Reviewing the Old to Discover the New (Series 23)

1. During tower and furnace maintenance, relevant permits such as fire permits must be obtained in advance. 2. Personal protective equipment must be worn correctly. 3. The personnel composition should be adjusted appropriately. 4. Conduct necessary flammable gas analysis and ensure safe operations. 5. Use security devices properly to protect personal safety.

1. The production unit must create favorable and safe conditions for maintenance; the maintenance unit must obtain permission from the production unit and is not allowed to dismantle any components at will. 2. The equipment being serviced must have its power cut off, and a visible sign must be placed on it. 3. Temporary lighting for maintenance work should use 36-volt safety lamps (12 volts for use inside containers); the equipment must have good insulation, and electric tools must be equipped with reliable grounding wires. 4. Workers working at heights must comply with the following regulations: 1) Safety nets, protective shelters and other safety facilities must be installed for multi-level cross-work; safety helmets must be worn when entering the maintenance site, and safety belts must be fastened when working at heights of more than two meters. 2) Persons suffering from heart disease, hypertension, fainting spells, or epilepsy must not be assigned to work at heights. Workers performing work at heights should pay attention to overhead wires; they must keep a distance of at least two meters from high-voltage lines. 3) Scaffolds must comply with safety regulations, and the total weight of materials stacked on the scaffold plus the weight of workers shall not exceed 270 kilograms per square meter. Anti-slip measures should be taken and fences installed on the scaffolding’s ladders and ramps. 4) Sufficient lighting is required for night operations ； Work outdoors shall be suspended in case of winds of force 6 or above. 5. When entering enclosed containers such as towers, tanks, and vessels for maintenance work, a dedicated supervisor must be assigned, a warning sign stating “Under maintenance – do not open” should be placed on the relevant connection valves, and reliable safety measures must be taken.

1. Safety and quality must be prioritized during maintenance work； 2. Operations must be carried out in accordance with the pre-approved maintenance plans, procedures, or work instructions, which ensures that the quality and safety of the maintenance are under control ； 3. The personal protective equipment of the personnel involved in maintenance work must be in order, and the construction machinery must be in good condition ； 4. Safety measures must be in place during maintenance operations, work permits must be complete, and safety isolation measures must be verified ； At the same time, it is necessary to pay attention to changes at the work site, carry out hazard identification and on-site monitoring; in particular, when entering confined spaces or carrying out hot-work operations, the frequency of monitoring must be increased ； 5. Ensure civilized construction and avoid damaging equipment, facilities, and the environment.

This post was last edited by zxsaqwe on 2016-5-17 at 10:13. 1. Before entering the maintenance site, one must learn* the relevant safety regulations. 2. Work may commence only after a fire permit has been issued. 3. Flammable solvents must not be used to clean equipment. 4. Oxygen cylinders and acetylene cylinders should be subject to stricter management.

