Analysis of 8 major high-risk operation risks and safety measures – extremely comprehensive

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This post was last edited by 68589544 on 2016-9-12 at 12:26. Analysis of 8 major high-risk operation risks and safety measures – very comprehensive! Today, we will share with you the risk analysis and safety measures for 8 types of hazardous operations. We hope everyone will study them carefully and apply what they have learned. 1. Hot work – Sequence number, Risk analysis, Safety measures: 1. Flammable, explosive, and hazardous substances: ① Clean and replace the materials inside the equipment and pipelines used for hot work, and ensure that they meet the required standards after analysis. ②When working on the storage tank, remove flammable materials, and fill the tank with clean water or use an inert gas for protection. ③Internal device protection (nitrogen, water vapor). ④When hot work is performed inside the tower, soak asbestos cloth in water and lay it on the adjacent two trays for isolation. ⑤When performing welding work in a confined space, it is necessary to obtain a \"Confined Space Work Permit.\" If sparks from the welding process spread to other equipment or if flammable materials come into contact with the welding equipment, the pipes connected to that equipment must be disconnected and sealed off using blind plates – a total of ____ blind plates should be used for this purpose. A sign should be placed there, and a \"Blind Plate Installation/Removal Work Permit\" must also be obtained. 3. Flammable materials are present around the area where welding will take place. ① Remove all flammable materials from the area around the welding site; also clear flammable substances from sewers, floor drains, ditches, cable trenches, etc., located in the vicinity, and seal them up afterward. ②When working with fire in cable trenches, remove any flammable gases and liquids from the trench; if necessary, isolate both ends of the trench. 4 Hazards of leakage current (induced electricity): The welding return circuit should be connected to the welded piece, not to other equipment, and it is prohibited to pass through sewers (wells). 5 Sparks from Mars ① For work at heights, obtain a \"High-Height Work Permit\" and take measures to prevent sparks from flying. ②Pay attention to the direction in which the sparks fly, and rinse the area where they land with water. 6 Insufficient spacing or improper placement of gas cylinders: ① The spacing between oxygen cylinders and acetylene cylinders dissolved in liquid form should be no less than 5 m, and the distance between each of these cylinders and the area where welding or cutting takes place should be no less than 10 m. ②Gas cylinders must not be exposed to direct sunlight, and acetylene cylinders dissolved in liquid form must not be placed lying down. 7 Defects in electric and gas welding tools: Before carrying out hot work, electric and gas welding tools must be inspected to ensure they are safe and reliable; it is prohibited to use them if they have any defects. 8 During the operation, if flammable materials leak out, work involving open flames must be stopped immediately in the event of material leakage, cross-contamination, or the presence of flammable gases. 9 Poor ventilation: ① When performing welding or similar tasks indoors, the doors and windows should be opened; surrounding equipment should be covered, sink traps should be sealed, oil stains should be removed, and no cleaning operations using flammable substances such as solvents should take place in the vicinity. ②Local forced ventilation is used ； 10 Unscheduled monitoring: ① The interval between sampling and hot work must not exceed 30 minutes; if this interval is exceeded or if the hot work is interrupted for more than 30 minutes, sampling and analysis must be performed again. ②Sampling points should be representative; analytical samples taken during special hot work must be retained until the hot work is completed. ③During the welding process, and when work is interrupted, no remaining embers should be left at the site. Before resuming welding, it is necessary to carefully check whether there have been any changes in the conditions at the site; if there have been changes, welding must not proceed. 11 Inadequate supervision: ① The person in charge of monitoring should be familiar with the site environment and ensure that safety measures are properly implemented; they must possess relevant safety knowledge and emergency response skills, remain in contact with their post, stay aware of any changes in operating conditions, and stay at the site at all times. ②The fire watcher extinguishes any spilling sparks at all times; if anything abnormal is detected, they immediately inform the person performing the work to stop and contact the relevant personnel to take action. 12 Insufficient emergency facilities or inadequate measures ① Fire-fighting equipment should be available at the site where welding is carried out (such as steam pipes, water pipes, fire extinguishers, sand, iron shovels, etc.). ②Put the fixed foam fire extinguishing system in a pre-start state. 