Special Topic | How to Conduct a Risk Analysis Before Starting a Task

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Petroleum and chemical enterprises often possess characteristics such as flammability, explosiveness, high temperatures, high pressures, toxicity, and harmfulness. A large portion of accidents that occur during on-site operations stem from insufficient awareness of the potential risks associated with these operations; effective safety precautions are not taken in a timely manner, operation permit procedures are not strictly followed, and workers lack proper safety training. Therefore, companies should take proactive measures by thoroughly analyzing, controlling, and managing the risks associated with their operational activities prior to carrying out those activities, in order to embody the philosophy of protecting themselves while also considering the well-being of others, and thus achieving the best possible HSE performance. Before discussing the methods for risk analysis prior to tasks, let’s first understand two concepts: the classification of operational activities. In a company’s daily production and operations, many related tasks are required, such as production control, maintenance, marketing, logistics, etc. As required, hazard identification should be carried out for all activities that involve risks, and corresponding countermeasures should be taken. Common high-risk operational activities in enterprises mainly include: 1) hot work ； 2) Entering a confined space for work ； 3) Tilling operation ； 4) Temporary power usage operations ； 5) Work at heights ； 6) Lifting operations ； 7) Equipment maintenance work ； 8) Blind plate opening and closing operations. Approach to risk analysis ◎ The presence of hazardous energy, harmful substances, and loss of control are the fundamental causes of hazards. Therefore, before carrying out operational activities, it is necessary to identify and distinguish between two types of hazard sources: The first type of hazard source – based on the theory of accidental energy release, those energies or hazardous substances present in a system that may undergo accidental release are considered to be the first type of hazard source. It is the physical essence that causes system hazards or system accidents, also known as an inherent hazard source. The second type of hazard source – various unsafe factors that cause the measures intended to contain or restrict energy to fail or be damaged – are referred to as the second type of hazard source. The second type of hazard source are the conditions that cause the first type of hazard sources to get out of control; they affect people, materials, and the environment. These conditions are what lead to a transition of the system from a safe state to a dangerous state. They are the triggers that result in the accidental release of energy within the system, thereby causing system failures, and are also known as trigger-type hazard sources. ◎ Who (or what) will be harmed can be considered in terms of physical harm (including injuries, illnesses, death, etc.), property losses (including disruptions to operations, legal issues, damage to reputation, etc.), and environmental damage (including the work environment and the natural environment). ◎ To understand how injuries occur, it is necessary to consider the characteristics of different hazards, identify and comprehend the conditions, timing, and methods by which injuries happen, so that targeted safety measures can be taken to prevent such injuries. For example, for a fire to occur, three conditions must be present (the three elements of fire: a heat source, flammable material, and an oxidizing agent). By preventing any one of these elements from existing, a fire can be effectively prevented. Hazard identification: Before each task, the workers and supervisors should first conduct hazard identification. The identification of hazards should start with people’s unsafe behaviors and the unsafe conditions of objects. ◎ Unsafe human behaviors: GB6441-86, the \"Classification Standard for Work-related Injuries and Deaths among Enterprise Employees\", categorizes unsafe behaviors into 13 major types: 1) Operational errors, neglecting safety, ignoring warnings ； 2) Cause the safety device to fail ； 3) Use of unsafe equipment ； 4) Use hands instead of tools to operate ； 5) Improper storage of objects (finished products, materials, tools, etc.) ； 6) Risking entry into dangerous areas ； 7) Climbing or sitting in unsafe positions ； 8) Working or staying under the lifted load ； 9) Tasks such as refueling, repair, inspection, adjustment, welding, and cleaning while the machine is in operation ； 10) Behaviors that distract attention ； 11) Failing to use personal protective equipment in tasks or situations where its use is required ； 12) Unsafe attire ； 13) Incorrect handling of hazardous materials such as flammable and explosive substances. Before carrying out each task, workers should think carefully, identify potential hazards, and adjust their behavior to protect themselves ； At the same time, it is important to pay attention to the improper behavior of others and point out their mistakes to one another, thereby protecting everyone from hazards in the workplace. ◎ Unsafe conditions of objects: GB6441-86, the \"Classification Standard for Work-related Injuries and Accidents among Enterprise Employees\", categorizes unsafe conditions of objects into 4 main types: 1) Lack or defects in protective, safety, signaling, and other devices ； 2) Defects in equipment, facilities, tools, and accessories ； 3) Personal protective equipment – protective clothing, gloves, goggles and face shields, respiratory protection, hearing protection, safety belts, safety helmets, safety shoes, etc. are missing or defective ； 4) The environment at the production (construction) site is poor. After identifying safety precautions and determining the hazards, it is necessary to adopt targeted safety measures based on their characteristics in order to prevent safety accidents from occurring. ◆ The occurrence of energy control accidents is the result of certain unnecessary energy interactions, and eliminating the triggering energy that causes these accidents is a key step in preventing them. Therefore, ensuring proper energy isolation is of utmost importance for effective risk control. For example, before carrying out welding work in hazardous areas or locations, effective isolation and separation measures must be taken, along with cleaning, purging, and verification through analysis to ensure compliance ； Warning lines and safety signs should be installed at maintenance and construction sites ； Machinery and tools used for maintenance and construction should be thoroughly inspected before use to ensure they are in good condition and suitable for operation. ◆ Job permits require strict procedures for application, approval, and job inspection for each on-site operation. For high-risk tasks such as hot work, entry into confined spaces, earthwork, temporary electrical work, work at heights, lifting operations, equipment maintenance, and plugging or removing blind flanges, strict work permit procedures must be followed, and the corresponding work permits must be obtained prior to carrying out the tasks. ◆ Safety training: Relevant personnel involved in the operations must receive safety training: 1) The safety rules and regulations that must be followed for the operations ； 2) Potential hazards during the operation process and countermeasures ； 3) Proper wearing and use of personal protective equipment and supplies during the work process ； 4) Work items, tasks, plans, and safety measures, etc. ◆ For personal protective equipment, enterprises should strictly comply with GB11651 \"Rules for the Selection of Personal Protective Equipment\", the \"Regulations on the Supervision and Management of Personal Protective Equipment\" (Order No. 1 issued by the State Administration of Work Safety), local regulations, as well as relevant guidelines from companies such as Sinopec. They must select, provide, and use personal protective equipment based on the characteristics of the working environment and specific circumstances.