How to carry out safety work during maintenance in refining and petrochemical enterprises

He who is in charge is responsible. It falls under electrical installation, led by the telecommunications department. It falls under ground works and is led by the infrastructure department. The security department strictly adheres to the \"three simultaneities\" requirement, urging relevant departments to carry out necessary safety and environmental assessments, formulating and implementing relevant safety prevention measures, and assigning these responsibilities to the appropriate departments or units in accordance with HSE management protocols. By including them in the assessment process, there’s no risk that they won’t take it seriously.

Regulations on Safety Management of Construction Operations Chapter 1 General Provisions Article 1 These regulations are formulated in order to standardize the safety management of the company’s construction operations, reduce accidents that occur during such operations, and ensure the safety of employees’ lives as well as the company’s property. They are based on the Ministry of Construction’s “Regulations on the Management of Construction Sites” (Order No. 15 of the Ministry of Construction), as well as China National Petroleum Corporation’s “Regulations on Safety Management of Inspection, Maintenance, and Repair Operations in the Refining and Chemical Industry,” “Regulations on Safety Management of High-Height Operations in the Refining and Chemical Industry,” and “Regulations on Safety Management of Lifting Operations in the Refining and Chemical Industry” (Documents No. 206 and No. 92 issued by the Petroleum and Chemical Industry Department). Article 2 These provisions apply to the safety management of the company and contractors during plant shutdowns for maintenance, repairs, emergency repairs, as well as construction activities in capital project implementation. Chapter 2 Responsibilities and Division of Labor Article 3 The Safety and Environmental Protection Department is the competent department in charge of construction operation safety, and is responsible for the supervision and inspection of such safety ； Responsible for approving the HSE Operation Plan for construction projects (processes) and related work permits. Article 4: The Mechanical Equipment Department is responsible for safety management during the inspection, maintenance, and emergency repair of production facilities; it is also in charge of supervising the implementation of work orders related to equipment modification and disassembly, as well as approving electricity usage permits ； It is responsible for organizing relevant units to approve special emergency repair construction plans, while the “10th Five-Year Plan” project command center is in charge of safety management for new projects. Article 5: The Technology Development Department is responsible for the supervision and management of the process purging process, as well as the approval of relevant plans, during the shutdown for maintenance of production facilities. Chapter 3: Management Content and Principles Article 6: For construction work, inspections, repairs, as well as emergency repairs in special situations (in areas with oil, under pressure, or at high temperatures), the contractor must prepare a practical HSE operation plan for the construction project (process). This plan must be reviewed by the Mechanical Equipment Department (“15th Five-Year Plan” Command Center) before being submitted to the Safety and Environmental Protection Department for approval ； The contents of the \"HSE Operation Plan for Construction Projects (Processes)\\" include: the contractor’s investigation records, its HSE performance over the past three years, the HSE objectives for the construction work to be carried out, the contractor’s organizational structure, and the HSE resources allocated by the contractor ； Identification of HSE risks for the contents and operations of this construction project. Article 7: The entity to which the construction site belongs and the party carrying out the work shall, in light of the characteristics of the construction, provide targeted safety training for the workers, as well as information regarding the equipment used in the work and the relevant materials, and cover methods for dealing with and providing first aid in case of accidents that may occur during the work ； Operators must follow the procedures and abide by the “five no’s for working”: (1) Do not work without a valid work order ； (II) No operation shall be carried out if the guardian is not present ； (III) Do not carry out the task if it is found that the time and location specified for the task do not match those indicated on the work order ； (IV) Do not carry out work if the protective clothing and equipment for labor protection do not meet the specified requirements ； {Protective equipment required for special tasks that may involve exposure to acidic or alkaline substances (such as respirators) is provided by the production workshop} (V) It is permissible to refuse to carry out work if instructions violating these regulations are given or safety measures are not implemented ； Article 8: The entity to which the construction site belongs shall assign personnel to supervise the work area where equipment is modified or removed; personnel shall also be assigned for supervision in areas where work is carried out at heights when necessary ； Guardians must stay at their posts and fulfill their duties: (1) They should be familiar with the environment, production processes, and equipment in the work area, possess the ability to identify and handle abnormal situations, and have knowledge of first aid ； (II) If flammable, combustible, toxic, or harmful substances are detected being discharged in the vicinity, the right exists to put a stop to it ； And notify the workers to leave in a timely manner according to the situation; work can resume only after the issue has been resolved satisfactorily ； (III) Carry work permits and be equipped with