13 Involvement of hazardous task combinations without appropriate safety measures in place: When carrying out hazardous tasks such as working inside reactors, at heights, removing or installing blind flanges, or performing maintenance on pipeline equipment, the relevant work permits must be obtained simultaneously. 14 Significant changes in construction conditions: If there are significant changes in the construction conditions, a new *Level Hot Work Permit must be obtained. 2. Entering confined spaces for work – Sequence Number, Risk Analysis, Safety Measures: 1. Unreliable isolation: ① The pipelines for materials, steam, and nitrogen connected to the equipment shall be isolated using blind flanges, and a ‘Blind Flange Installation/Removal Permit’ must be obtained. ②Dismantling of related pipelines: 2. Mechanical injuries. Procedures for de-energizing equipment must be carried out; the power supply to the equipment should be cut off, and a “Do Not Close Switch” warning sign must be posted. A designated person should supervise the process. 3 Substitution fails: After substitution, sampling and analysis are conducted until it meets the standards. 4 Insufficient oxygen: The oxygen content inside the equipment is 18–21%. 5 Poor ventilation ① Open the device’s ventilation holes for natural ventilation. ②Forced ventilation is used. ③Wear an air respirator or long-tube mask. ④Air is supplied through ducts; prior to ventilation, it is necessary to analyze and confirm the contents within the ducts as well as the air source. The introduction of oxygen for oxygenation is strictly prohibited. ⑤The temperature inside the equipment must be suitable for personnel to work in. 6 Unscheduled monitoring ① Within 30 minutes prior to operations, gas samples must be taken from inside the equipment for analysis; entry into the equipment is permitted only after passing the test. ②The sampling points should be representative. ③During the operation, regular monitoring should be strengthened, and the operation must be stopped immediately if any abnormalities are detected. 7 Electric shock hazards ① The lighting voltage inside equipment should be ≤36V; when working in wet or confined containers, it should be ≤12V. ②When using hand-held power tools with a voltage exceeding the safe level, a leakage protector must be installed as required. 8 Inadequate protective measures ① Wearing a self-contained breathing apparatus in environments with low oxygen levels or toxic substances ； ②In environments where flammability and explosiveness are risks, use explosion-proof low-voltage lighting and spark-free tools; wearing synthetic fiber clothing is prohibited ； ③In corrosive environments such as those with acids and alkalis, wear appropriate corrosion-resistant protective gear, including slag removal suits, acid-resistant boots, acid-resistant gloves, and safety goggles. 9 Unobstructed passages: There must be no obstacles blocking the entry and exit routes for personnel at the equipment’s access points. 10 Improper supervision: ① Before entering the equipment, the supervisor should, together with the workers, check the safety measures and establish a unified communication signal ； ②The supervisor must remain in contact with the equipment at all times and must not leave their post ； ③The supervisor secures the worker with a safety rope to carry out the work. 11 Insufficient emergency facilities or inadequate measures ① Appropriate first-aid supplies such as air respirators, fire-fighting equipment, and clean water are available outside the equipment ； ②When rescuing victims from an accident inside equipment, rescue workers must take proper protective measures before entering the equipment to carry out the rescue. 12 Involvement of hazardous task combinations without appropriate safety measures in place: When carrying out hazardous tasks such as welding, working at heights, or removing/blanking plugs, the relevant work permits must be obtained simultaneously. 13 Significant changes in working conditions: If there are significant changes in the working conditions, it is necessary to obtain a new ‘Confined Space Work Permit’. 14 Foreign objects remaining inside the equipment: After work is completed inside the equipment, it is essential to thoroughly inspect both the inside and outside of the equipment to ensure that no tools or other items are left behind. 3. Temporary electrical work Sequence Number Risk Analysis Safety Measures 1 Illegal operations ① Workers must hold a certificate for safe electrical work. ②The overhead height of temporary power lines should be no less than 2.5 meters inside the facility, and no less than 5 meters on roads. ③All temporary power lines must not use exposed wires. ④Temporary power lines, being overhead lines, must not be installed on trees or scaffolding. 