Guidelines for the Establishment and Implementation of a Dual Prevention System for the Safety of Special Equipment Used in Ammonia-Based Refrigeration

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Guidelines for the Establishment and Implementation of a Dual Prevention System for the Safety of Special Equipment Used in Ammonia-Based Refrigeration 1 Scope These standards specify the terms and definitions, basic requirements, risk classification and control, identification and rectification of potential hazards, document management, and continuous improvement related to the establishment of a system for the classification-based management of safety risks and the identification and resolution of potential hazards in entities that use ammonia-based refrigeration systems in Shandong Province. This standard applies to ammonia-related refrigeration enterprises in Shandong Province in carrying out risk classification and control as well as the establishment of systems for identifying and addressing potential hazards. It is also applicable when various industries develop dual-prevention systems for work safety, particularly with regard to the risk classification and control of safety hazards associated with special equipment used in ammonia-related refrigeration processes, as well as the identification and resolution of related accident risks. 2 Normative reference documents The following documents are essential for the application of this document. For reference documents dated, only the version dated shall apply to this document. For reference documents without a date, the latest version (including all amendment sheets) applies to this document. GB50072 Code for Design of Refrigerated Warehouses; GB28009 Safety Regulations for Refrigerated Warehouses; GB18218 Identification of Major Hazard Sources of Hazardous Chemicals; TSG21 Technical Supervision Regulations for Fixed Pressure Vessels; TSG R0005 Technical Supervision Regulations for Mobile Pressure Vessels; GB7231 Basic Colors, Identifying Symbols, and Safety Markings for Industrial Pipelines; TSG D0001 Technical Supervision Regulations for Pressure Pipelines – Industrial Pipelines. Special Circular No. 61 [2013] from the Bureau of Special Equipment of the General Administration of Quality Supervision, Inspection and Quarantine: Guidelines on the Special Rectification Work Related to Special Equipment in Ammonia Refrigeration Systems; TSG 08 Rules for the Use and Management of Special Equipment; 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 Production Safety Incidents; DB37/T 3078 Detailed Provisions on the Risk Classification and Control System for Special Equipment; DB37/T 3079 Detailed Provisions on the System for Identifying and Addressing Potential Hazards in Special Equipment Incidents. 3 Terms and Definitions: The terms and definitions defined in DB37/T 2882, DB37/T 2883, DB37/T 3078, and DB37/T 3079, along with the following terms and definitions, apply to this document. 3.1 Ammonia refrigeration enterprises are those that use anhydrous ammonia as a refrigerant to carry out the refrigeration cycle, in order to freeze or cool products such as meat products, aquatic products, agricultural products, livestock and poultry products, and other items. 3.2 Ammonia refrigeration special equipment: Pressure vessels such as ammonia storage tanks, condensers, oil separators, oil collectors, gas-liquid separators, intercoolers, and low-pressure circulation liquid storage tanks used in ammonia refrigeration systems, as well as the pressure pipelines connecting these refrigeration systems (including all safety accessories). 4 Basic Requirements
4.1 Entities responsible for implementation
Enterprises engaged in ammonia-based refrigeration shall independently plan, prepare, and implement the dual prevention mechanism. This includes carrying out specific tasks such as hazard identification, risk analysis, risk assessment, organization of risk-related information, identification and rectification of potential hazards, statistical analysis, and continuous improvement. 4.2 Establishment of an organization: Enterprises shall establish an organizational structure for the dual-prevention mechanism of risk classification control and hazard identification and rectification, consisting of the main person in charge, the person in charge responsible for special equipment, safety management personnel for special equipment, and operators who have received training in refrigeration processes. 4.3 Division of Responsibilities: The user entity shall establish a safety management organization for special equipment in accordance with the requirements of TSG 08 and DB37/T 3078. It must define the job responsibilities of the entity’s principal responsible person, the person in charge of special equipment safety management, special equipment safety managers, special equipment operators, and heads of various functional departments. In line with the principle of “whoever is in charge, bears the responsibility,” they shall jointly formulate a work plan for building a dual-prevention system, and organize the implementation of risk classification control and hazard identification and rectification related to the safe use of pressure pipelines. 4.4 Formulating a plan: Ammonia-based refrigeration enterprises should develop an implementation plan for building a dual-prevention system within their own organizations. The implementation plan should specify the work objectives, implementation steps, schedule, and safeguard measures for building a dual-prevention system. Safeguard measures should be established through aspects such as strengthening organizational coordination, ensuring funding allocation, enhancing education and training, and implementing supervision and evaluation, in order to ensure that tasks are effectively carried out. 4.5 Establishment of systems 4.5.1 Risk management system Refrigeration enterprises using ammonia should define the workflow for establishing a risk management system for special equipment involving ammonia, 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. 