Guidelines for the Establishment of a System for Classified Control of Safety Risks and the Identification and Rectification of Hidden Dangers in the Use of Pressure Pipelines

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1 Scope This standard specifies the terms and definitions, basic requirements, risk classification and control, hazard identification and rectification, document management, and continuous improvement related to the establishment of a system for the classification and control of safety risks associated with the use of pressure pipelines in Shandong Province. This standard is applicable to the entities using pressure pipelines in Shandong Province in carrying out risk classification and control, as well as in building systems for the identification and rectification of potential accident hazards. The hazard sources listed in this standard do not represent all the hazard sources of pressure pipelines. 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 reference documents without a date, the latest version (including all amendment sheets) applies to this document. GB 18218 Identification of Major Hazard Sources for Hazardous Chemicals GB 32167 Code for Integrity Management of Oil and Gas Transmission Pipelines GB 50251 Design Code for Gas Transmission Pipelines GB 6441 Classification Standards for Work-related Injuries and Deaths of Enterprise Employees GB/T 51359 Technical Standards for Interplant Pipelines in Petrochemical Plants GB/T 19285 Inspection Rules for Corrosion Protection of Buried Steel Pipelines TSG 03 Guidelines for Reporting, Investigating, and Handling Accidents Involving Special Equipment TSG 07 Licensing Rules for Manufacturers and Filling Units of Special Equipment TSG 08 Rules for the Operation and Management of Special Equipment TSG D0001 Safety Supervision Regulations for Pressure Pipelines – Industrial Pipelines TSG D7003 Rules for Periodic Inspections of Pressure Pipelines – Long-distance (Oil and Gas) Pipelines TSG D7004 Rules for Periodic Inspections of Pressure Pipelines – Public Service Pipelines TSG D7005 Rules for Periodic Inspections of Pressure Pipelines – Industrial Pipelines T/CPASE GT008 Classification and Grading of Hidden Dangers Related to Accidents Involving Special Equipment DB37/T 2882 General Principles for the Graded Control System of Work Safety Risks DB37/T 2883 General Principles for the System for Identifying and Addressing Hidden Dangers in Work Safety Accidents DB37/T 2971 Detailed Rules for the Graded Control System of Work Safety Risks in Chemical Enterprises DB37/T 3010 Detailed Rules for the System for Identifying and Addressing Hidden Dangers in Work Safety Accidents in Chemical Enterprises DB37/T 3078 Detailed Rules for the Graded Control System of Safety Risks Related to Special Equipment DB37/T 3079 Detailed Rules for the System for Identifying and Addressing Hidden Dangers Related to Accidents Involving Special Equipment 3 Terms and Definitions The terms and definitions defined in TSG 08, TSG D0001, GB 18218, GB 32167, 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 Pressure Piping Pressure piping refers to tubular devices that use a certain pressure to transport gases or liquids. It includes pipes with a maximum operating pressure of 0.1 MPa (gauge pressure) or more, where the medium is a gas, liquefied gas, steam, or a liquid that is flammable, explosive, toxic, corrosive, and has a maximum operating temperature equal to or higher than its standard boiling point; such pipes also have a nominal diameter of 50 mm or more. Except for pipes with a nominal diameter of less than 150 mm and a maximum operating pressure of less than 1.6 MPa (gauge pressure), as well as the pipe sections that form part of the equipment used for transporting non-toxic, non-flammable, and non-corrosive gases (excluding liquefied gases, steam, and oxygen). 3.2 Rehabilitation (Alteration) The rehabilitation of pressure pipelines refers to activities that involve changing the structure of the pressurized parts of the pipelines – such as altering the specifications and materials of the pressure-bearing components, changing the structural layout of the pipelines, or adjusting the positions of supports and hangers – thereby resulting in changes in the performance parameters or characteristics of the pipelines. 3.3 Major Repairs Major repairs of pressure pipelines refer to the maintenance of the pressure-bearing components in those parts of the pipeline that cannot be mechanically disassembled, as well as the replacement of pipe sections and valves using welding methods, pipe straightening, patching and welding of pressure-bearing components, and sealing leaks while the pipeline is under pressure. 3.4 Ditch (Channel) A passage for rainwater, sewage, cables, thermal pipes, etc., which cannot be observed directly; it is characterized by the creation of an explosive environment upon penetration into flammable media. 3.5 Densely Populated Area: Public places for gatherings, buildings, or areas classified as level 2 or above according to GB 50251, where the number of people present exceeds 50. 3.6 High Consequence Areas (HCAs) are areas where a pipeline leak could cause significant adverse effects on the public and the environment. The level of high consequence is divided into three grades in accordance with GB 32167. 4 Basic Requirements 4.1 Risk classification management and control, as well as hidden danger investigation and rectification 4.1.1 The user unit shall, in accordance with the standards for risk classification management and control and the risk assessment methods specified in DB37/T 3078 and this implementation guide, identify and evaluate risks associated with pressure pipelines, determine their risk levels, identify the responsible departments and personnel for risk management and control, implement appropriate control measures, and compile a list of risk classification management and control measures. 