【Haichuan Chemical Safety Updates】Maoming Petrochemical: Safety responsibilities assigned to each position

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Maoming Petrochemical: Safety responsibilities assigned to each position 2016-12-02 Source: Petrochemical News To further strengthen the safety management of the facilities, the High-Pressure Workshop of Maoming Petrochemical’s Chemical Division implemented various measures such as verifying inspection records through four verification steps, ensuring seamless handover between shifts, and setting up inspection-related incentives on-site, thereby assigning safety responsibilities to every position and individual within the workshop. From January to October, workers in the high-voltage workshop identified 7 potential hazards at the sub-department level and 1 hazard at the company level; over 300 workshop-level hazards were rectified. “We break down safety management into various levels, implementing safety measures in every aspect of work at the team level, strictly controlling production safety, addressing non-compliant behaviors, and reducing safety risks. ”said Liang Ge, the director of the high-pressure workshop. Check the records for the four stages: “That’s not right; the outlet pressure of pump D has always been stable at 3 MPa. Why does the gauge on site show 2 MPa?” ”Lao Li, the shift supervisor of Unit 2’s high-pressure equipment team, looked at the record book in confusion. On November 15th, when Chen, who was in the field, returned to the control room with the notebook for Li, who was inside the control room, to sign it, Li noticed that the recorded outlet pressure of catalyst transfer pump D at 10 o’clock was 2 MPa, but the DCS displayed 3 MPa, which raised his alertness. Lao Li immediately called Squad Leader Zhang to verify the situation. After a thorough inspection, Squad Leader Zhang found that it was the outlet pressure gauge of Pump D that was faulty, which caused a discrepancy between the internal and external parameters. He promptly contacted the instrumentation team for repairs, and this minor issue was resolved quickly. Since the beginning of this year, the high-pressure workshop has implemented standardized and scientific record-keeping practices, adopting a dynamic management approach. It requires that all data records go through four verification steps: entry of data by operators on site, comparison with values monitored by the DCS system, joint verification by both internal and external operators, and final confirmation with the signature of the shift leader. This ensures that operators can monitor parameters in real time and with accuracy, enabling early detection of any abnormalities. “Since the four checkpoints were established, even the slightest potential issues can be detected immediately through deviations in parameters, resulting in a significant improvement in the quality of inspections. ”said Guo Qinseng, the process director of the high-pressure workshop. Seamless handover between shifts: \"The oil temperature of Fan No. 4 is on the high side; closer monitoring is needed. There is also a slight abnormal noise in the bearing of Catalyst Pump B. I have already contacted the mechanic to check it, and special care must be taken until the mechanic arrives.\" ” At the site of Unit 2 high-pressure equipment, two shift handovers are in progress, with detailed information being transferred between the crew members. Inside the control room, the operators also provided detailed instructions, saying, “The inter-stage pressure of the compressor has been a bit high lately; I’ve found that this little trick can be used to keep the pressure under control…” The operator on duty passed on the experience he had gained without reservation to the operator taking over. This workshop emphasizes thorough handover procedures; the team leaving duty must arrange for two people to accompany the incoming crew to the equipment site prior to leaving, in order to carry out the handover and preliminary inspection. The key points and areas that require special attention at the equipment site are handed over carefully one by one. Workshop managers conduct surprise inspections from time to time to ensure that a clear understanding is achieved between the two shifts. Since the implementation of the shift handover ‘briefing session’, in just July alone, the workers in this workshop identified 3 sub-departmental level hazards and 1 company-level hazard; moreover, they addressed over 100 workshop-level hazards. No corner is left unchecked in the search for treasures on site – \"We’ve found two more treasures; there might be more as well. Everyone, go and check around quickly!\" ”Zhao Long, the shift leader of Unit 2’s high-pressure equipment team, returned to the outdoor control room holding two treasure hunt cards and said happily. Since the beginning of this year, in addition to the daily preliminary inspections and regular routine inspections, the high-pressure workshop has set up \"additional\" inspection points in hidden areas and at high elevations within the facility to carry out a \"treasure hunt\" activity. Managers place treasure hunt cards from time to time, and crew members who hand them in to the safety team within the specified time receive bonus points; these points are linked to performance evaluations. In October, 102 treasure hunt cards were placed in that workshop, all of which were checked by the staff on duty within half an hour. At the same time, this workshop adopts a \"three-no\" inspection method that involves unannounced checks at irregular times and locations. Workshop leaders inspect the managers, who in turn check the performance of those responsible for routine inspections. Scores are then determined based on the results of hazard inspections carried out by various teams, and the team with the highest score each month is awarded the title of \"Outstanding Team.\" It receives a reward of 300 yuan as part of the monthly financial assessment. Additionally, one member from the \"Outstanding Team\" is honored with the title of \"Inspection Star,\" receiving 100 yuan in cash. Teams and individuals who identify major hazards are recommended to compete for the company’s annual awards for outstanding safety teams and safety champions. (Zhong Dahai, Hou Feng, Liang Baowen)