1. A safety inspection and maintenance leadership team shall be established in the workshop, with the top leader of the unit serving as the team leader, under a system of responsibility held by the top leader. 2. All units participating in the maintenance work must conduct a safety training session for all employees prior to starting the work, explaining the safety considerations related to each item and each step outlined in the safety plan for the maintenance tasks. Responsibilities must be assigned to specific teams and individuals. Before carrying out each maintenance task, the person in charge must provide a \"five-point briefing\", namely explaining the tasks to be carried out, the safety measures, the safe methods of execution, the precautions to take regarding safety, and the requirements to abide by relevant regulations. Eliminate the occurrence of “three violations”, namely: unauthorized commands, illegal operations, and breaches of labor discipline. Achieve the \"four no-harms\": do no harm to oneself, do no harm to others, avoid being harmed by others, and prevent others from being harmed. 3. All teams must strictly implement the shutdown plan to carry out a orderly shutdown. Thoroughly replace, purge, and wash towers, vessels, pipelines, etc., to ensure that there is no oil, water, or vapor remaining inside the pipelines and equipment; simultaneously, completely clean up any oil stains from the floors, surface drains, and sewers. It is strictly prohibited to discharge oils, sewage, liquefied gas, toxic and harmful gases, etc. arbitrarily. All manhole covers and drains within the enclosed area must be sealed to eliminate potential safety hazards; responsibilities must be assigned to specific individuals, and relevant records must be kept. 4. Before shutting down, check that all fire-fighting equipment is in good condition and ready for use. During maintenance, ensure that the fire roads within the plant are unobstructed and that there is sufficient water pressure for firefighting, just in case. 5. All personnel entering the maintenance site must wear the required personal protective equipment, especially safety helmets, work uniforms, safety belts, etc. Those who fail to comply with safety regulations or do so inadequately and cause accidents shall bear the consequences themselves, and the unit leaders and responsible persons will be held accountable in accordance with relevant regulations. 6. Strictly implement the safety management system for working on equipment. Anyone entering containers, towers, furnaces, manholes, flue ducts, or other enclosed equipment for work must be inspected by safety personnel. They must obtain a permit for working inside containers before entry is permitted. There must also be someone outside the container to supervise and remain at their post. 7. Carefully inspect all types of construction equipment to ensure they are in good condition; prevent any unsafe tools from entering the construction site. The site should be arranged reasonably to minimize overlaps and interferences, thereby ensuring both progress and safety. The removed waste materials must be taken away promptly to keep the fire lanes clear. Effective measures should be taken to prevent iron sulfide from catching fire on its own, and the iron sulfide and other materials collected should be buried underground. 8. Strictly implement the blind plate isolation system. Whenever it is necessary to maintain equipment or pipelines, they must be isolated from related systems. The system of installing and removing blind flanges must be strictly followed; blind flanges should be numbered uniformly, and diagrams showing their installation and removal should be prepared. Safety measures must be explained to personnel performing blind flange removal and installation operations, to prevent poisoning and burn accidents. It is strictly prohibited to use materials that do not meet the requirements, such as asbestos boards or galvanized sheet metal, in place of blind flanges. The blind plate must have sufficient strength, and its thickness should generally not be less than that of the pipe wall. 9. During maintenance, the power supply to all equipment within the plant area is disconnected; water, electricity, steam, and air must not be turned on or off without the approval of the workshop. For operations such as power supply and disconnection, hot work, earthwork, working at heights, and entry into containers, it is necessary to follow the prescribed procedures and coordinate with the dispatching department to obtain the relevant permits. When using fire-fighting water during maintenance, a permit must be obtained; the water should be used only after approval, in order to avoid affecting the operation of other equipment. Working without a ticket is prohibited; otherwise, the respective unit and the company carrying out the work will be subject to severe penalties, and those responsible will be held accountable. 