2 Cable damage: Concealed conduit installations and underground cable lines should be equipped with direction markers and safety signs, with the cables buried at a depth of more than 0.7 meters. 3 Short circuits in distribution panels and boxes: Temporary electrical distribution panels and boxes at the site should be equipped with rain protection measures. 4 Preventing damage to facilities ① Temporary electrical installations should be equipped with leakage protectors. ②Electrical equipment, circuit capacity, and load must meet the required standards. 5 Prevention of fires and explosions: All temporary electrical equipment and wiring used must meet the corresponding explosion-proof requirements. 6 Significant changes in working conditions: If there are significant changes in the working conditions, a new ‘Temporary Electricity Use Permit’ must be obtained. 4. Working at heights
No. Risk analysis Safety measures
1 Workers are unfamiliar with the working environment or lack relevant safety skills
Workers must receive safety training, become familiar with the site environment and construction safety requirements. Only after checking and confirming that all safety measures have been properly implemented in accordance with the contents of the “Permit for Working at Heights” may they commence work. 2. Workers fail to wear fall prevention and anti-slip equipment, use it improperly, or the equipment does not meet relevant safety standards. Workers must wear safety helmets, fasten safety belts, and wear anti-slip shoes. Before use, check that it meets relevant safety standards, and it should be used correctly during operation. 3. No guardian assigned or failure to fulfill guardianship duties: The job guardian should be familiar with the site environment and ensure that safety measures are in place; they must possess relevant safety knowledge and emergency response skills, remain in contact with the workers, stay aware of any changes in working conditions, and stay at the site at all times. 4 The scaffolding planks are not fixed, and the scaffolding and protective fences do not meet relevant safety requirements; the scaffolding and protective fences installed must comply with relevant safety regulations. 5 Working with lightweight materials such as asbestos shingles and shingle purlins: When working with lightweight materials like asbestos shingles and shingle purlins, it is necessary to set up and work on a fixed load-bearing platform. 6 Falls of workers during climbing, or falls of tools, materials, and parts from heights that cause injuries. Tools, materials, and parts used for work at heights must be placed in tool bags, and one should not hold anything in their hands while going up or down. It is prohibited to throw or catch tools, materials, and other items in the air. When tools and materials that are prone to sliding or rolling are placed on scaffolds, measures should be taken to prevent them from falling. 7 Improper positioning below workers at height or failure to implement adequate isolation measures. It is strictly prohibited to have people standing directly below workers at height. When working in conjunction with other tasks, movement must take place along designated routes; vertical work above and below one another is forbidden. When work must be performed vertically, reliable isolation measures should be taken. 8 The distance from electrical equipment (wires) does not meet safety requirements, or no effective insulation measures have been taken. When working at heights near electrical equipment (wires), the required safety distances must be observed. When performing live high-altitude work using the ground (zero) potential or equipotential working method, insulating tools must be used. 9 The illumination at the work site is poor. Sufficient lighting is required for work at heights. 10. No communication or liaison tools, or poor communication: For work at heights exceeding 30 meters, communication and liaison tools must be provided. A designated person should be responsible for maintaining contact, and all relevant liaison details must be recorded in the supplementary section on safety precautions in the “Work at Heights Permit”. 11 Workers suffering from occupational contraindications such as hypertension, heart disease, or acrophobia, or those in poor health, are not permitted to perform work at heights. Individuals with occupational contraindications, the elderly and frail, those experiencing excessive fatigue, those with poor eyesight, persons under the influence of alcohol, and anyone else in poor health must not engage in work at heights. 12 Performing work at heights under adverse weather conditions such as strong winds and heavy rain. In cases of heavy rain, dense fog, or winds exceeding force 6, work at heights must be halted. 13 When carrying out dangerous tasks such as welding or removing/blanking plugs, corresponding safety measures must be implemented; if such dangerous tasks are involved, the relevant work permits must also be obtained. 14 Significant changes in working conditions: If there are significant changes in the working conditions, a new ‘High-Height Work Permit’ must be obtained. 