necessary first-aid equipment ； (IV) For work at heights inside towers or containers, the supervisor outside the tower should hold the end of the safety belt tied to the worker, so as to be able to maintain timely contact with them ； Article 9: Each contractor is responsible for ensuring the safe execution of all construction tasks related to the project they are undertaking (such as removing or installing blind flanges, working at heights, and lifting operations), as well as for implementing the necessary safety measures. They are also responsible for issuing permits for work at heights. Chapter 4 Equipment Purging Article 10 The production workshop is responsible for preparing plans for purging the process equipment and pipelines for tasks such as plant shutdown for inspection and maintenance, as well as emergency repairs, and submitting these plans to the Technical Development Department for approval. Article 11: When purging equipment pipelines, components prone to clogging such as orifice plates, control valves, flame arresters, and filters should be removed (when removing valve flanges, proceed from bottom to top and from far to near) ； Isolate the safety valve with a blind flange, and close the pressure gauge hand valve as well as the connection valve for the level gauge ； Depending on the equipment, different media (fresh water, seawater, steam, nitrogen) are used for purging ； When using steam for purging, the pipes should be warmed up gradually; condensate water must be directed to a safe location for disposal, and measures should be in place to prevent burns ； For low-point drainage and high-point venting, they should be opened and closed one by one in the direction of purging ； After the specified purge time has elapsed, the valve should be closed first before stopping the steam supply. After purging, the area should be dried with air or nitrogen to prevent steam condensation from causing damage to equipment and pipelines due to vacuum conditions ； Ensure that all areas are thoroughly purged, with no dead corners. Article 12: For equipment that has been used to contain self-polymerizing substances, it must be steamed or boiled before use, and a polymer heating test must be conducted. Article 13: Depending on the nature and requirements of the operation, the substances contained within the equipment used for the operation must be replaced ； Hydrogen systems should be thoroughly purged with nitrogen, while hydrocarbon systems should be purged with steam ； The toxic substances present in the equipment shall meet the requirements of TJ36 \"Hygienic Standards for Industrial Enterprise Design\" ； Equipment and pipelines used for storing or transporting hydrogen fluoride must never be flushed or cleaned with water or steam directly ； After nitrogen displacement, further processing is carried out. Article 14: The combustible, toxic, and hazardous materials removed through the purging and displacement of equipment must be properly disposed of ； The vent should be located in a safe area or under supervision to prevent environmental pollution and physical injury. Article 15: After cleaning and purging, sampling of the equipment for analysis may be necessary, and the samples taken must be representative ； Samples should be taken at higher points for media with a density lower than that of air, and at lower points for those with a density higher than that of air ； A dedicated person should accompany the sampling in the production workshop. Article 16: Whenever it is necessary to carry out maintenance work on equipment and pipelines that cannot meet the aforementioned requirements regarding separation, purging, and analysis, the production workshop must establish effective safety measures. These measures must be reviewed by the Technical Development Department, the Production Operations Department, and the Safety and Environmental Protection Department, before being approved by the company’s senior management. Article 17: Equipment that needs to be removed to the maintenance department for repair must also undergo purging, displacement, and analysis in accordance with these regulations before it can be removed and taken away. Chapter 5: Blind Plate Installation and Removal Article 18: When performing tasks such as equipment purging, hot work, or the removal or modification of equipment, it is necessary to cut off the flow of materials between those areas and the sites where purging or work is being carried out; for this purpose, blind plates must be installed ； Operations involving the installation and removal of blind flanges must be carried out in accordance with HG 23013 \"Safety Regulations for the Installation and Removal of Blind Flanges in Plant Areas\". Article 19: Before removing or installing blind flanges, the workshop shall carry out preparatory work and formulate safety measures ； Draw a flowchart for the process of removing and installing blind flanges, and identify the project leader and supervisor ； Blind plates shall be manufactured in accordance with the requirements of technical specifications and kept by a designated person; it is not allowed to use iron sheets or asbestos rubber sheets as substitutes ； Explain the manufacturing process, working methods, and potential hazards to the workers, as well as safety and environmental protection precautions, and carefully check the implementation of these safety and environmental measures ； During the emergency repair process, when blind plates are installed or removed, the production workshop also needs to obtain an operation permit ； Only after inspection by the workshop supervisor to confirm there are no issues and with a supervisor present, can work on installing or removing blind plates be carried out. Article 20: When performing operations involving the installation or removal of blind flanges, unauthorized personnel must be evacuated; if necessary, production and maintenance activities in the vicinity should be halted, and any welding or heating operations within a radius of 30 meters must also be stopped. Article 