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A Brief Analysis of the Safety of Chemical Processing Equipment

2009-03-18View Original

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Chemical production is characterized by flammability, explosiveness, toxicity, high temperatures, high pressures, and corrosivity; as a result, it poses greater risks compared to other industrial sectors. Therefore, safety holds a paramount importance in chemical production. Without safety guarantees, various accidents are likely to occur, and smooth production becomes impossible.   In chemical production, the occurrence of various accidents is often caused by employees' illegal operations, improper instructions, and violations of labor discipline. According to relevant statistics, among all the accidents that have occurred, those caused by employees’ violations of safety rules account for about 75%. The most obvious manifestation of such accidents is usually damage to the equipment; in other words, accidents in which equipment damage is the apparent symptom make up the vast majority, accounting for over 70% as well. Therefore, it is particularly important to strengthen equipment safety management in chemical production. I have gained a deep understanding of this from my many years working in chemical companies.   The safety management of equipment mainly covers five aspects: design, manufacturing, installation, operation, and maintenance. Among these, the operation and maintenance of equipment are most directly related to accidents caused by employees’ violations of safety rules. Therefore, I believe that the safety management of equipment should primarily focus on strengthening both operational safety and maintenance safety.   I. Safe operation of equipment   1. As managers of workshop equipment on the production front line, it is necessary to conduct regular inspections; ideally, these inspections should take place daily, with records kept. Whenever any abnormal issues are detected in the equipment, an incident report must be submitted promptly, and corrective and preventive measures must be established to address those problems. As the department responsible for equipment management, it should conduct inspections at least once a week, while other relevant departments (such as the safety management department) should organize comprehensive safety inspections on a monthly basis, as well as carry out irregular checks on the operation of the equipment and the status of safety management.   2. As operators, it is necessary to master the “four understandings and three abilities” for equipment operation” ; Work with a valid certificate ; Equipment shall be started, operated, and stopped in strict accordance with the operating procedures; illegal operations are strictly prohibited ; Stay at one’s post, strictly implement the routine inspection system, and carefully fill out operation records ; Carefully carry out equipment lubrication and keep proper records. Equipment lubrication must be carried out strictly in accordance with the \"five fixed principles\" and \"three filtrations\" ; Strictly implement the shift handover system to ensure that all situations during the shift are clearly communicated ; Regularly clean all parts of the equipment to remove oil residues and leaks, ensure smooth operation, and promptly address any issues of leakage or inefficiency in the equipment.   3. As maintenance personnel, one should proactively understand the operating condition of the equipment and conduct inspections at regular intervals and in designated locations. Maintenance or operation personnel detect that the equipment is not functioning properly ; The cause should be investigated immediately, and the relevant departments or personnel should be informed in a timely manner; in emergency situations, decisive actions must be taken right away. Stop the vehicle; do not drive blindly without identifying the cause and ruling out any faults. The circumstances that occurred and the actions taken must be recorded in detail and accurately, and explained clearly to the next shift.   4. During the period when the equipment is not in use, a dedicated person should be assigned to carry out regular inspections and maintenance. Attention should be paid to preventing dust, moisture, freezing, and corrosion. For transmission equipment, it is also necessary to regularly turn it over and switch it between different modes to keep it in good condition ;   II. Safety in Equipment Maintenance   1. Preparations before equipment maintenance   a. For minor repairs, unplanned maintenance, and routine maintenance of equipment, a designated person must be assigned to handle these tasks, and all necessary procedures and permits must be completed; at the same time, a safety officer must also be appointed. The annual major maintenance of the equipment is the responsibility of the plant manager in charge, who also forms a maintenance project team to develop a maintenance plan; in addition, it is necessary to appoint a person responsible for ensuring safety during the equipment maintenance.   b. For major overhauls of equipment, safety and protection measures must be established, in addition to plans for replacement, cleaning, neutralization, purging, installing and removing blind flanges, and handling heavy lifting operations. It has also undergone a technical safety review by the relevant departments and been approved.   c. Before the maintenance work begins, in addition to the safety regulations already established by the company, additional safety requirements must be set forth based on the specifics and scope of the maintenance tasks. The procedures for carrying out the work as well as the safety rules must be clearly defined, and a dedicated person must be assigned to oversee safety inspections at the site.   d. Before maintenance work begins, it is necessary to prepare the required materials, accessories, and equipment based on the specific tasks, contents, and requirements of the maintenance. Safety checks must be conducted on all tools and equipment, scaffolding must be set up in accordance with regulations, and a designated person must carefully inspect the safety protective equipment, measuring instruments, and fire-fighting equipment.   e. Before carrying out maintenance work, it is necessary to clarify various coordination procedures and signals.   f. Before construction, a comprehensive training session must also be conducted for all personnel involved in the maintenance work; special types of workers require additional focused training.   2. Implementation of maintenance work a. The construction unit must obtain various safety permits, such as maintenance work permits and fire safety operation permits, before carrying out the maintenance work.   b. Before maintenance, safety and technical measures such as installing blind flanges, cleaning and purging, depressurizing, and cutting off power supply must be taken on the equipment to eliminate its hazardous factors.   c. During maintenance, the site should be cleaned regularly to keep the roads clear; safety signs or protective fences should be installed in hazardous areas.   d. During maintenance, it is required that personnel at all levels take responsibility for specific areas, with clear responsibilities assigned to individuals, and that regular inspections be carried out to enhance on-site safety management.   e. During maintenance, detailed records must be kept of the tasks to be carried out and the methods used; all operations must comply with relevant safety regulations.   3. Acceptance of equipment maintenance a. Upon completion of the maintenance, the technicians must clean up the site, remove all types of waste, and restore all safety devices to their original state, to prevent any tools or equipment from remaining inside the equipment.   b. Before completion acceptance, a comprehensive inspection of the maintenance work must be carried out to check whether there are any omissions in the maintenance tasks, whether the quality of the maintenance meets the requirements, and whether the rotation of the rotating equipment is normal, among other things.   c. After a thorough inspection, the equipment must be tested, including temperature testing, pressure testing, leak testing, as well as testing the sensitivity of safety devices and instruments.   d. After the trial run is successful, acceptance procedures must be carried out; a thorough recheck in accordance with the quality standards for acceptance is required. Once everything meets the requirements, an acceptance certificate is issued, and the equipment is officially handed over for production use. At the same time, the repair records are transferred and archived for future reference.

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