10. For work at heights, a permit for working at heights must be obtained. Planks and scaffolding must be sturdy and reliable. It is strictly prohibited to work while standing on pipelines or guardrails, and throwing objects from heights is not allowed. All tools and items must be securely fastened to prevent them from falling off and causing injury or damage. 11. Strictly strengthen electricity management during maintenance ； (1) For rotating equipment and maintenance work, the power supply must be disconnected and a warning sign placed; if necessary, the fuse should be removed ； (2) Explosion-proof lighting fixtures must be used, and a safe voltage of 36 volts or 12 volts must be employed for lighting inside the equipment ； (3) All types of temporary electrical wires must not be wrapped together; joints should be securely tied up. They must not come into contact with equipment that generates high temperatures. Where possible, they should be installed in an elevated position. Temporary distribution boxes must have rain protection measures and their doors must be locked ； (4) Mobile devices such as hand-held power tools should be equipped with leakage protectors that meet safety requirements to prevent electric shock accidents. 12. Strictly enforce the safety regulations regarding the use of fire; for any fire use during construction, a fire permit must be obtained, and strict approval procedures must be followed. The principle of \"no fire use under any circumstances\" should be adhered to: no fire use without an approved permit, no fire use if fire prevention measures are not in place, and no fire use if the person responsible for monitoring the fire is not present. It is necessary to ensure that the tickets match the actual situation on site; multiple uses of one ticket are strictly prohibited. 13. In special circumstances, when working in areas with toxic or harmful substances, it is necessary to select appropriate special protective equipment such as gas masks and self-contained breathing apparatus. 14. It is necessary to strictly control the quality of maintenance work, ensuring intrinsic safety from the outset. To lay a solid material foundation for the long-term safe operation of various installations, it is necessary to strictly control the acceptance process in terms of the quality of equipment, materials, and spare parts, as well as the quality of welding and installation work, in order to ensure the intrinsic safety of these installations. 15. All external construction teams must sign a Safety Contract with the Safety Production Department to clarify their responsibilities. The safety department has the right to stop any team that fails to operate in accordance with safety regulations; in the event of an accident, such team shall bear the consequences. If repairs are delayed or the company suffers losses due to equipment damage or personal injuries, the construction team and the responsible persons of the relevant units will be held strictly accountable. 16. During maintenance, safety regulations such as the strict prohibition on smoking are maintained without exception. 17. During maintenance periods, the Safety Production Department and leaders at all levels shall conduct inspections and supervision, and impose penalties on units and individuals that fail to comply with safety regulations and systems or do so inadequately. 18. Designated personnel shall be responsible for organizing the maintenance of key equipment. 19. During maintenance, the DCS and ESD in the control room must not be adjusted or activated arbitrarily to prevent accidents. 20. During maintenance, if a pipeline or equipment needs to be purged with steam, it is necessary to carefully check and confirm that it is safe before introducing steam. 21. When pressing packing, replacing gaskets, changing valves, or installing/removing blind flanges, it is necessary to communicate with the upstream and downstream systems and proceed only after confirming that there are no issues. 22. The inside of the equipment pipes after maintenance must be thoroughly cleaned; they can only be sealed after careful inspection, and inspection records along with the signatures of the maintenance personnel are required. 23. Before driving, conduct a thorough inspection of all safety facilities such as ventilation, communication systems, fire suppression equipment, ladders, platform railings, and lighting, to ensure they are in good condition. 24. Before the installation is put into operation, the procedures and operating methods must be updated in a timely manner in light of any changes in the process, as well as in equipment and instruments/electrical systems. The workers on duty must receive thorough training, and only after passing the examinations may they start working. Appendix: I. Requirements for cleaning the sedimentator of coke 1. Strictly comply with the eight mandatory rules for entering containers and equipment. 2. The equipment must be cooled to below 35°C; then, procedures for entering the container should be carried out, along with proper testing. 