21: Necessary protective measures must be taken during blind plate isolation and removal operations to ensure the personal safety of the workers. (1) It is not allowed to bring materials or use pressure to remove or install blind flanges ； During the start-up and shutdown of the equipment, tasks such as introducing gas, performing hot work, and conducting pressure testing must not be carried out simultaneously with blind plate removal or installation; moreover, these tasks must not be performed independently of each other. (II) The bolts should be removed one by one, alternating between loosening and tightening, at a slow pace; the bolts can only be taken off once it is confirmed that there is no gas, no liquid, and no pressure present ； The operators must stand upwind and must not be directly facing the flange gap ； For pipes with flanges that are located far from the supports, temporary supports and hangers must be installed ； After all the flange bolts have been tightened, a thorough inspection should be carried out to ensure that nothing has been overlooked before leaving the site. (III) When performing blind plate removal or installation on equipment that contains flammable, explosive, or toxic substances, the workers must wear isolated gas masks ； If working indoors, it is necessary to first open the doors and windows or implement forced ventilation ； When working with equipment exposed to corrosive substances such as acids and alkalis, personnel carrying out tasks (such as modifying or removing the equipment) must wear acid and alkali resistance masks as well as appropriate clothing and boots ； The working hours for operators should not be too long; they should take breaks every 30 minutes ； If you feel unwell while working, you should immediately leave the work area to rest or seek medical attention for examination and treatment. Article 22: Clear signs must be placed at the locations where blind flanges are installed, and a dedicated person shall be assigned to oversee their registration and management in order to prevent omissions in installing or removing such flanges ； Pipelines carrying flammable, toxic, and other hazardous materials, after having blind flanges installed, should be equipped with warning signs stating “Material inside; fire prevention required”. Article 23: After the plugging and removal of blind flanges for major and medium-scale repair projects are completed, they must be checked by the workshop’s process technicians against the blind flange diagrams before they can be handed over to the operating party or put into use in production. Chapter 6: Modifications and Disassembly of Equipment Article 24: Modifications and disassembly of equipment refer to the manual alterations or disassembly of equipment carried out within the production area during equipment maintenance or emergency repairs. (For changes in other non-production areas and equipment installation/dismantling tasks, the provisions of this chapter shall be followed.) Article 25: When issuing a work permit for one type of task, if other tasks are also involved (such as hot work, use of electricity, entry into confined spaces, lifting operations, or work at heights), corresponding work permits for those other tasks must be issued in accordance with relevant regulations ； Various work tickets cannot be substituted for one another. Article 26: The “Work Order for Modifying or Disassembling Equipment” is issued by the unit responsible for the work site. The procedures for handling it are as follows: (1) The person responsible for modifying or disassembling the equipment must submit an application to the unit in charge of the work site, along with the construction plan or schedule as well as the maintenance plan ； (II) The equipment operator of the unit responsible for the work site issues a work order based on the construction plan and the actual conditions at the work site, and fills in the specific start and end times, the location of the work, as well as the safety measures on the work order ； (III) The person in charge of the production workshop shall assign a supervisor and work with this supervisor to implement safety measures; mark a “√” in the corresponding section under “Safety Measures” on the back of the second copy of this work order to confirm this, record the section number in the “Safety Measures” column, and after ensuring that everything is in order, sign together with the worker to give approval ； After completing the work order, the person responsible must inform the unit’s dispatcher by phone, and fill in the dispatcher’s name in the “Person in charge of the working unit” field before proceeding with the work ； A work order without the signature of a supervisor is invalid ； (IV) The “Work Order for Modifying and Disassembling Equipment” consists of three copies ； The first copy (soft copy) is handed to the supervisor by the person carrying out the task, the second copy is kept by the person carrying out the task, and the third copy (hard copy) is retained by the workshop equipment officer for reference ； (Note: For the ‘Machine Pump Maintenance Work Ticket’ in the water supply and drainage workshop, the procedures and requirements outlined above can be followed.) Article 27: During operations involving the modification or disassembly of equipment, the workers involved and other relevant personnel must take safety and pollution prevention measures in light of the characteristics of such operations: (1) All types of disassembly tasks must not be carried out under pressure ； During the work of modifying and disassembling equipment, it is strictly prohibited to carry out any type of testing, pressure testing, experiments, or other concurrent operations related to this work ； (II) Before preparing to remove the equipment manhole, its internal temperature must be reduced to below 60°C, and the components should be opened from top to bottom ； When opening the bottom manhole, the valve at the very bottom for discharging material and slag should be opened first; this can be