The 6 most dangerous maintenance tasks and corresponding safety measures

Thread Content

Relevant data shows that during chemical plant maintenance, accidents caused by unsafe behaviors of workers account for approximately 88% of the total number of accidents; such unsafe behaviors are the primary cause of accidents. Please don’t worry your family; go out carefully and return home safely! Be sure to keep in mind the safety measures for these 6 maintenance tasks below! Risk Analysis and Safety Measures – Maintenance operations on production equipment? NO1: Maintenance operations involving corrosive media. Operational risks: Leaking corrosive liquids and gases can cause varying degrees of damage to the workers’ limbs, clothing, and tools, as well as lead to environmental pollution. Safety measures: 1. Before carrying out maintenance work, it is necessary to contact the process engineers to drain out any corrosive liquids or gases, clean the area, and rinse it; after analysis confirms that everything is satisfactory, an ‘Operation Permit’ must be obtained. 2. Workers shall wear protective equipment as required, and be familiar with the work tasks, especially the opinions issued by the relevant departments. 3. Inspections should be carried out in low-lying areas; there should be no accumulation of corrosive liquids on the site to prevent slips and injuries during work. 4. The working surface where corrosive liquids are handled should be below waist level; otherwise, relevant personnel should be contacted to set up scaffolding to prevent residual liquids from splashing and damaging the body or clothing. Temporary supports such as iron drums shall not be used for this purpose. 5. When working, wear appropriate personal protective equipment such as rubber gloves, protective face shields, and rubber boots, depending on the specific circumstances. 6. When removing, the connection surfaces can be rinsed with clean water to reduce the erosion caused by corrosive liquids and gaseous media. 7. Limbs, clothing, tools, etc. that have come into contact with corrosive substances should be cleaned promptly ； If any discomfort occurs, it should be treated promptly. 8. After the work is completed, ensure that all materials are removed and the site is clean; maintain good cleanliness at the location. NO2: Maintenance work on rotating equipment. Risk: During the maintenance of rotating equipment, incorrect operation of electrical or steam supplies may cause unintended rotation, putting the lives and property of the maintenance workers at risk ； When the equipment (or spare parts) is large (heavy) and safety measures are inadequate, mechanical injuries can occur. Safety measures: 1. Before carrying out maintenance work, it is necessary to contact the process engineers to effectively isolate the system, remove all flammable, explosive, toxic, and harmful substances from the equipment and pipelines that will be used for welding or maintenance, flush them, and conduct proper analysis; thereafter, a \"Work Permit\" must be obtained. 2. When repairing live (steam) equipment, it is necessary to contact the relevant personnel and teams, cut off the power (steam) supply, and hang a sign on the switch box that reads “Do not close – work in progress”. 3. The person in charge of the task must implement all safety measures related to that task, as well as obtain the necessary work permits and carry out the relevant approvals ； For tasks with extremely high risks, a safety assessment should be conducted together with the person in charge of safety at the work site, in order to develop a safe operation plan. 4. Workers shall wear protective equipment as required ； Be familiar with the work requirements, especially the opinions issued by the relevant departments, and strictly follow them both before and during the work. 5. The removed parts and components should be stored in designated areas and properly protected; special personnel should be assigned to watch over important parts or components. 6. When using pneumatic, electric, hydraulic, or other types of tools, operate them in accordance with the \"Safety Operation Instructions\" to ensure safe construction. 7. When equipment (or spare parts) is large (heavy) and requires coordination among multiple types of workers, unified command must be maintained to ensure orders are carried out and prohibitions are observed. 8. Strengthen the management of oily substances; all waste oil should be poured into recycling bins. 9. After the work is completed, ensure that all materials are removed and the site is clean; maintain good cleanliness at the location. NO3: High-altitude maintenance work. Risk: Since the work location is at a higher height than the normal working level, there is a risk of people and objects falling, which can lead to accidents. Safety measures: 1. The person in charge of the task shall arrange for the issuance of the \"Task Permit\" and the \"High-Height Work Permit\", with approval processes determined based on the working height ； The head of the production department where the task is carried out signs the departmental opinion. 