Compilation of safety emergency response plans for the instrument workshops in various units

Emergency Plan for Fire Incidents in the Instrumentation Workshop of the Fertilizer Plant: In accordance with the requirements set by the fertilizer plant regarding fire incidents, and in order to minimize the damage caused by fires in our workshop, this emergency plan has been formulated based on the specific conditions of our workshop. 1. Scope of Application: This plan applies to the instrumentation workshop of the Fertilizer Plant at Daqing Petrochemical Company. II. Emergency Organization and Responsibilities 1. Members of the emergency organization 2. Responsibilities of emergency personnel at various levels Chief Commander: Responsible for overseeing operations on-site ； Judgment, decision-making ； Organize relevant teams to carry out rescue, protection, security, evacuation of personnel, removal from the area, and first aid, and decide on all feasible measures to effectively control the spread of the situation. Deputy Commander: Assists the Chief Commander in overseeing all aspects of work; in the absence of the Chief Commander, takes over the responsibility for overall command at the scene. The liaison team is headed by the workshop scheduler: responsible for internal and external, as well as vertical communication in emergency situations, and for conveying instructions from management ； Coordinate various teams to carry out the maintenance of instrumentation equipment. The emergency response and repair team is headed by the person in charge of workshop equipment technology; they must follow the instructions of the emergency command center ； Responsible for the safety protection of on-site instruments, as well as organizing their maintenance and repair ； Contact the relevant units to carry out on-site repairs for equipment failures ； Responsible for collecting information related to the disaster site and conducting inspections of the damaged equipment. Responsible for preparing and reviewing emergency repair plans to restore equipment operation as much as possible. The technical team is headed by the workshop’s technical supervisor: it obeys the instructions of the emergency command center, assists in carrying out emergency procedures related to the manufacturing process, and ensures the proper operation of instrumentation equipment. The rescue team is headed by the workshop’s safety officer: responsible for the rescue, handling, and evacuation of those in danger at the scene ； The transfer of property that has been damaged. It is also responsible for securing and guarding the accident scene. The logistics and medical rescue teams are under the responsibility of the workshop union: they must follow the instructions of the emergency command center ； Responsible for the supply of emergency supplies, as well as on-site command, the classification and treatment of poisoned and injured persons, and escorting them to the factory’s medical emergency station. Additionally, in the event of an accident, the on-duty shift leader takes temporary charge of on-site command, and then command is passed on in the order in which the workshop supervisor and other responsible persons arrive. III. Principles for Emergency Response To ensure the smooth progress of emergency operations in the workshop after a fire occurs, to safeguard the instrumentation and equipment installed there, and to minimize casualties and property losses as well as reduce the impact of the fire disaster, the following principles should be followed during emergency response: 1. Call for help first, then extinguish the fire. After a fire breaks out, the person who discovers it should call the police immediately. Call 119 to inform the fire department of the location of the fire, the materials on fire, and the scale of the fire. 2. Save people first, then save property. After a fire breaks out, every measure should be taken to ensure the safety of people, with priority given to treating the injured and evacuating people. 3. First, carry out emergency rescue; then, provide disaster relief. After a fire accident occurs, emergency rescue efforts must first be directed at the areas that have already posed or may pose significant danger and harm. 3. Focus on the key points first, then the general ones. After a fire accident occurs, it is necessary to ensure the safety of key units, hazardous areas, and important equipment in the production facilities first. 4. Safety first, production second. After a fire accident occurs, it is necessary first to organize the operation of the equipment and the resumption of production, ensuring safety in the process. 5. Protect first, then carry out repairs. After a fire accident occurs, it is necessary to first assess the extent of damage to the equipment, take effective measures to prevent potential secondary hazards resulting from the fire, and mobilize appropriate resources for the urgent repair of the equipment and facilities. 