5. Road closure operations – Sequence number, Risk analysis, Safety measures: 1. Unclear signage and poor communication can disrupt traffic and lead to accidents. ① Before starting the work, the construction party should place traffic barriers and signs at the road closures to guide vehicles to alternate routes. ② Once the traffic management department approves the ‘Road Closure Permit’, relevant departments such as the dispatch team should be informed immediately. 2. During operations, the absence of proper safety measures or their inadequate implementation may lead to traffic accidents or injuries. ① During road closure operations, the construction contractor shall be responsible for setting up fences and traffic warning signs at the construction site; red warning lights must also be displayed at night. ② While carrying out road closure construction, the contractor must assign safety inspectors to ensure that the road remains accessible at all times in case of emergencies. ③During circuit breaking construction work, the contractor must not pile up construction materials randomly. 3 After the work is completed, if the site is not cleaned thoroughly, it can impede traffic and lead to accidents. ① After circuit interruption work is finished, the construction party shall be responsible for cleaning up the site, removing the barriers, circuit interruption signs, fences, warning signs, and red warning lights installed there, and reporting this to the traffic management authorities. ②After conducting an on-site inspection, the traffic management authorities notified the relevant units that the road closure work was complete and that traffic could be resumed. Unapproved changes led to the accident. ① Road closure operations must be carried out in accordance with the details specified in the Road Closure Permit; it is strictly prohibited to alter or lend this permit, as well as to change the scope of the work, expand it, or move the location of the work without authorization. ②If the disconnection work is not completed within the time specified in the Disconnection Work Permit, the entity that requested the disconnection must proceed with the procedures again. 5 Involvement of hazardous task combinations without appropriate safety measures in place: When carrying out hazardous tasks such as work at heights or earthwork, the relevant work permits must be obtained simultaneously. 6 Significant changes in construction conditions: If there are significant changes in the construction conditions, a new ‘Work Stoppage Permit’ must be obtained. 6. Groundwork operations Sequence Number Risk Analysis Safety Measures 1 Damage to pipelines and cables, leading to accidents ① Electric cables have been identified, and protective measures have been implemented. ②The telecommunications cable has been confirmed, and protective measures have been implemented. ③The underground water supply and drainage pipelines as well as the process pipelines have been identified, and protective measures have been implemented. ④When digging approaches underground concealed facilities, it should be done gently; the use of mechanical tools such as grabs is prohibited. ⑤Construction has been carried out in accordance with the construction plan drawings. ⑥ Road construction work has been reported ； Transportation, fire protection, dispatching, and safety supervision departments 2 In the event of a collapse: ① When multiple people are digging simultaneously, they should maintain a certain safety distance between themselves. ②Excavation should be carried out from top to bottom; the method of digging from the bottom up is prohibited. The excavated soil must not be used to block drains and manholes. ③Support must be provided when digging ditches, pits, etc. without slopes. Before excavation, surface water should be removed, and drainage measures must be taken once digging reaches below the groundwater level. ④Sloping and wall stabilization support have been carried out. ⑤Workers must wear safety helmets. People are not allowed to stand or walk on the upper edges of pits, grooves, wells, and ditches. 3 Poisoning occurs ① Have combustible gas detectors and toxic substance detectors on hand. ②Workers must wear protective equipment. ③Protection measures for personnel entry, exit, and evacuation have been implemented: Ladder A, B, and slope repair. 4 Causes of falls: ① Fencing, warning lines, signs, and night-time warning lights at the work site have been installed as required. ②Sufficient lighting is available at the work site at night: A ordinary lights, B explosion-proof lights. ③A stepping board should be laid when workers go up and down. 5 In cases involving combinations of hazardous operations for which appropriate safety measures have not been implemented, relevant operation permits must also be obtained when working at heights or performing tasks that involve breaking connections, etc. 6 Significant changes in construction conditions: If there are significant changes in the construction conditions, a new ‘Excavation Permit’ must be obtained. 