4.1.2 The using unit shall, based on the risk control list, and in accordance with the relevant laws, regulations, safety technical specifications for pressure pipelines as well as the requirements of DB37/T 3079, establish standards for identifying potential hazards, determine the types and frequency of such hazard inspections, and carry out the inspections. Designate specific personnel to organize the rectification of potential hazards or to ensure that such rectifications are carried out within a set time limit. 4.2 Principal Responsibility 4.2.1 The user entity is the principal responsible party for the safety of special equipment. 4.2.2 The user unit shall establish a special equipment safety management organization in accordance with the requirements of TSG 08 and DB37/T 3078, clarify the job responsibilities of the unit’s principal responsible person, the person in charge of special equipment safety management, special equipment safety administrators, special equipment operators, as well as the heads of various functional departments. Following the principle of \"whoever is in charge is responsible,\" they shall jointly develop a work plan for building a dual-prevention system, and organize the implementation of risk classification control and hazard investigation and rectification measures for the safe use of pressure pipelines. 4.3 Establishment of systems 4.3.1 Risk management system The using entity shall define the work process for establishing a safety risk classification and management system for pressure pipelines, 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 entity shall establish a work process for building a system for identifying and addressing hazards associated with pressure pipelines, 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 addressing potential hazards in pressure pipelines, 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 reward and punishment mechanism in place by the using unit should include elements related to the operation of the dual-prevention system for pressure pipelines. The performance of this dual-prevention system, particularly the implementation of measures to address potential risks, should be linked to the salaries of employees in relevant positions within the unit, so as to implement rewards and punishments and ensure that these corrective measures are carried out. 4.4 Requirements for Training All Employees 4.4.1 Training Content Training for personnel working with special equipment should be organized at least once a year. The main contents of such training include: 00001 – Laws, regulations, standards, systems related to the dual-prevention system for pressure pipelines, as well as job responsibilities and operating procedures ； 00002——Procedures and methods for hazard identification and risk assessment ； 00003——Overview of Risk Assessment for Pressure Pipelines ； 00004——Risk control measures ； 00005——Other risk information. 4.4.2 Training records The training process at the user unit shall maintain training records. These records include: 00006 – Training plan ； 00007——Training materials or textbooks ； 00008——Training sign-in sheet ； 00009——Records of training assessment or performance evaluation ； 00010——Other relevant materials. 5 Risk Classification and Control 5.1 Identification and Investigation of Risk Points It is advisable for the user unit to use individual pressure pipelines in use, as well as the associated operational activities, as units for identifying risk points. A \"Risk Point Registration Table – Pressure Pipelines\" should be established, containing basic information such as the user unit’s pipeline registration number, the name of the risk point (pressure pipeline), the pipeline level, the process identification number/location/start and end points, specifications, length, design/work conditions, the medium used, and the safety level (see Appendix A.1). When conducting hazard identification and analysis for chemical enterprises with complex production processes, it is possible to treat multiple risk points within the same production section or unit as a single entity for such analysis, following the principles of comprehensive screening, clear scope definition, easy identification, and convenient management. 5.2 Hazard Identification and Analysis 5.2.1 Contents of Hazard Identification When identifying hazards, the using unit shall implement the requirements for pressure pipeline safety management, namely \"three implementations, two certifications, one inspection, and one plan\", as well as the requirements for operation and maintenance. In accordance with the accident characteristics listed in TSG 03, potential hazardous factors associated with individual pressure pipelines (or pipe sections) and their operation processes shall be identified. The scope of this identification should take into account four aspects: human factors, physical factors, environmental factors, and management factors. Among these: 00011 – Human factors include the safety management personnel of the pressure pipeline using unit, the certification status of personnel, safety training, staffing levels, operational skills, and working behaviors ； 00012——The physical factors should include the intrinsic safety condition of pressure pipelines (such as procurement, manufacturing, acceptance, corrosion, etc.), safety accessories or protective devices, equipment attachments and tools, inspection and testing, usage markings, protective devices, working media (low temperature, high temperature, toxic, harmful, corrosive), etc ； 00013— Environmental factors should include the conditions of the facility where the pressure pipeline is located, the site foundation, water supply and drainage conditions, the working environment, and the natural environment (temperature, humidity, air pressure), etc ； 00014——Management factors should include safety management organizations