done only after confirming that there is no residual material inside ； (III) The removed equipment, components, pipelines, and accessories shall be transported immediately after removal; they must not be piled up within the plant area. Those that cannot be transported away temporarily should be stacked in an orderly manner at the edge of the plant, in a way that does not hinder the movement of vehicles and people, with transportation to take place within three days ； (IV) At each disassembly site, measures must be in place to prevent used oil, wastewater, and waste residues from falling to the ground and causing environmental pollution ； When removing it, if it is not possible to close the valve or connect the pipeline at the same time, a blind flange of the appropriate grade should be installed; it must not remain open for an extended period to prevent material leakage or other accidents ； (5) During demolition work in Class A plant areas, supervisors should regularly monitor the concentrations of combustible gases or vapors as well as hydrogen sulfide in the atmosphere ； When the alarm threshold is reached, maintenance personnel should be immediately notified to stop working and leave the site; work can resume only after the issue has been resolved successfully ； Chapter 7: Work at Heights Article 28: For work at heights, the JGJ 80 \"Safety Technical Specifications for Work at Heights in Construction\" and HG 23014 \"Safety Regulations for Work at Heights in Industrial Areas\" shall be followed ； Work at height refers to work carried out at a height of 2 meters or more (including 2 meters) above the reference level for falls. It is divided into two categories: general and special, with the general category further divided into four levels ； Special high-altitude work refers to situations such as wind speeds of level 6 or higher, extreme temperatures, rainy or snowy weather, nighttime, being in proximity to or in contact with live electrical conductors, having no stable footing or insufficiently secure footing, carrying out rescue operations in the event of sudden disasters, working in confined spaces, or in environments where toxic or harmful gases are present or where dust concentrations exceed allowable levels ； Article 29: A ‘High-Altitude Work Permit’ must be obtained before carrying out high-altitude work ； After the safety managers of the party carrying out the work and the safety officers in charge of the workplace jointly inspect and confirm the safety measures in place at that location, they are responsible for filling out and approving the high-altitude work permit ； Work is strictly prohibited without a work order ； For special high-altitude work, the contractor must also develop a work plan, which must be approved by the safety officer in charge of the workplace, before it can be issued by the contractor’s own safety officer ； In emergency situations when rescuing people, the construction supervisor or another manager may give verbal approval for work to be carried out without a work order, provided that the safety of the rescue personnel is ensured; the work order must be submitted to the Safety and Environmental Protection Department immediately after the work is completed, and the proper work order must be issued afterwards. Article 30 During the operation process, construction workers and relevant personnel shall take safety precautions and pollution prevention measures in light of the characteristics of work at heights. (1) As diagnosed by doctors, those suffering from hypertension, heart disease, anemia, epilepsy, or other conditions that prohibit working at heights shall not engage in such work ； (II) Workers working at heights must wear safety belts and helmets, and their clothing should be comfortable; it is prohibited to wear shoes with hard soles or nails that may cause slipping ； No components of the seat belt shall be removed arbitrarily, and those that are damaged must not be used ； Safety belts shall comply with GB 6095 \"Safety Belts\", and safety helmets shall comply with GB 2811 \"Safety Helmets\" ； (III) Safety belts should be worn high and used low; they must be attached to sturdy components located above the work area, and not to areas with sharp edges. There should be sufficient clearance below the attachment point of the safety belt. It is strictly prohibited to use ropes tied around the waist as a substitute for safety belts ； (IV) The erection of scaffolding must comply with the requirements of **relevant standards** ； It is prohibited to use large barrels as scaffolding or support points for carrying out construction work on them ； When working at heights, it is necessary to maintain a specified safe distance from overhead power lines to prevent electric shock ； Safety nets must be installed for work at heights of 2 meters or more above the reference level of the fall height ； (5) Sufficient lighting must be provided for work at heights at night ； When working at heights, it is necessary to clean the ice and snow from the pathways and work areas, as well as to take anti-slip measures ； Outdoor work at heights is not permitted when the wind speed is 10.8 meters per second or higher, or under weather conditions such as thunderstorms, heavy rain, or dense fog ； (VI) When carrying out dangerous construction tasks such as welding under oil and pressure at heights, facilities for the workers’ escape routes should be set up simultaneously ； (7) During demolition work at heights, it is not allowed to pile components and materials on the scaffolding of the structural elements at height; they should be placed in specialized containers and lifted up and down using ropes. Throwing them up or down is strictly prohibited ； Pipelines and components removed from high locations should be taken down immediately after removal; otherwise, they must be secured to prevent them from falling and causing injury to people or damaging equipment ； A safety perimeter should be established below the work area, with clear warning signs in place, and a dedicated