Share: A comprehensive list of common hazards in chemical companies – use it as a reference for inspections!

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This article outlines the various common hazards in chemical enterprises, in the hope of being helpful to colleagues working on safety in this sector. [1] Equipment and facilities 1. Reactor and reactor 1) Abnormal noise from the reducer 2) Excessive oil stains on the reducer or frame 3) Plastic blades of the reducer are melted and deformed 4) Machine seal and reducer are short of oil 5) Gasket leaks 6) Anti-static grounding wire is damaged and not installed 7) Safety valve is not inspected annually, leaks, and no account is established 8) Thermometer is not inspected annually and is damaged 9) The pressure gauge has not been inspected annually, is damaged, or is blocked by materials. 10) The key reactors do not use double sets of temperature and pressure displays, and do not record alarms. 11) The bursting discs are not replaced when expired, leaking, and no account is established. 12) The valve under the bursting disc is not opened. 13) There is an explosion hazard. The reactor is not equipped with bursting discs. 14) The temperature is too high, the stirring is interrupted, etc., and there is abnormal pressure increase or charging. 15) The bottom valve is easy to block during discharging. 16) Acid corrosion exists in stainless steel or carbon steel kettles17) Overload operation such as charging volume exceeding the specified limit18) The enamel in the enamel kettle is damaged and is still used in corrosive, flammable and explosive places19) The liner of the reactor is corroded and damaged at the steam inlet of the jacket20) The pressure vessel has exceeded its service life, has poor manufacturing quality, and still leaks after repeated repairs21) The pressure vessel does not have a nameplate22) The serial number is missing or unclear23) Failure to effectively isolate explosion-sensitive reactors 24) No safety checklist for important equipment 25) Lack of spare parts or spare machines for important equipment 2. Storage tanks, tank farms, tank trucks 1) Liquid level gauges are blurred or damaged or clogged 2) Electrostatic grounding wires are loose or not connected 3) Leakage at flange gaskets 4) High-level storage tanks such as small platforms cannot be effectively fixed 5) The safety liquid seal level does not meet the requirements 6) Normal pressure storage tanks are used under pressure 7) The loading quantity exceeds the specified limit 8) The non-temperature storage tank is not equipped with a thermometer 9) The container has cracks and is still in use 10) Frequent exposure to alternating loads of vacuum and nitrogen causes damage to the storage tank 11) Low-boiling solvent or liquefied gas storage tanks are exposed to direct sunlight 12) Outdoor storage tanks are at risk of being hit by transport vehicles 13) The cofferdam holes of the dangerous goods tank area are not blocked 14) The protective embankment of the hazardous chemicals tank area is not tightly sealed, and drainage holes are arbitrarily opened. 15) The stop valves leading to the drainage pipes are always open and other unsafe conditions. 16) The outlet pipelines for flammable or corrosive materials in the hazardous chemicals tank area are not equipped with hanging pressure spring compensation measures, or flexible connection short pipes are directly used. 17) The hazardous chemicals tank area does not have various warning signs such as no mobile phones, no fire sources, height and speed limits, etc. 18) There are no leaks, feeding operation records and daily inspections in the dangerous goods tank area. 19) Tractors enter the dangerous goods tank area at will. 20) There are open flames or forest fires around the dangerous goods tank area. 21) The operation room of the dangerous goods tank area uses electric stoves, electric tea kettles, electric hot plates and other illegal electricity. 22) The tanker has no grounding device at the loading and unloading site. 23) There are no measures to prevent operators from falling from the tanker. 24) The tanker enters the tank area without being equipped with an effective flame arrester and in unqualified condition (the lighting is damaged or the brake fails) 25) The safety accessories (pressure gauge, thermometer, safety valve) of the tanker tank have no inspection date or are invalid 26) The tanker tank is not marked with the next inspection date of the pressure vessel 27) There is no electrostatic drag chain, anti-virus equipment or valve leakage on the tank 28) The grounding is not allowed to stand for more than 10 minutes before and after unloading 29) When the tank truck is unloading, the driver and escort leave the unloading site, and there are no on-site monitoring personnel. 