ； 00060— Other control measures. 5.3.3.2 Management measures include: 00061 – Assigning appropriate personnel for the management and operation of special equipment ； 00062—— Establish management regulations for pressure vessels ； 00063——Formulate operating procedures for pressure vessels ； 00064——Reduce exposure time (e.g., abnormal temperatures or harmful environments) ； 00065——Regular inspection and patrol of pressure vessels ； 00066——Conduct regular inspections in accordance with the scheduled inspection cycle and requirements ； 00067—Calibration and inspection of safety accessories for pressure vessels ； 00068——Qualification management for units engaged in the installation, modification, and maintenance of pressure vessels ； 00069——Set up warning signs ； 00070——Other control measures. 5.3.3.3 Training and education measures include: 00071——Training and education on laws and regulations regarding pressure vessels ； 00072——Training on the operating procedures for pressure vessels ； 00073——Training and education on pressure vessel management systems ； 00074——Training and education received by special equipment supervisors and operators for obtaining certification, etc ； 00075——Training on emergency rescue measures for pressure vessels ； 00076——Other control measures. 5.3.3.4 Personal protective measures include: 00077 – Provision of personal protective equipment ； 00078——Other control measures. 5.3.3.5 Emergency response measures include: 00079——Formulating emergency plans ； 00080——Regularly organize emergency rescue drills ； 00081——Emergency rescue equipment supply (including fire-fighting supplies, rescue tools, and emergency medications) ； 00082——Other control measures. 5.3.3.6 Based on the results of risk assessment and risk classification, the using unit shall evaluate the effectiveness of existing control measures from aspects such as those mentioned above. If the existing control measures are insufficient to mitigate this risk, one or more appropriate control measures should be adopted to eliminate or reduce the risk until it becomes acceptable (including but not limited to the items mentioned above). 5.4 Risk Classification and Control 5.4.1 Risk Classification After selecting an appropriate evaluation method to assess risks, the using entity classifies them into major risks, relatively high risks, general risks, and low risks in accordance with the corresponding principles specified in Table 1; these are indicated by the four colors red, orange, yellow, and blue respectively.