for pressure pipelines, safety management systems, training systems, usage registration, change management, regular inspections, maintenance, handling of abnormal situations, operating procedures, safety technical records, emergency rescue plans, safety warning signs, 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 pipeline equipment fails, which correspond to the most severe consequences of those accidents. It usually manifests as explosions, deflagrations, leaks, deformation, fractures, damage, uncontrolled collapse, or failures. Consequences caused by hazard sources include personal injuries, people being trapped, property damage, work stoppages, legal violations, damage to business reputation, deterioration of the working environment, environmental pollution, etc. 5.2.3 Procedure for identifying hazard sources The using unit may refer to the following process for identifying hazard sources: 00015 – 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 ； 00016——Collect relevant information on laws and regulations, safety technical specifications, procedures, standards, systems, accident cases, etc., related to the safety of pressure pipelines ； 00017——Analysis of accidents or failures that have occurred and may occur in pressure pipelines ； 00018——Classify and identify hazard sources (hazard 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: 00019 – In accordance with relevant laws, regulations, rules, safety technical specifications, and standards related to pressure pipelines, 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 ； 00020——Pressure pipelines 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 ； 00021——For pressure pipelines, it is advisable to use the safety checklist method (abbreviated as SCL) for identification; other effective and feasible methods can also be chosen depending on the specific circumstances of the organization. 5.3 Risk Assessment
5.3.1 Methods of risk assessment
For the identified hazard sources, it is advisable to use the risk matrix (LS) method to evaluate their level of risk (see Appendix B.1–B.4). Based on the evaluation results, categories should be assigned, and the “Analysis and Evaluation Record of Safety Checklists” should be completed accordingly (see Appendix B.5–B.10). The using units may also adopt other risk assessment methods based on their actual circumstances. 5.3.2 Principles for determining risk levels The risk level of a single pipeline/section is determined based on the highest level identified among all the hazard sources of that pressure pipeline. The risk levels are divided into 5 categories, from highest to lowest: 1, 2, 3, 4, and 5. Among them, Level 1 represents the highest risk, while Level 5 represents the lowest risk. For pressure pipelines used in areas with high population density, their risk level is elevated by one grade from the originally determined level. 5.3.3 Risk control measures 5.3.3.1 Engineering and technical measures include: 00022—Installation of safety accessories for pressure pipelines ； 00023——Install corrosion protection devices such as cathodic protection and drainage systems for pressure pipelines ； 00024——Install safety interlock devices for pressure pipelines ； 00025——Set up the automatic control system ； 00026—— Closed recovery devices shall be employed for the safety relief outlets of pressure pipelines ； 00027——Installation of monitoring and control equipment as well as alarm systems (for flammable, explosive, and toxic substances) ； 00028——Seal off pressure pipeline areas that generate or cause hazards ； 00029——Separate people from hazardous areas through isolation ； 00030——Regular inspection of pressure pipelines, repair of defects identified during inspections ； 00031— Other control measures. 5.3.3.2 Management measures include: 00032 – Assigning appropriate personnel for the management and operation of special equipment ； 00033——Establish a management system for pressure pipelines ； 00034— Formulate operating procedures for pressure pipelines ； 00035—— Reduce exposure time (e.g., to abnormal temperatures or harmful environments) ； 00036——Regular inspection and testing of pressure pipelines (wall thickness, potential, stray current, etc.) ； 00037——Conduct regular inspections in accordance with the scheduled inspection cycle and requirements ； 00038——Calibration and inspection of safety accessories for pressure pipelines ； 00039——Qualification management for units engaged in the installation, modification, and maintenance of pressure pipelines ； 00040——Set up warning signs ； 00041——Implement the requirements for pressure pipeline safety management: “three implementations, two certifications, one inspection, and one plan” ； 00042——Other control measures. 5.3.3.3 Training and education measures include: 00043——Training and education on laws and regulations regarding pressure pipelines ； 00044——Training on operating procedures for pressure pipelines ； 00045——Training and education on pressure pipeline management systems ； 00046——Training and education received by special equipment managers to obtain certification, etc ； 00047——Training on pressure pipeline accident cases and emergency rescue measures ； 00048——Other control measures. 5.3.3.4 Personal protective measures include: 00049——Equipping with personal protective equipment ； 00050——Other control measures. 5.3.3.5 Emergency response measures include: 00051——Development, dissemination, and training of emergency plans ； 00052——Regularly organize emergency rescue drills ； 00053——Emergency rescue equipment supply (including fire-fighting supplies, rescue tools, and emergency medications) ； 00054——Activate the emergency response plan, mobilize personnel, resources, and community forces for emergency handling ； 00055——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 to eliminate or reduce the risk shall be implemented until the risk 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.