3. Before entering the equipment, protective gear must be worn as required, and tools must be used in accordance with safety regulations. 4. When using lifting tools, be careful to ensure safety and prevent slips that could injure people or damage items. 5. The scaffolding should be sturdy, reliable, and convenient to use, with proper fixing points in place. 6. The personnel responsible for cleaning the coke should carry out the task from top to bottom, rotate workers frequently, improve ventilation, and take care to protect themselves. Smoking, dozing off, or resting inside the container is strictly prohibited. Supervisors must remain at their posts and maintain frequent communication. 7. The removed coke lumps should be placed in woven bags and delivered to the ground promptly; it is prohibited to leave them on the guardrails or platforms, as this can block traffic. 8. When the coke lump delivery device is in use, prevent damage to fire-fighting and other facilities. 9. If the coking removal operation is interrupted for more than 30 minutes, it is necessary to arrange for a re-check; work may resume only once approval is given. 10. When cleaning the coke, it is strictly prohibited to carry out operations simultaneously from above and below to prevent coke blocks from falling and causing injury to people or damage to property. 11. All tools should be handled with care to prevent them from falling. 12. In case of any situation, the supervisor should promptly contact the relevant personnel. II. Removal and installation of the tower and the two manholes 1. First, identify the manholes that need to be removed or installed, put on the necessary personal protective equipment, and prepare the tools. 2. All tools should be handled with care; during operation, prevent tools from slipping out of hands and causing injuries. 3. The removed screw nuts should be placed neatly in appropriate locations. 4. Standing on the guardrail while working is prohibited; try to leave the work area when resting. III. Loading, unloading, and cleaning of the tower tray 1. When entering the tower, it is necessary to strictly follow the eight requirements and wear appropriate personal protective equipment. 2. The principle for removing trays is to do so from top to bottom, while installing trays should be done from bottom to top; ensure there are safe places to stand to avoid slipping. 3. The cleaned trays should be properly labeled; do not lean on the guardrails to prevent slips that could cause injury. The area should be cleaned promptly, and care should be taken to avoid spontaneous combustion of ferrous sulfide. 4. All tools must meet safety requirements, and supervisors should maintain regular contact with the workers. 5. Throwing objects from heights is strictly prohibited; in special cases, someone must be on the ground to supervise. 6. Operators should ensure good ventilation and avoid working for long periods of time. IV. Maintenance of cooling exchange equipment 1. The maintenance personnel and relevant staff in the workshop must confirm that the equipment is pressure-free before work can commence. 2. When performing work, protective gear must be worn in accordance with safety regulations. 3. All tools should be handled with care to prevent them from falling and hurting someone; the removed bolts should be placed neatly. 4. All lifting equipment and steel cables must be safe and reliable. It is strictly prohibited to use steel wire ropes to lift the core; a core extractor must be used instead. 5. The removed ferrous sulfide should be buried promptly to ensure that work is completed, materials are cleared away, and the site is tidy. V. Lining Construction 1. When entering the container, the relevant regulations on the eight musts must be strictly followed. 2. Apply for a permit to enter the container; entry is permitted only after approval is granted. 3. Before construction, a thorough inspection of the scaffolding must be carried out; it must be sturdy and reliable, and personal protective equipment must be used properly. 4. There must be a supervisor outside to maintain timely contact. 5. All tools and equipment must comply with relevant safety regulations. VI. Maintenance of pumps 1. When entering the maintenance area, it is necessary to wear the required personal protective equipment, such as safety helmets and gloves. 2. The tools used should be handled with care. 3. The removed parts should be placed neatly and not left scattered around. 4. The lifting equipment and steel cables must be safe and reliable. 5. Ensure the work is completed, all materials are removed, and the site is clean. VII. Monitoring personnel in the control room: 1. Stay at their posts and closely monitor changes in the temperature of various towers, heat exchangers, gasoline pipelines, etc., to prevent spontaneous combustion of ferrous sulfide; report any abnormalities immediately for prompt handling. 2. Strengthen inspections to prevent theft. 3. Have the authority to stop unsafe behaviors. 【From Haiyou’s post】

