Lessons from HSE management

Thread Content

Insights from HSE Management by Wang Junfeng, Hengli Petrochemical (Dalian) Co., Ltd. H–Health, S–Safety, E–Environment: These three criteria represent the goals that employees in modern enterprises strive for in their work and daily lives – namely, an ideal working environment free from casualties, property losses, and environmental pollution. In the serious accidents that occur around us, we often hear about several deaths, billions in property losses, toxic and harmful gases filling the air, oil slicks stretching for kilometers across the sea surface, many poor creatures dying from suffocation – all these bloody scenes, such terrifying facts. Each accident results in: extremely heavy casualties ； The property losses are extremely large ； Social impact and its negativity ； The company’s reputation has been severely damaged ； It causes environmental pollution and has an impact on human health. Implementing HSE management ensures that in chemical production, **property is not damaged, employees’ health is protected, and no environmental pollution occurs. Since implementing HSE can bring so many tangible benefits and improvements to our company, why not adopt HSE management? To integrate HSE management into workshop operations, it is first necessary to understand the policies and objectives of HSE management. Hengli Refining & Chemical’s HSE policy: Safety first, prevention foremost, participation from all employees, comprehensive management, environmental improvement, health protection, scientific management, and sustainable development. The HSE goals for the refining and petrochemical industry are: zero fatalities, zero major equipment accidents, zero fire and explosion incidents, zero radiation accidents, zero major liability accidents, and zero environmental pollution incidents. Strive to achieve world-class HSE performance by minimizing accidents, protecting human health, and preserving the environment. To implement HSE management in a workshop, first of all, the management must establish that HSE must be given priority in any decision-making ； Each position carries corresponding HSE responsibilities ； Safety is a prerequisite for hiring employees ； Whoever is in charge is responsible ； Whoever carries it out is responsible ； Whoever holds the position is responsible ； Safety “one-vote veto” system” ； \"Three simultaneities\" for construction projects” ； \"Four Nos\" for accident management” ； The concept of “five simultaneities” in daily work. Secondly, as team leaders, they are the ones at the forefront and backline, and they serve as the core force in actually guiding employees to implement HSE. They are required to possess qualities related to safety management; that is, they must have a serious and responsible work attitude ； One should have substantial practical experience in production ； Understanding relevant safety technical knowledge ； One must have a certain level of scientific and cultural knowledge ； I can do ideological work. Team leaders are required to: strictly enforce rules and regulations ； Arrange safety measures based on production conditions ； Supervise and inspect that employees correctly use tools and equipment, and strictly adhere to operating procedures ； Conduct regular safety inspections to promptly eliminate potential safety hazards ； Organize safety activities and carry out team safety training ； Emergency organizations provide rescue services in emergencies ； Illicit command is strictly prohibited, and unlawful operations must be stopped. Cultivating team leaders’ leadership skills in safety management: leading by example and setting a good precedent ； It is necessary to implement the principle of relying on the masses ； It is necessary to implement the principle of the rule of law ； Security management must prioritize strictness ； Rewards and punishments must be implemented ； Implement **management ； Actively participate in various forms of safety competitions ； One must set an example and lead by example ； It is necessary to maintain unity with group members. As the leader of the MTBE refining workshop, one must always pay attention to cultivating employees’ HSE qualities and capabilities. Employees required to work with MTBE must be conscientious and responsible in their duties, abide by rules and regulations, and possess a strong sense of responsibility and dedication ； In abnormal situations, decisive action is taken, with strong capabilities in production management and accident response ； Skilled in business operations and proficient in practical tasks, capable of accurately analyzing and resolving issues related to production processes and equipment ； Possesses a strong awareness of safety, environment, and health, and is able to proactively carry out HSE tasks ； Able to use fire suppression and rescue equipment properly, with strong skills in self-rescue and assisting others ； After completing all HSE technical training, they possess all necessary qualifications and work with valid certificates. The chemical industry and the construction of related facilities involve high levels of risk, which means that the risk management approaches used must also be complex. Although traditional risk management methods can achieve certain results, the HSE systematic management approach is more suitable for risk management in the chemical industry, enabling effective HSE management in MTBE production facilities. First, it is necessary to establish practical HSE management systems: post responsibility systems, training systems, reward and punishment as