30) Open and splash unloading are used. 31) When unloading, the storage tank exceeds the standard liquid level or the full material overflows. 32) When the vinyl chloride tank truck is unloading, the hose or flange leaks. 33) When the vinyl chloride is transported and fed, the tank is full. 34) When the tank truck is not full, it is transported and unloaded multiple times in the factory. 35) The unloading vehicle is stalled and handbraked or the vehicle is started during unloading. 36) When high-intensity lightning and lightning strikes are frequent, the unloading operation is performed. 37) There are no 2 grounding points for the oil tank (WeChat ID: mahoupao2009) 38) When loading and unloading gasoline and toluene, the operators did not wear anti-static work clothes and anti-static shoes. 39) There were no accident cofferdams and emergency spray dilution facilities in the storage areas of liquid ammonia and other storage tanks. 40) There were no emergency spray and eyewash facilities on site. 41) There were no measures to prevent mispacking of materials, such as loading ethyl acetate into gasoline tanks. 42) Welding while standing on gasoline barrels. 43) Cutting gasoline barrels or welding storage tanks without cleaning 44) Liquid ammonia and vinyl chloride storage tanks are overfilled 45) When tank trucks are unloading, block fire passages and encroach on access roads 46) The collector leaves the unloading site 47) Iron, plastic and other tools that are prone to sparks are used at the loading and unloading site 48) There are no operation records for material storage tanks sent from the tank area to the workshop 3. Condensers and reboilers 1) Leakage caused by corrosion, aging gaskets, etc. 2) The temperature of the material after condensation is too high 3) The heat exchange medium layer is blocked by silt and microorganisms 4) The high-temperature surface is not protected 5) When cooling high-temperature liquids (such as 150 ℃), the cooling water inlet and outlet valve is not opened, or the cooling water volume is insufficient 6) The evaporator heats up rapidly when it is first used 7) The heat exchanger does not take anti-shock measures into account, causing the connecting pipes to loosen and leak due to vibration 4. Pipes and fittings 1) After the pipeline is installed, the internal welding slag and other foreign objects are not cleaned. 2) The sight glass glass is not clean or damaged. 3) The sight tube material is not suitable for pressure and temperature resistance. The sight tube is improperly installed. 4) The sight tube is cracked or used under pressure for a long time. 5) The anti-static grounding wire is damaged. 6) The pipe, flange or bolt is seriously corroded or cracked. The color marking of the pipelines is unclear 11) The valves connected in series for different materials are not blinded during debugging 12) Abandoned pipelines are not cleaned in time 13) The installation position of the pipe valve is low, easy to hit the head or difficult to operate 14) No protective measures are taken for corrosive material pipelines, flanges and other leaky places 15) There is the possibility of water, nitrogen, air, steam, etc. entering the material pipeline 16) Iron barrels or plastic barrels of flammable and explosive materials are placed next to high-temperature pipelines 17) The material selection of pipes or pipe fittings is unreasonable and easy to corrode. 18) The glass tube liquid level gauge has no protective measures. 19) The protective metal mesh is not installed on the sight glass that may explode. 20) The check valve cannot move flexibly or fails. 21) The electric valve loses power and the pneumatic valve stops gas. 22) Pressure pipelines such as hydrogen are not regularly maintained or operated with illness. 23) When using pressure pipelines, the operators are untrained or unlicensed. 24) Maintenance personnel are not qualified to repair or modify pressure pipelines. 25) The welding quality of pressure pipelines is poor, with welding defects such as undercuts, pores, slag inclusions, and incomplete welding. 26) Safety accessories are not installed on pressure pipelines in accordance with regulations or safety accessories have not been verified beyond the expiration date. 27) Files and operating procedures have not been established for pressure pipelines. 28) Glass-lined pipelines are impacted by steel pipes. 