6. All emergency response personnel shall comply with the unified command and arrangements of the Emergency Response Command, adhering to the principle that local interests should yield to the overall interests, and that regular tasks should give way to emergency response efforts. 7. Emergency response personnel should enhance their self-protection awareness during emergency operations, and participate in rescue efforts only while ensuring their own safety. Wear protective equipment when necessary. 8. When emergency responders detect a hazard, they should immediately report to the emergency command center and take necessary emergency measures based on the conditions at the scene. 9. During emergency response, it is necessary to fully take into account the characteristics of the instruments and equipment in various systems, in order to minimize the occurrence of serious hazards such as fires, explosions, and poisoning that may result from secondary effects of fire accidents, as well as to prevent damage to the equipment. 10. Once the danger has been completely eliminated and all personnel, operations, and property have been brought to safety, the chief commander issues the order to lift the emergency state. IV. Alarm procedure: When a fire breaks out, the personnel on site should, while ensuring their own safety, promptly inspect the area where the incident occurred and inform the team leader or workshop supervisor right away. The workshop supervisor shall then report the situation to the control room without delay. The details of the alarm include: the name of the unit where the incident occurred, the time and location of the incident, the nature of the fire accident, the level of danger, whether there were any casualties, as well as the name of the person who reported the incident and their contact information. Instrument Workshop Control Room, accident scene, various departments of the fertilizer plant, various teams in the Instrument Workshop, Fertilizer Plant Control Room, leaders of the Instrument Workshop. file:///C:/DOCUME~1/ADMINI~1/LOCALS~1/Temp/msohtml1/01/clip_image001.gif file:///C:/DOCUME~1/ADMINI~1/LOCALS~1/Temp/msohtml1/01/clip_image002.gif file:///C:/DOCUME~1/ADMINI~1/LOCALS~1/Temp/msohtml1/01/clip_image003.gif 5. Emergency preparedness work 1. Learn knowledge related to fire fighting, improve fire prevention awareness, and enhance rapid response capabilities. 2. Strengthen the maintenance and management of equipment and facilities, reduce and eliminate weak points in critical areas, and improve the safety of such equipment and facilities. 3. Conduct regular inspections of fire-fighting equipment and gas protection devices to ensure they are complete and in good condition. 4. Various monitoring, alarm, and interlock systems must be sensitive and reliable, so as to effectively serve as a safety safeguard. 5. Strengthen the inspection and maintenance of instrumentation equipment in the tank area to ensure its reliable operation in case of emergencies. 6. Remove obstacles from fire lanes and emergency exit areas in a timely manner to ensure unobstructed access for fire and rescue vehicles, as well as for people in emergency situations. 7. Each team must make preparations for the supply of spare parts needed for emergency repairs during production. 8. Once a fire breaks out and the emergency plan is activated, personnel will arrive promptly and the emergency response mode will be initiated. VI. Fire Emergency Response 1. Potential impacts on production (1) A plant-wide power outage. (2) Interruption of field gas supply. (3) Damage, deformation, tilting, cracking, or collapse of important equipment and facilities. (4) Instrument air interruption. (5) Insufficient or interrupted steam supply at the power plant. (6) The red flag bubble is interrupted in the water. (7) Leakage from large and small ammonia tanks. (8) Damage to acid and alkali tanks. (9) Buildings are damaged or collapse. (10) Over-temperature, over-pressure, and material leakage during production. (11) Severe accidents such as fires, explosions, poisonings, and suffocations occur. (12) Widespread environmental pollution caused by factors such as material leakage. 2. Formulate emergency response measures (important and critical) (1) In the event of a plant-wide power outage, an interruption in oil field gas supply, severe damage to key equipment and pipelines, an interruption in instrument air supply, or an explosion, the plant shutdown plan must be implemented immediately. The technical team and the emergency repair team should cooperate to ensure a plant-wide shutdown. Ensure the safe and reliable operation of instrumentation equipment. (2) Insufficient or interrupted steam supply in the power plant: When the pressure in the 4.0Mpa steam pipeline network falls below 3.8Mpa, it is not possible to meet the requirements of fertilizer production; the technical team and the emergency repair team must work together to shut down the hydrolysis process in the urea production unit, reduce its load, and stop the evaporation and granulation systems. Ensure the safe and reliable operation of instrumentation equipment. 