The maintenance of refining and chemical equipment is the basic guarantee for the normal production of the refining and chemical industry. Whether the quality of maintenance is good or bad, and whether safety and reliability are high or low, not only directly affects the "safe, stable, long-term, full and optimal" operation of the refining and chemical plants, but also endangers the lives and property safety of the general public. Today Xiaoqi will lead everyone to understand how to ensure safety during maintenance and repair of petrochemical equipment.
1. Overview of Refining and Chemical Plants 01 Equipment of Refining and Chemical Plants
Refining and chemical plants are composed of various equipment and are combined according to certain process requirements. Therefore, the performance of oil refining equipment is the key to affecting the production level of the unit. Different refining and chemical enterprises and different units use different equipment, but refining equipment can be divided into six types according to their functions, namely: fluid transportation equipment, heating equipment, heat exchange equipment, mass transfer equipment, reaction equipment and containers. Fluid transportation equipment mainly includes various types of pumps, compressors, blowers, pipelines, pipe fittings and valves; heating equipment mainly includes heating furnaces, heating kettles, etc.; there are also heat exchange equipment (such as air coolers, heat exchangers, etc.) and various types of Towers (reaction, fractionation) and storage tanks (crude oil, light oil, lubricating oil).
2 The main risk factors in refining and chemical plants are fire and explosion ①
(1) Materials flowing into each other cause explosions. Most of the various materials in production have flammable and explosive properties. Therefore, when the materials cross each other, such as oxygen flowing into flammable gas, combustible gas flowing into air (oxygen), or equipment being overhauled, there will be enough Any source of energy can cause an explosion.
(2) Illegal fire causing explosion. Failure to take necessary safety measures before maintenance and illegal fires are one of the main causes of explosion accidents.
(3) Scrubbing the equipment with gasoline and other volatile liquids may cause an explosion. During equipment maintenance, petrochemical companies use detergents as required to clean dirt, but some employees use volatile flammable liquids such as gasoline as detergents, resulting in many major fire and explosion accidents.
(4) Pressurized operation causes explosion. Pressurized operations are more commonly used in petrochemical enterprises, especially in old equipment. Due to the aging of the equipment, running, blowing, dripping and leaking often occur. In order to ensure normal production, practical safety measures should be adopted as much as possible. Leakage plugging under pressure is allowed and safe. However, some companies often cause explosion accidents by hot-tightening bolts, eliminating leaks and replacing gaskets without reducing pressure.
Occupational Poisoning ②
In refining and chemical production, the sources of toxic and hazardous substances are many: some are used as raw materials, by-products, finished products, auxiliary raw materials, reaction products or wastes, etc. Appear in various ways, such as mixed benzene, catalyst, hydrogen sulfide, ammonia, etc., as well as toxic and harmful dust, smoke, fog, steam, gas, etc. generated during maintenance and overhaul. Most of the ways of invading the human body are inhalation, cannibalism or absorption through the skin, causing poisoning of maintenance personnel and employees.
Other factors ③
In addition to the above-mentioned main dangers and hazards, there are also injuries caused by people falling or falling objects and electrical equipment caused by working at heights during maintenance of petrochemical equipment. Or electric shock injuries caused by circuits, mechanical injuries caused by rotating equipment, burns from high-temperature media, frostbite from low-temperature media, noise hazards, etc.
2. Characteristic requirements for maintenance of refining and chemical equipment 1. Maintenance characteristics
(1) Complexity. If the residual raw materials and products in the petrochemical process equipment are not thoroughly cleaned and purged, fires, explosions and poisoning incidents will occur; the tower of the equipment is tens of meters high, the pipelines are crisscrossed, various equipment is everywhere, and various types of workers are crisscrossed. Cross-working.
(2) Systematic. The process device consists of various equipment to form a huge system according to process requirements, and maintenance is classified and carried out in layers according to the system structure.
(3) Normative. Maintenance equipment, safety facilities, fire-fighting equipment, the placement of machinery and tools, the disassembly and installation of various equipment and facilities in process installations, the posting and hanging of safety signs and warnings, the equipment and use of labor protection supplies, etc. must be programmed and standardized. Must comply with safety technical regulations.
(4) Reliability. The quality must be up to standard during maintenance and debugging, so that the device can achieve the goal of "safe, stable, long-term, full and excellent" operation.
2 Maintenance requirements
The maintenance stage often involves electrical work, demolition work, hot work, earth-moving work, high-altitude work, welding work, hoisting work, entering equipment, etc. , all relevant regulations should be strictly implemented to ensure the smooth progress of maintenance work. Due to space limitations, the following only introduces the safety requirements for hot work and work entering equipment.
Hot work ①
(1) Fixed hot and no-fire areas. "Fixed fire areas" should be demarcated based on the degree of fire risk and the needs of production, maintenance, construction and other work, upon application by the user, registration and approval by the plant safety and fire prevention department. All areas outside the fixed fire area are no-fire areas.
(2) Hot work and classification. Welding and cutting operations in fire-prohibited areas and the use of blowtorches, electric drills, grinding wheels, etc. in flammable and explosive places to perform temporary operations that may produce flames, sparks or red-hot surfaces are all hot operations. Hot work is divided into three categories: special hot work, first-level hot work and second-level hot work. Hot work must undergo fire analysis and be qualified before proceeding.
(3) Fire safety work permit system.