well as assessment systems, inspection systems, fire safety management systems, environmental protection management systems, occupational health management systems, emergency and accident management systems, maintenance safety management systems, and operation safety management systems. Second is the establishment of HSE management ledgers: training and education ledger, safety meeting ledger, inspection ledger, special equipment and specialized personnel ledger, fire safety management ledger, emergency management and incident management ledger, occupational health management ledger, hazardous chemicals management ledger, and contractor/supplier management ledger. Third, carry out specific tasks: organize safety meetings on a weekly basis, conduct employee training as scheduled (three-level training for new employees, regular team-based training, and orientation for construction workers), perform regular safety inspections (team inspections at set intervals, daily inspections in the workshops), address potential hazards, manage fire safety (inspect and maintain facilities, provide training for staff, improve emergency response plans, and ensure complete documentation), manage environmental protection (maintain operational facilities, conduct proper analysis and monitoring, and keep accurate records), manage occupational health (provide health check-ups for employees, maintain occupational health records, and ensure that toxic and harmful substances at the workplace are under control), implement responsibility-based evaluation systems with appropriate rewards and penalties, ensure safe operation of processes and equipment, manage construction activities (control access to the work site, identify risks associated with tasks and implement corresponding measures, supervise the work process, and enforce work order systems), manage emergency situations (improve emergency response plans, stockpile emergency supplies, and organize emergency drills), handle accidents (provide rescue services, conduct investigations, hold those responsible accountable, and share lessons learned from accidents), and manage the work site through 6S principles. Fourth, specific implementation details: I. Safety management 1. Given that the media used in this facility is flammable and explosive, hazard identification and risk assessment must be conducted prior to any related operations. Except for special circumstances such as maintenance, open flames or any activities capable of generating sparks are prohibited within the facility. Should there be a legitimate reason to use fire, strict procedures for obtaining authorization must be followed before any firing can take place. 2. It is prohibited to drink alcohol before entering the facility or while working there; it is not allowed to change positions arbitrarily, and loud noises or rough behavior are not permitted inside the facility. No dozing off at work. It is strictly prohibited to enter the maintenance work site or areas where multiple tasks are carried out without wearing a safety helmet. 3. It is prohibited to enter the facility wearing shoes with iron nails; high heels and sandals are also not allowed. It is strictly forbidden to wear clothing that can generate static electricity when working in oil and gas areas. 4. It is not allowed to read various books, newspapers, and periodicals after entering the facility. Bicycles and other equipment should be placed in designated locations; they must not be left around casually. 5. It is strictly prohibited to tamper with instruments, valves, and electrical equipment. Unauthorized personnel from outside or those without the qualifications to assume duties must not operate them. 6. It is prohibited to use gasoline, kerosene, or other solvent oils to wash clothes, tools, mechanical equipment, and floors. Flammable items such as rags, mops, and brooms are not allowed to be placed on steam pipelines and other high-temperature pipelines and equipment. 7. It is prohibited to strike high-temperature equipment and equipment in areas where flammable and explosive materials are present with iron tools or other objects. Faults in pressurized equipment must not be handled without taking special measures. 8. Smoking is strictly prohibited within the factory, and it is also forbidden to bring matches, lighters, as well as flammable, explosive, toxic, or corrosive items into the facility. 9. The discharge of light oils, liquefied gas and gas, as well as chemical hazards, on-site is strictly prohibited. 10. Those who fail safety education and job-specific technical examinations are strictly prohibited from operating independently at their posts. 11. Do not casually enter opened equipment, containers, manholes, etc., to prevent suffocation or poisoning. 12. Maintain good communication at work, follow instructions, and abide by all rules and regulations. Visitors from outside must be accompanied by a designated person. 13. On-site fire alarm phone: 66522119. II. Technical Regulations for Equipment Safety 1. Equipment and pipelines should be regularly inspected for signs of corrosion, and thickness testing should be carried out; any defects or leaks must be addressed through appropriate measures. 2. For the safety accessories and protective devices of mechanical equipment or pressure vessels, they must be complete and in good working condition; it is strictly prohibited to disable them. 3. The rotating parts of mechanical equipment must be equipped with protective devices; it is strictly prohibited to clean or disassemble them while they are in operation. 