29) Existing pipeline valves are still used after the production process medium is changed, without considering material adaptability. 30) Nitrogen pipe and air pipe are connected in series 31) Brine pipe and cooling water pipe are connected in series 5. Transfer pump and vacuum pump 1) Pump leakage 2) Abnormal noise 3) Coupling without protective cover 4) No pressure gauge or check valve installed at the pump outlet 5) When the pump and pipe are not used for a long time, the liquid in the pump and pipe is not drained, causing corrosion or freezing 6) When the positive displacement pump is running, the outlet valve is closed or a safety return valve is not installed 7) The pump inlet diameter is small or the pipeline is long or has many turns. 8) The installation height of the centrifugal pump is higher than the suction height. 9) No anti-static belt is used. 6. Centrifuge 1) Filter the solvent without filling it with nitrogen or the nitrogen pipe is clogged or there is no flow meter on site to display. 2) When a centrifuge is required to filter the solvent in the fine drying package, an oxygen meter and alarm device are not installed. 3) Brake quickly or use auxiliary tools (such as iron rods, etc.) to brake. 4) The centrifuge is not effectively grounded. 5) Anti-static belts are not used in the explosion-proof area 6) Abnormal vibrations occur when the centrifuge is running 7. Double cone 1) No guardrails and safety interlocking devices 2) Personnel climbs into the double cone to replace the vacuum bag 3) The transmission belt is not protected 4) Shaft seal leaks 5) The vacuum pipeline is blocked or the vacuum valve is not opened during use 8. Gas cylinders 1) The gas cylinder is not equipped with a bottle cap or anti-shock ring 2) When hydrogen cylinders are transported and stored in summer, there are no sunshade measures, resulting in exposure 3) Some gas cylinders have exceeded the annual inspection period 4) When acetylene cylinders and oxygen cylinders are used at the same time, the safe distance does not exceed five meters 5) Use catalytic gloves to close the hydrogen cylinder valve 6) Knock and collide with the gas cylinder 7) After the gas cylinder is used, the air pressure is less than 0.05Mpa 8) The gas cylinder set, pipeline connections and valves are damaged 9) When the hydrogen cylinder is used, the anti-static device is not used or is damaged 10) The gas cylinder has no anti-falling measures 11) There are trenches and secret passages in the storage place. 12) The storage place is not ventilated or has poor ventilation or corrosive gases have entered. 13) Lack of fire extinguishing equipment. 14) Use acetylene gas cylinders upside down. 15) The color of the gas cylinder is unclear. There are steam water, material pipes, dust, and corrosive substances in the power distribution room, which cause the electrical equipment in the power cabinet to age and cause short-circuit accidents. 5. There is acid mist corrosion or solvent infiltration or excessive dust outside the transformer. 6. There are clothes and other debris behind the control cabinet or substation cabinet. 7. The power distribution cabinet is too old and prone to short circuits. 8. Cables are close to high-temperature pipelines. Buried cables are corroded by groundwater 11. Serious infiltration of sewage in cable wells and trenches 12. Cable bridges are severely corroded 13. Cable protection casings are aged and broken 14. When cables or steel pipes laying electrical lines pass through holes in walls or floors between different places, non-combustible materials are not strictly blocked 15. The movable exhaust is pulled indiscriminately, causing cable joints to fall off and leakage 16. The equipment serial number corresponding to the switch button is not clearly marked 17. There are scattered and unknown cables in the workshop 18. The emergency lighting is not installed or is broken 19. There is no protective cover for the open-air motor 20. The illumination at the operation site is not enough 21. The equipment is not matched with the electrical equipment (Mavericks towing carts, Lao Niu tows carts), causing thermal damage to electrical equipment and fires 22. Water flushing on electrical equipment and cable bridges 23. Explosion-proof mirror lamps and lighting lamps have loose screws and light leakage [3] Static electricity 24. In flammable and explosive places, reactors, pipelines, storage tanks, condensers, transfer pumps, flanges, and valves are not grounded or have poor grounding. 25. In flammable and explosive places, powder feed hoppers are not grounded and filled with nitrogen. 26. The safe flow rate is exceeded (v2