2. The person in charge of the task shall check and ensure that the scaffolding (ladders, hoists), safety belts, ropes, and other equipment used for work at heights are safe, and shall assign a supervisor to the work site ； When work requires it, a warning line should be set up. 3. Workers must wear protective equipment as required, and be familiar with their tasks, especially the opinions issued by the relevant departments: when using safety belts, the provisions of the \"Regulations on the Use of Safety Belts\" must be followed ； When using a ladder at work, follow the \"Ladder Safety Management Regulations\" ； When using scaffolding, follow the \"Safety Management Regulations for the Use of Scaffolding\" ； When working inside a basket or hanger, comply with the \"Regulations on Safety Management of Lifting Equipment\". 4. When working at heights, vertical operations should not be carried out simultaneously both upward and downward. In special cases where vertical work must be carried out simultaneously, approval from the unit’s management is required, and a dedicated protective canopy must be installed or other isolation measures taken. 5. Avoid working at heights at night. When high-altitude work must be carried out at night, approval from the relevant authorities is required; the person in charge of the work must conduct a risk assessment, establish safety measures, and ensure adequate lighting. 6. High-altitude work is not permitted in conditions of severe weather such as winds of force 6 or above, thunderstorms, heavy rain, or dense fog that impair vision and hearing, or when personal safety cannot be ensured. 7. During high-altitude work: The chief supervisor must maintain regular contact with the workers at height, must not engage in any other tasks, and under no circumstances shall leave their post without permission ； When an abnormal situation occurs in the production system, immediately notify the workers working at heights to stop working and evacuate the site ； When there are significant changes in the working conditions or environment, a new High-Altitude Work Permit must be obtained. 8. After the work is completed, ensure that all materials are removed and the site is clean; maintain good cleanliness at the location. NO4: Hot work maintenance operations. Risks associated with these operations include heating, the scattering of slag, and sparks that can cause burns to people, as well as fires and explosions. Arc radiation and electric shocks can also pose hazards to human health. Safety measures: 1. Before carrying out maintenance work, contact the process engineers to effectively isolate the system, and remove, flush, and replace any flammable or explosive substances present in the equipment and pipelines. 2. After the analysis is approved, proceed with the hierarchical approval for the \"Work Permit\" and the \"Hot Work Permit\" ； Once the sampling analysis shows satisfactory results, no one shall change the process conditions ； During hot work, if there is an interruption of more than half an hour, sampling and analysis must be repeated. 3. The Hot Work Permit must be carried by the person performing the hot work at all times. All workers must be clear about the work requirements, especially the opinions issued by the relevant departments. 4. Workers must wear protective equipment as required and hold the appropriate qualification certificates ； Before carrying out welding or cutting operations, it is necessary to remove any flammable materials from the surrounding area, set up warning barriers, and hang clear signs; the area where welding or cutting takes place must not be expanded without permission. 5. A supervisor must be assigned for hot work, and fire extinguishers must be available ； During operations, unauthorized personnel are prohibited from entering the area where welding is being performed. When carrying out construction work in a Class A no-fire area, the project supervisor must, as required, notify professional firefighters in advance to be on site to assist with supervision. 6. When performing welding work, check that the joints and wiring are in good condition to prevent accidents caused by electric leakage. 7. During gas welding operations, the distance between the oxygen cylinder and the acetylene cylinder should be maintained at over 5 meters, and the distance between these two cylinders and the point where welding is taking place should be kept at over 10 meters. It is also necessary to check that the gas pipes are in good condition. 8. When performing welding or cutting tasks at heights, a fire tray must be used to prevent sparks from falling ； At the same time, all combustible materials below must be removed, and trenches, manholes, cables, etc. need to be covered. 9. When performing hot work on combustible gases under pressure without displacement, a work plan must be prepared and safety measures must be implemented. At the same time, the pressure inside the device must not be less than 0.98 kPa, nor exceed 1.5691 MPa, to ensure that no negative pressure is created ； The oxygen content inside the equipment must not exceed 0.5%. Otherwise, hot work shall not be carried out. 10. When the workers leave the area where welding is being carried out, they should promptly cut off the power supply used for the work and extinguish any remaining sources of fire, so as to avoid leaving any potential hazards. 