4. For floating-head heat exchangers, heating in a single pass is allowed, with the temperature difference not exceeding 130°C; fixed-tube-sheet heat exchangers do not permit heating in a single pass. 5. For pressure testing of equipment, when using water, the pressure applied to newly installed equipment should be 1.25 times the operating pressure; when testing vertical equipment, the static pressure of the water column must be taken into account. 6. The set pressures of safety valves on all equipment must be adjusted as prescribed; no arbitrary changes are allowed. The set pressure value must not be exceeded during operation ； If the safety valve activates, handle it as an accident. Once takeoff occurs, after the pressure has returned to normal, promptly remove the safety valve and re-set the pressure. III. Fire Protection and Protection against Hazardous Gases 1. All operators of the facility must be aware of the locations and usage methods of all fire extinguishers, gas protection equipment, as well as fire-fighting water and steam systems available within the facility. 2. Fire-fighting equipment must not be moved around arbitrarily; it should be kept in fixed locations, and the paths leading to it must remain unobstructed to ensure that fire-fighting operations can proceed smoothly. 3. Fire-fighting equipment should be inspected regularly, and any defective items should be replaced promptly. 4. When using fire for maintenance during device production, it is necessary to comply with the company’s “Regulations on Safe Use of Fire”. Hazard identification and risk assessment must be carried out prior to any maintenance work. It is strictly prohibited to use fire for construction purposes within the factory without going through the required procedures. 5. When using fire, a Fire Operation Permit must be obtained; it must also be inspected and signed. 6. When using fire, production staff must cooperate properly, and there must be a dedicated person to supervise. 7. Safety preparations before using fire: a) Thoroughly remove all flammable and explosive materials from both inside and outside the area where fire will be used (or within the boundary of containers, equipment, pipelines, or support structures). Equipment and pipelines should be thoroughly purged with steam. Before any hot work on towers, they must be purged with steam for at least 8 hours. Prior to performing any hot work on towers, vessels, and similar equipment, an explosion hazard analysis must be conducted; hot work is permitted only after the analysis yields satisfactory results. If the valid time for detonation analysis is exceeded, re-analysis is necessary; only after it passes the test can fire be used ； b) The area where fire is used must be isolated from the system. The use of fire near equipment and pipelines for light oil, gas, liquid hydrocarbons, etc., must be isolated using blind flanges ； c) At locations where fire is used, fire-fighting equipment that has been inspected and confirmed to be in good working order must be provided, and there must be designated personnel on site to monitor and safeguard the fire ； d) No hazardous materials should be present around the fire source; drainage ditches, floor drains, and sewers at the site must be covered with asbestos cloth or sealed off with water, and any debris in the surrounding area must be removed ； e) No safety-impeding activities shall be carried out in the vicinity of flames, such as venting gas, sampling, draining oil, or dismantling equipment ； f) The fire work permit must be filled out by the safety engineer (safety officer) in the area where the work is to be carried out, and approved by the supervisor of the operation center. Firework use is only permitted after relevant personnel have conducted on-site inspections and implemented safety measures. 8. Before depressurization, ensure that hydrocarbons inside the equipment are drained as completely as possible. When releasing a small amount of gas into the atmosphere, pay attention to the wind direction to ensure safety. 9. When the device is operating normally, attention should be paid to any leaks. Should any abnormal gases such as gas or liquefied gas be detected, the cause must be identified and addressed promptly. 10. For sampling at high temperatures, cooling is necessary first; sampling cannot be done by direct venting. 11. During normal operation or shutdown periods, hydrogen, gas, gasoline, liquefied gas, and the like must not be discharged or released into sewers under any circumstances. 12. When responding to oil leaks, gas leaks, or liquefied gas accidents, explosion-proof tools must be used, and overall explosion-proof requirements must be met. 13. Fully understand the types of harmful gases present in the equipment, as well as their physical and chemical properties. Take proper self-protection measures to ensure the “four no-harms”: do not harm oneself, do not harm others, avoid being harmed by others, and protect others from harm. Finally, let us bear in mind Heinrich’s chain of accident causation, thoroughly understand his accident pyramid theory, and seriously reflect on the fact that no accident resulting in injury or death is accidental; it must be the result of countless instances of negligence. Let us always keep in mind that details determine success or failure. Learn from the lessons of the iceberg theory and gain a deep understanding of the Bradley Curve. Let us work together to become qualified refining and chemical workers, and with great enthusiasm and sound judgment, achieve top-tier HSE performance. MTBE Workshop, January 21, 2016