4.5.2 Hazard identification system: Ammonia-based refrigeration enterprises should establish a workflow for building a system for identifying and addressing potential hazards related to special equipment used in ammonia-based refrigeration, and clarify the responsibilities of each position regarding such hazard identification and mitigation ； It stipulates measures for the establishment, operation, and management of a system for identifying and rectifying potential hazards in special equipment used in ammonia-based refrigeration. It clarifies the entities responsible for inspections, the inspection cycles, contents, and implementation procedures, as well as the workflows for hazard rectification and acceptance. 4.5.3 Reward and Punishment System: Enterprises dealing with ammonia-based refrigeration systems should link the operation of the dual-prevention system to the salaries of employees in various positions within the company, and implement rewards and punishments based on this. 4.5.4 Comprehensive Training: Such enterprises shall develop training plans to ensure that their staff understand how to identify hazards associated with ammonia-based refrigeration equipment, how to conduct risk assessments, as well as the standards, procedures, and methods for identifying and addressing potential problems; they must also keep records of such training. 4.5.5 Training content The main contents of the training include: 00001 – Laws, regulations, safety technical specifications and standards related to the dual prevention system for special equipment used in ammonia-based refrigeration, as well as the management systems and safety operating procedures formulated by the enterprise ； 00002——Hazard identification and risk assessment methods ； 00003——Overview of Risk Assessment for Special Equipment Used in Ammonia-Based Refrigeration ； 00004——Risk control measures ； 00005——Other risk information. 4.5.6 Training records: Ammonia refrigeration enterprises must keep records of their training processes. These records include: 00006 – Training plan ； 00007——Training materials and textbooks ； 00008——Training Sign-in Sheet ； 00009——Training assessment or performance evaluation records ； 00010——Other relevant materials. 5 Risk Classification and Control 5.1 Identification of Risk Points The special equipment-related risk points in ammonia-based refrigeration enterprises mainly include pressure vessels, pressure pipelines, and other pressure-bearing equipment and facilities involving ammonia. The “Risk Point Registration Table” can be filled in using the device name (see Appendix A). 5.2 Hazard identification 5.2.1 Hazard identification Refrigeration enterprises using ammonia should establish a hazard identification management system and organize all employees to conduct a comprehensive and systematic identification of the hazards present in the facility. When identifying, it is necessary to follow the safety management requirements for special equipment, which include \"three implementations, two certifications, one inspection, and one emergency plan,\" as well as the specific safety management rules for ammonia-based refrigeration equipment. The listed characteristics of accidents should take into account four aspects: human factors, physical factors, environmental factors, and management factors. Among these, 00011 – human factors – should include information regarding the certification status of the key personnel, technical supervisors, safety managers, operators, and safety officers in ammonia-based refrigeration enterprises, as well as details on safety training, staffing, responsibilities, and the behaviors and skills required for performing tasks ； 00012— Material factors shall include, but not be limited to, the safety conditions of equipment such as pressure vessels, pressure pipelines, safety accessories, and instruments related to special ammonia-refrigeration equipment, as well as information regarding their periodic inspections, verifications, calibrations, etc ； 00013— Environmental factors should include the equipment’s location, supporting safety facilities, fire safety equipment, personal protective equipment, alarm systems, etc ； 00014——Management factors should include the organizational structure of ammonia-based refrigeration enterprises, post responsibility systems, safety management systems, operating procedures, emergency response plans, safety technical records, safety warning signs, etc. 5.2.2 Characteristics and consequences of accidents caused by hazard sources. The main characteristics of accidents related to ammonia-based refrigeration special equipment include explosion, deflagration, leakage, deformation, poisoning, frostbite, corrosion, asphyxiation, etc. The resulting consequences include personal injuries, property losses, damage to the working environment, and environmental pollution. 