2.2 The pressure in the 4.0Mpa steam pipeline network is below 3.6Mpa. The flow rate cannot meet 100 T/H; the technical team and the emergency repair team must work together to shut down the urea plant’s tower, ensuring the proper operation of instrument 3102-J. Work with the synthesis unit to maintain low-load operation. 2.3 In the event of a sudden interruption in the supply of 4.0 Mpa steam, the technical team and the emergency repair team shall work together to shut down the plant by using urea to seal the tower, as well as to stop unit 3102-J. If the process still cannot meet the production requirements, units 103-J and 105-J shall be shut down accordingly, while ensuring that the instrumentation in the upstream process continues to function properly. 2.4 In case of a shortage of 4.0 Mpa steam, the technical team and the emergency repair team should work together to adjust the operation of pumps in accordance with the process requirements. (3) Disruption of water supply to Hongqi Pao 3.1 Prioritize ensuring water for production. The technical team and the emergency repair team ensure the reliable operation of the instruments for production water use. 3.2 Shutdown of the domestic water system ； Hot water supply to the building is suspended. The technical team and the emergency repair team ensure the reliable operation of the instruments for domestic water supply. 3.3 Decide whether to shut down production based on the water level in the water storage tank and the duration of water outage. The technical team and the emergency repair team ensure accurate indication of the water tank level. (4) Leakage from large and small ammonia tanks 4.1 Immediately notify the fire department (119) and the emergency medical service (120). A security perimeter has been set up to prevent anyone or any vehicles from entering the area. 4.2 Process handling: In the event of a severe ammonia tank leak, personnel in the instrumentation workshop must be prepared to use personal protective equipment. If the synthesis and urea production units come to a stop, the technical team and the emergency repair team must ensure that the DCS and ESD systems, among other instrumentation devices, in those units continue to function properly. 4.4 Unrelated personnel are not allowed to enter the warning area. Properties of ammonia: Ammonia has the molecular formula NH3, a molecular weight of 17.03, a auto-ignition temperature of 651°C, and an explosion limit of 15.7% to 27.4%. Its physical and chemical properties are that it is a colorless gas with a pungent odor, it is toxic, and the maximum allowable concentration in the air is 30 mg/m3. The hazardous characteristic is that it can form an explosive mixture when mixed with air, and combustion and explosion can occur in the presence of an open flame or high heat. Ammonia is considered to have low toxicity; it primarily causes irritation and corrosion to the respiratory tract. At high concentrations, it can increase the excitability of the central nervous system, leading to spasms. Through reflex actions at the trigeminal nerve endings, it can cause cardiac arrest and respiratory failure. Ammonia solution can also cause skin burns. 4.5 The rescue team is responsible for the rescue, treatment, and evacuation of people in distress at the scene ； The transfer of property that has been damaged. Those who have been poisoned at the accident scene need to be rescued, but the prerequisite for such rescue is that the rescuers must wear air respirators to ensure their own safety before attempting to help the injured. After rescuing the injured person from the dangerous area, they should be promptly placed in a place with fresh air for treatment; in severe cases, it is necessary to contact an emergency service and transport the person to a hospital for further care. (5) After the fire is extinguished, the workshop should promptly organize emergency repairs to the damaged areas, and once the repairs are completed, it should resume production in accordance with the standard procedures. VII. Necessary communication messages