7. Lifting operations Sequence Number Risk Analysis Safety Measures 1 Operation without proper certification: Lifters and supervisors must receive professional training and work with valid certificates. 2 Confused command: In situations that are not urgent or accidental, there should be a single person in charge at the site to give clear instructions. 3. No warning lines or signs are in place; a comprehensive lifting plan should be established, warning lines should be set up, safety signs should be placed, and access should be prohibited for persons other than those involved in the construction work. 4 Poor working conditions ① Sufficient lighting must be available at the work site at night. ②Operations must be halted in case of severe weather conditions such as heavy rain, dense fog, or winds of force 6 or above. 5 Failure to strictly adhere to the “10 rules against lifting” for lifting operations: ① Do not lift if the command signals are unclear or confusing ； ②Do not lift if overloaded or if the weight of the object is unknown ； ③Do not lift heavy objects by pulling them at an angle ； ④There is insufficient light; it’s not possible to see clearly, so heavy objects should not be lifted ； ⑤Do not lift people under heavy objects ； ⑥Heavy objects buried underground are not lifted ； ⑦The heavy object is not securely fastened; the rope is knotted, and it should not be lifted if the rope is not in good condition ； ⑧Sharp-edged objects must not be lifted without protective padding ； ⑨Do not lift if safety devices are malfunctioning ； ⑩Do not lift heavy objects that are higher than a person’s head. 6 Involvement of hazardous task combinations with corresponding safety measures not implemented. ① If road traffic needs to be blocked during lifting operations, a \"Road Closure Permit\" must be obtained. ②At the lifting site, when workers perform tasks at heights of more than 2 meters, they must obtain a \"High-Height Work Permit\". ③For other hazardous operations, the relevant operation permits must be obtained. 8. Blind plate removal and installation operations – Sequence Number, Risk Analysis, Safety Measures: 1. Defective blind plates: The material of the blind plate must be suitable; its thickness should be determined through strength calculations. High-pressure blind plates must pass flaw detection tests. The blind plate should have one or two handles to facilitate identification and removal/installation, and matching gaskets should be used. 2 Hazardous and harmful substances (energy) are of particular concern. ① Before removing or installing blind flanges, the pressure in the pipeline should be reduced to atmospheric pressure or slightly positive pressure ； ②It is strictly prohibited to carry out two or more blind plate removal and installation operations on the same pipeline at the same time ； ③The gas temperature should be less than 60℃ ； ④Workers are strictly prohibited from standing directly in the direction from which hazardous substances (energies) may emerge; they must use appropriate personal protective equipment. 3 Open flames and other sources of fire: When working in areas prone to fire and explosion, no open-flame operations are allowed within 30 meters of the work site ； Explosion-proof lighting fixtures are used for work lighting ； Use explosion-proof tools; it is prohibited to strike pipelines, flanges, etc. with iron tools. 4 Operational errors: ① When removing or installing multiple blind flanges, the person in charge of the operation should give unified instructions based on the blind flange location diagram and their corresponding numbers ； ②A sign should be placed at each plug and blind flange to indicate its location. 5 Poor ventilation ① Open doors and windows to enhance natural ventilation ； ②Local forced ventilation is used. 6 Improper supervision ① There should be a dedicated person to supervise the work, and this supervisor must not leave the work site until the work is completed ； ②The supervisor should be familiar with the site environment and verify that safety measures have been properly implemented; they must possess relevant safety knowledge and emergency response skills, remain in contact with the personnel on duty, and stay informed of any changes in operating conditions at all times. 7 Insufficient emergency preparedness: In locations where tasks are complex and highly dangerous, in addition to the supervisor, personnel from relevant departments should also be present at the site to prepare for emergencies. 8 Involvement of hazardous task combinations without appropriate safety measures in place: When carrying out hazardous tasks such as welding, work in confined spaces, or work at heights, the relevant work permits must be obtained simultaneously. 9 Significant changes in operating conditions: If there are significant changes in the operating conditions, a new ‘Blind Flange Installation/Removal Permit’ must be obtained.