5.2.3 Methods and processes for identifying hazard sources Specialized units dealing with ammonia-based refrigeration systems can use the following process to identify hazard sources: 00015 – A identification team is formed consisting of the person in charge of safety management, the technical supervisor, safety officers, inspectors, operators, experts, etc., from such enterprises ； 00016——Collect and study relevant laws, regulations, rules, safety technical specifications, and standard requirements pertaining to special equipment for ammonia-based refrigeration, such as pressure vessels and pressure pipelines ； 00017 — Analyze accidents or malfunctions related to special equipment for ammonia-based refrigeration that have occurred or may occur within the industry ； 00018——Break down the risk points associated with ammonia-based refrigeration special equipment into various specific inspection items. Based on relevant standards, specifications, and management experience, determine the inspection criteria for each item when it is in good condition; identify situations where each item fails to meet these criteria (hazard sources) and the possible consequences thereof ； 00019 – The scope of hazard identification should encompass all elements of the filling activities, taking into account three states—normal, abnormal, and emergency—as well as three time periods: past, present, and future ； 00020——Appropriate methods and procedures should be used for hazard identification, which must be in line with the actual conditions on site; other effective and feasible methods can also be selected based on the actual operational processes of this ammonia-based refrigeration enterprise. 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. When conducting risk assessment, it is necessary to consider the possibilities and the severity of consequences related to people, equipment, and property. Based on the actual conditions of the organization, standards for determining the likelihood, severity, and risk level of potential consequences (accidents) should be established, and appropriate risk assessment criteria should be applied in order to determine the risk level. Grade levels are determined based on the evaluation results, and the safety inspection form analysis and evaluation records should be filled out (the format can refer to Appendix B). 5.3.2 Risk Level The risk level of a hazard is determined using risk assessment methods, and it is classified into 5 levels from highest to lowest: 1, 2, 3, 4, 5. Among these, level 1 represents the highest risk, while level 5 represents the lowest risk. 5.3.2.1 For special equipment used in public gathering places, its risk level is increased by one tier based on the original assessment level. 5.3.2.2 According to the provisions of GB18218, for special equipment involving ammonia where the storage volume of liquid ammonia exceeds 10 tons, its risk level is directly classified as Level 1. 5.3.3 Risk control measures 5.3.3.1 Management measures include: formulating and implementing work procedures, safety permits, work plans, safety operating procedures, etc. Such as establishing operating procedures for defrosting low-temperature pipelines and evaporators, procedures for filling and draining refrigerant from the system, and a safety permit system for hot work operations ； 00021——Reduce the number of exposed people, the frequency, and the duration of exposure. By properly planning the work procedures and reducing the number of unnecessary personnel at hazardous work sites, etc ； 00022——Prediction, early warning. Such as safety production risk prediction and early warning information systems, etc ； 00023——Statistical analysis. Such as statistical analysis of accidents and near-misses, etc ； 00024——Risk transfer (sharing). Such as purchasing work safety liability insurance, etc. 00025——Others. 5.3.3.2 Engineering and technical measures include: 00026——Installing interlock devices to reduce the concentration of toxic and harmful gases, thereby preventing poisoning and asphyxiation. Such as the interlock between the ammonia concentration alarm in the liquid ammonia refrigeration plant and the emergency exhaust fan ； 00027——Regular calibration or verification of safety accessories and associated instruments ； 00028——Equipped with local ventilation and exhaust systems, lightning protection devices, static electricity elimination devices, vibration damping devices, noise reduction devices, etc ； 00029——Equipped with automated filling equipment and an automatic alarm system ； 00030——In areas prone to failures and high risks, install conspicuous safety colors and safety signs. Sound, light, or a combination of sound and light alarm devices should be installed when necessary. Such as painting the liquid ammonia pipelines with safety colors, installing wind vane indicators, and setting up audio-visual alarms. 00031——Regularly inspect the control stations, as well as various valves installed on refrigeration containers and pipelines, to prevent unauthorized leakage of these valves, which could cause frostbite to the workers ； 00032——Others. 5.3.3.3 Training and education measures include: 00033——Three-level training for employees upon entering the factory ； 00034——Annual retraining ； 00035——Continuing education for safety management personnel and special operation workers ； 00036——Safety and technical instructions prior to work commencement ； 00037— Training in other aspects. 5.3.3.4 Emergency measures include: 00038——emergency situation analysis, development of emergency plans and on-site response plans, and preparation of emergency supplies ； 00039——Improve the emergency response capabilities of relevant personnel through measures such as emergency drills and training ； 00040——Others. 5.4 Risk classification and control
5.4.1 Implementation of risk classification and control
After conducting risk assessment and classification in accordance with the established evaluation methods and risk determination criteria, ammonia refrigeration enterprises classify risks into major risks, relatively significant risks, general risks, and low risks based on the corresponding principles specified in Table 1. These risks are represented by four colors—red, orange, yellow, and blue—respectively. Subsequently, the appropriate levels of control are determined, and classified control measures are implemented.