This post was last edited by oatobnus on 2009-10-20 at 10:02. Distribution number: xxx ten thousand tons/year heavy oil catalytic unit DCS system abnormality handling plan. Unit name: Heavy Oil Catalytic Workshop. Prepared by: xxx. Reviewed by: xxx. Approved by: xx. Implementation date: February 2005. I. Principles for handling DCS system abnormalities 1. Reporting: Once an abnormality occurs in the DCS system, the shift supervisor should immediately inform the workshop management, report to the plant’s control room, and contact the DCS maintenance team to handle the situation urgently in the control room. 2. Identify the cause of the fault promptly; determine the nature of the fault – whether it is a problem with the FCS control station or the ICS operation station – and also be aware of the time required to restore the system. 3. Make full and effective use of the real-time data acquisition network. By logging into the website, all process parameters can be viewed. 4. All personnel on duty shall, under the unified command of the production supervisor, coordinate with each other across different positions, take immediate action, and use manual control as much as possible to maintain the stability of the equipment. 5. If an abnormality in the DCS system can be resolved within 60 minutes, the device will handle it according to the respective \"DCS system abnormality handling methods\". 6. If an abnormality occurs in the DCS system and cannot be resolved within 60 minutes, certain types of abnormalities under the category of “Abnormality in DCS system” must be handled by initiating a shutdown sequence. II. Methods for Handling Abnormalities in the DCS System 1. Power outage in the DCS system: The DCS display does not show any information, and the control valves on site are in the state where air-operated valves are fully closed and air-shut valves are fully open. Action: Contact the DCS maintenance staff and electricians promptly to handle the issue, and at the same time report the situation to the plant dispatcher to find out the reason for the DCS system outage and its duration. In the event of a short-term power outage, all control valves shall be switched to manual operation on-site; the liquid levels in each tower and tank shall be determined based on the readings from the on-site glass level gauges. The flow rates in various sections shall be assessed by referring to the current consumption of the pumps. Additionally, enhanced on-site inspections and better coordination between different teams are necessary to ensure the stable operation of the facility. In the event of a prolonged power outage, the device will shut down in a cyclic manner. 2. DCS operation station freezing issue: The DCS display is operational but the data does not change, and the keyboard stops working. The valves on site were in their state before the shutdown. Handling: Contact the DCS maintenance staff promptly to handle the issue, and at the same time report the situation to the plant dispatch team and relevant units. If the operation station freezes and the problem can be resolved in a short time, the current operations shall remain unchanged; the operators should increase their inspections. The flow rates in various sections should be determined based on the current readings of the pumps, while the liquid levels in various towers and tanks should be monitored using the on-site glass level gauges, in order to maintain stable operation of the facility. If the control station freezes and requires a long time to resolve, it is decided whether to cycle the device or shut it down, depending on the circumstances. 3. Power loss of the two CPUs in the control station or a power outage in the control station: All its parameters display as “*****”, and the on-air valves are in the fully closed state while the off-air valves are in the fully open state. Action: Contact the DCS computer technicians and electricians promptly to handle the issue, and at the same time report the situation to the plant dispatcher to find out the reason for the DCS system outage and its duration. In the event of a short-term power outage, all control valves shall be switched to manual operation on-site; the liquid levels in each tower and tank shall be determined based on the readings from the on-site glass level gauges. The flow rates in various sections shall be assessed by referring to the current consumption of the pumps. Additionally, enhanced on-site inspections and better coordination between different teams are necessary to ensure the stable operation of the facility. In the event of a prolonged power outage, the device will shut down in a cyclic manner. 4. Node failures of the instruments or power loss in a certain module: The display on the instruments shows “*****”, and the corresponding control valves are in the state where the air-opening valves are fully closed and the air-closing valves are fully open. Handling: Contact computer specialists promptly to address the issue, and inform the relevant departments. Switch the faulty control valves to manual operation on-site, and pay close attention to regular inspections to ensure the steady operation of the equipment. 5. Touchscreen malfunction at the control station: The touchscreen is not working properly. Handling: Use the keyboard to operate, and contact the DCS maintenance staff promptly for handling.

Is there anything more detailed? I need more details, haha!

Not bad, thumbs up. Are there any from chemical industry units as well?

Thank you, I’ve learned it. Are there any other projects? ? :lol