person should be assigned to supervise it ； Various tools should be equipped with anti-drop ropes, and the tools should be placed inside tool bags ； (8) It is strictly prohibited to walk on or work on roof trusses, the upper chords of trusses, supports, purlins, cantilever frames, cantilever beams, masonry, unsecured components, or unstable structures (such as asbestos shingles, wooden planks, etc.) in the absence of safety protection measures ； A “No Stepping” warning sign should be placed in prominent locations on such structures ； Do not sit on platforms or the edges of holes, nor lie down in passages or safety nets to rest ； Holes in the floor slabs should be fitted with sturdy covers or enclosures ； For high-altitude work at heights of over 30 meters, a communication device supervised by a dedicated person should be installed to maintain contact with the ground ； (IX) Exterior elevators and lifting cages shall be equipped with reliable safety devices ； Unmanned elevators and lifting cages must not be used by people ； Workers working at heights should ascend and descend along walkways and ladders; they must not climb using ropes, poles, or railings. Chapter 8 Lifting Operations Article 31 Lifting operations refer to the process of using various machinery to lift heavy objects and move them to different locations ； The classification and grading of lifting operations, as well as the safe operation and management of such operations, are in accordance with HG 23015 \"Safety Regulations for Lifting Operations in Industrial Sites\" ； When using specialized lifting machinery (caterpillar cranes, truck cranes, bridge cranes, etc.) for lifting operations, the operating procedures specific to that machinery must also be followed. Article 32: Under normal circumstances in lifting operations (for objects with a weight of 40 tons or more and the main structural elements of civil engineering projects) ； Although weighing less than 40 tons, they have complex shapes, low stiffness, a high length-to-diameter ratio, are precise and valuable, and require special construction conditions; therefore, a lifting plan should be prepared in the \"HSE Operation Plan for Construction Projects (Processes)\\" ； The lifting construction plan can be implemented only after being reviewed by the Mechanical Equipment Department (the Command Office for the 10th Five-Year Plan Project) and the Safety and Environmental Protection Department. Article 33: Crane operators must hold a certificate for working in special types of jobs ； For lifting operations involving objects with a weight of over 10 tons, a \"Lifting Safety Operation Permit\" is required (this permit must be obtained by the party carrying out the operation). For lifting tasks that require the use of fire exits for emergency repairs, a \"Road Occupation Permit\" is necessary. Article 34: Before carrying out lifting operations, the party responsible for the work shall first set up safety warning signs at the lifting site and assign a dedicated person to oversee the area. The lifting equipment and its safety accessories must be inspected to ensure that the safety devices are sensitive and reliable. A trial lift should also be conducted before actual lifting, and operations may only proceed once everything is confirmed to be in order ； It is strictly prohibited to use pipelines, pipe racks, utility poles, mechanical and electrical equipment, etc. as lifting anchor points ； Buildings and structures shall not be used as anchors without review and calculation by the Mechanical Equipment Department. Article 35: During lifting operations, lifting must be carried out within the specified load limits, and lifting equipment and rigging shall be selected and used after proper calculations ； Sufficient lighting should be provided for night work. Outdoor work should be stopped in case of heavy snow, heavy rain, dense fog, or winds of force 6 or above ； The communication signals for lifting operations shall be in accordance with GB5082 \"Signals for Commanding Lifting Operations\" ； No one shall ascend or descend together with the lifted load or lifting machinery; in special cases, reliable safety measures must be taken ； Ropes, wind ropes, and pulling ropes at the lifting site should be kept away from live power lines to avoid contact, and a safe distance must be maintained ； Standing, passing, or working under suspended heavy objects is strictly prohibited.

Let me share my views: 1. The safety and environmental department should first bring together the **registered safety engineers in the factory to form a professional team. Allocate HSE management responsibilities to the relevant departments or units, and include their work performance within the assessment framework, so as to ensure they take it seriously. ⒉Whoever is in charge is responsible; management is carried out on a local basis. It falls under the responsibilities of units responsible for electrical work, tool use, equipment maintenance, and routine upkeep; these maintenance units take the lead and are responsible for specific tasks, while the local production units oversee and evaluate performance. ⒊The logistics support unit is responsible for ensuring proper logistical support, so that the maintenance personnel have food and water available ； Material supply must keep up with the maintenance pace and must not hold back maintenance work. ⒋The comprehensive management department needs to have a clear strategy for effectively evaluating the units involved during maintenance work, in order to ensure the quality of such maintenance.

During maintenance, it is of course the department in charge of safety within the company that oversees and manages things. There is always a specific department responsible for each aspect; every project has a designated project leader. With such a hierarchical structure, responsibilities are clear and definite – whoever is responsible must take action, with no possibility of shirking responsibility. In short, whoever is responsible for the project is accountable for it.