11. After the work is completed, ensure that all materials are removed and the site is cleaned up, maintaining good cleanliness at the location. NO5: Maintenance work in confined spaces. Risks associated with such work: Confined spaces can present hazards such as low oxygen levels, high temperatures, toxic and harmful substances, as well as flammable and explosive gases. If appropriate safety measures are not taken, fires and explosions can occur, leading to casualties and other accidents. Safety measures: 1. Contact process personnel to cut off the power supply connecting the equipment to the external power source, and implement locking measures along with posting warning signs ； Effectively isolate all equipment and pipelines connected to confined spaces or containers. 2. After the confined space has been drained, isolated (by installing blind flanges), cleaned, purged, and ventilated, and sampling analysis shows satisfactory results, the workers shall obtain the \"Work Permit\" and the \"Permit for Working in Confined Spaces\", which are subject to hierarchical approval. Once the sampling analysis shows satisfactory results, no one shall change the process conditions. 3. Before starting the work, prepare emergency rescue supplies, including safety belts, safety ropes, long-tube masks, lighting with a safety voltage of no more than 24V, electric shock (leakage) protection devices, as well as communication equipment. 4. Supervisors shall wear protective equipment as required and select an appropriate location for safety supervision ； During the supervision process, regular communication is necessary; any abnormalities should be reported immediately to the workers so that they can stop working and evacuate from the dangerous area ； At the same time, it is necessary to pay attention to self-protection. 5. Workers must wear protective equipment as required. When entering a confined space for the first time, it is necessary to wear a gas mask (long-tube type or air respirator), as well as safety belts and ropes ； Be familiar with the work content, especially the opinions issued by the relevant departments ； Workers working in confined spaces follow a shift system, change shifts on time, and retreat outside to rest promptly. 6. After removing the cover from a confined space, barriers, fences, lighting, etc. must be installed to prevent accidents. 7. When working in confined spaces, online analysis is necessary; if any abnormalities are detected, evacuation should be carried out promptly. 8. After the work is completed, ensure that all materials are removed and the site is clean; maintain good cleanliness at the location. NO6: Electrical maintenance work. Risks associated with this work include the danger of electric shock, arc hazards, or accidents caused by sparks resulting from short circuits; these can lead to injuries such as electric shock, burns caused by arcs, and injuries due to explosive shocks. Furthermore, electrical accidents can also pose dangers such as fires, explosions, and power outages of the equipment. Safety measures: 1. Before carrying out maintenance work, contact the operators to cut off the power supply connected to the equipment, and apply locking measures by attaching a prominent sign that reads “Do not close – work in progress” on the switch box or the main circuit breaker. 2. All personnel working on or near live equipment must obtain an \"Operation Permit\" and follow the \"Permit Management Procedure\". 3. Operators shall wear protective equipment as required (in compliance with the \"Requirements for Personal Protective Equipment during Substation Work\"), and be familiar with the work tasks, especially the comments provided by the operators in charge. 4. Electrical work must be performed only by certified and qualified personnel. At least two people must be present during the work, with one of them acting as a supervisor. 5. Electrical monitoring personnel must undergo professional training, obtain a certification to work, and be qualified to cut off the power supply to equipment and activate alarm signals ； Prevent unauthorized personnel from entering dangerous areas during operations ； No other work tasks may be carried out. 6. During maintenance, repairs, and fault handling, no one shall arbitrarily change or adjust the set values of protective and automatic devices. 7. Analysis and prevention of arc hazards: For equipment with energy levels exceeding 5.016 J/m², an analysis of arc hazards must be conducted to ensure safe and effective operation. 8. For processes or systems prone to static electricity generation during maintenance, a static hazard analysis should be conducted, and corresponding measures and procedures should be established to prevent static hazards. 9. Metal ladders, chairs, stools, etc. must not be used in electrical work areas.