Safety, special operations: hot work, confined spaces, excavation, lifting, etc. Monitoring of toxic and harmful gases, emission and collection of pollutants, etc

Safety precautions during maintenance work: 1. The production unit must create favorable conditions for safe maintenance, and the maintenance unit must obtain approval from the production unit; it is not allowed to disassemble components arbitrarily. 2. The equipment being serviced must have its power cut off, and a visible sign must be placed on it. 3. Temporary lighting for maintenance work should use 36-volt safety lamps (12 volts for use inside containers); the equipment must have good insulation, and electric tools must be equipped with reliable grounding wires. 4. Workers working at heights must comply with the following regulations: 1) Safety nets, protective shelters and other safety facilities must be installed for multi-level cross-work; safety helmets must be worn when entering the maintenance site, and safety belts must be fastened when working at heights of more than two meters. 2) Persons suffering from heart disease, hypertension, fainting spells, or epilepsy must not be assigned to work at heights. Workers performing work at heights should pay attention to overhead wires; they must keep a distance of at least two meters from high-voltage lines. 3) Scaffolds must comply with safety regulations, and the total weight of materials stacked on the scaffold plus the weight of workers shall not exceed 270 kilograms per square meter. Anti-slip measures should be taken and fences installed on the scaffolding’s ladders and ramps. 4) Sufficient lighting is required for night operations ； Work outdoors shall be suspended in case of winds of force 6 or above. 5. When entering enclosed containers such as towers, tanks, and vessels for maintenance work, a dedicated supervisor must be assigned, a warning sign stating “Under maintenance – do not open” should be placed on the relevant connection valves, and reliable safety measures must be taken. 6. Safety regulations for the maintenance of electrical equipment: 1) The maintenance of electrical equipment or circuits must be carried out by certified electricians; a thorough inspection must be conducted before starting work to ensure that there is no electricity present ； Reliable safety measures must be in place during live working. 2) Temporary electrical installations used for maintenance should be grounded in accordance with relevant safety regulations; temporary wires should be installed at a height of not less than 2.5 meters above the ground, and when spanning roads, at a height of not less than 5 meters above the ground. 3) Electric tools must not be used in rainy weather, in humid areas, or when the body is wet. 4) When repairing electrical equipment, the power supply must be turned off, and a prominent warning sign such as “Do not close the switch” should be placed on it. Before climbing, electricians working at heights check whether the climbing tools meet safety requirements to prevent accidents such as pole breaks and slips. 5) In the event of a fire involving electrical equipment, conductive extinguishing agents must not be used; instead, carbon dioxide and dry powder fire extinguishers should be employed to avoid electric shock. 7. The following safety procedures must be followed for welding work: 1) Flammable and explosive materials in the area around the welding site must be removed completely before starting welding with an open flame. 2) Maintain a distance of 7–10 meters between the acetylene generator, the oxygen cylinder, and the location where welding is to be carried out. The oxygen in the cylinder should not be used up completely; there should be at least 0.5 kg/cm2 of residual pressure. 3) Oxygen cylinders must not be placed near heat sources; the area around them must be well-ventilated. Collision during handling is strictly prohibited. The acetylene generator and safety water seal must maintain an appropriate water level. 4) When welding in areas where multiple people are present, use screens to enclose the area in order to prevent the arc from injuring others’ eyes. When welding in humid areas or inside metal containers, measures must be taken to prevent electric shock. 8. Safety regulations for using cranes, overhead cranes, or elevators: 1) The use of cranes, overhead cranes, or elevators must be supervised by a designated person; both the operator and the supervisor must be individuals who have passed relevant professional examinations. 2) A thorough and detailed inspection of all safety devices must be carried out before lifting. 3) A fence should be installed around the area, along with a “No Entry” sign. Lifting beyond the rated capacity is prohibited; it is strictly forbidden for anyone to stand on the lifted object or to stay or pass beneath it vertically. 4) When lifting materials and equipment, pay attention to the surrounding environment and avoid damaging equipment, pipes, wires, etc.

1. During tower and furnace maintenance, relevant permits such as fire permits must be obtained in advance. 2. Personal protective equipment must be worn correctly. 3. The personnel composition should be adjusted appropriately. 4. Conduct necessary flammable gas analysis and ensure safe operations. 5. Use security devices properly to protect personal safety

This post was last edited by llzzff529 on 2016-5-17 at 16:24: 1. Process preparation before maintenance, management of equipment spare parts, and safety precautions; 2. Maintenance personnel must receive safety training before entering the site. 3. Strengthen the management of oxygen cylinders and acetylene cylinders. 4. Flammable solvents must not be used to clean equipment at the maintenance site. 5. The construction machinery and tools must be in good condition. 6. Maintenance tasks with high risks, such as hot work, must be carried out in strict accordance with the work order system.