① To carry out hot work in a fire-prohibited area, a "Fire Safety Work Permit" must be obtained, and the application, review and approval procedures must be strictly followed. ② After receiving the fire certificate, the personnel working on the fire must check all the contents in detail. If they find that the fire safety regulations are not met, they have the right to refuse to start the fire and report to the fire prevention department of the unit. Those who start a fire must carry a fire permit with them, and operations without a permit or with incomplete procedures are strictly prohibited. ③ Before starting a fire, the fire operation personnel should submit the fire certificate to the person in charge of the site for inspection. After confirming that the safety measures have been implemented correctly, the fire operation can be carried out according to the specified time, location and content. ④When the location or content of the fire is changed, the certification procedures should be re-completed; otherwise, the fire is not allowed. ⑤ When carrying out hot work at high places and hot work inside equipment, in addition to the "Fire Safety Work Permit", you must also apply for the "Safe Work at High Places Permit" and "Safe Work in Equipment Permit".
(4) Fire analysis and standards. Hot work must undergo fire analysis and be qualified before proceeding.
Hot-hot analysis should comply with the following regulations:
① Sampling must be representative, and special hot-fire analysis samples must be retained until the end of hot work.
② The time between sampling and hot work shall not exceed 30 minutes. If this interval is exceeded or the hot work stop time exceeds 30 minutes, sampling and analysis must be re-sampled.
③Standards for dynamic fire analysis: If an explosion detector is used, the concentration of gas or vapor in the measured object should be less than or equal to 20 of the lower explosion limit (volume ratio, the same below); if other chemical analysis is used means, when the lower explosion limit of the measured gas or vapor is greater than or equal to 10, its concentration should be less than 1; when the lower explosion limit is less than 10, greater than or equal to 4, its concentration should be less than 0.5; when the lower explosion limit is less than 4, greater than or equal to When equal to 1, its concentration should be less than 0.2. If there are two or more mixed flammable gases, the one with the lower explosion limit shall prevail.
④ When entering the equipment to start a fire, the toxic and harmful gases and oxygen content in the air must also be analyzed and measured. The toxic and harmful gas content must not exceed the maximum specified in the "Hygienic Standards for Design of Industrial Enterprises" (GBZ1-2002) The allowable concentration and oxygen content should be 18 to 22.
Working in the equipment ②
(1) Working in the equipment and its dangers. Any operation carried out in tanks, towers, kettles, tanks, balls, furnaces, drums, pipes, containers, etc. in petroleum and chemical production areas, as well as in basements, wells, pits, sewers or other closed places is called operations within the equipment. .
(2) Safety points for operations within the equipment:
① To operate within the equipment, a "Safe Operation Certificate within the Equipment" must be obtained, and the approval procedures must be strictly followed.
② Before entering the equipment for work, the equipment must be safely isolated from other equipment (add a blind plate or remove a section of pipeline, other methods are not allowed to replace it), and clean and replace them.
③ Samples must be taken and analyzed 30 minutes before entering the equipment. The concentration of combustible gases, toxic gases and oxygen content must be strictly controlled within the safety indicators. Only those who pass the analysis are allowed to enter the equipment.
④ Take appropriate ventilation measures to ensure good air circulation in the equipment.
⑤ There should be sufficient lighting. The lighting voltage in the equipment should not be greater than 36v. When working in humid containers or narrow containers, it should be less than or equal to 12v. Lamps and power tools must meet safety requirements such as moisture-proof and explosion-proof.
⑥ When working in equipment containing corrosive, suffocating, flammable, explosive, or toxic materials, you must wear appropriate personal protective equipment and equipment in accordance with regulations.
⑦ If you want to start a fire in the equipment, you must apply for a fire permit and perform the required procedures in accordance with regulations.
⑧Designated personnel must be assigned to supervise operations within the equipment and maintain effective contact with the personnel working within the equipment.
⑨ When maintenance operation conditions change and may endanger the safety of workers, personnel must be evacuated immediately; if operations need to continue, approval procedures for entering the equipment must be re-approved.
⑩After the work is completed, the maintenance personnel, guardians and the person in charge of the using department shall jointly inspect the inside of the equipment and confirm that there are no people, tools or debris in the equipment before the equipment holes can be closed.
3. Safety Countermeasures for Maintenance and Inspection 1. Maintenance organizational measures, HSE maintenance management organizational responsibility implementation and responsibilities
Establish a maintenance leading group to implement unified leadership and unified command for maintenance. Its members must have a clear division of labor and each shall bear their own responsibilities. The maintenance leading group is divided into six professional groups. Various professional groups coordinate, cooperate, supervise and provide services on the front line of equipment maintenance. As an important member of the maintenance leading group, the maintenance HSE team deploys, inspects, summarizes, and evaluates the safety work throughout the entire maintenance process. HSE supervisors are responsible for overall supervision and inspection of HSE management in all aspects of the entire maintenance process. Organize on-site safety inspections and report any potential safety hazards to the leadership team immediately, and be responsible for formulating rectification plans and supervising on-site rectifications. HSE inspectors should be assigned to workshops, teams and scattered operating groups to be responsible for the safety of on-site operations, so that maintenance safety is always under control.
2 Overhaul safety technical measures
① Overhaul HSE rules and regulations
Adhere to the safety policy of "safety first, prevention first", implement the "who The principle of “who is in charge and who is responsible”. Strictly implement the "Industrial Fire Safety Regulations for Petroleum Enterprises", "Safe Fire Management Regulations for China National Petroleum Corporation's Refining and Chemical Enterprises", "Safety Management Regulations for Refining and Chemical Enterprises Working at High Altitudes", and "Management Regulations for Refining and Chemical Enterprises to Operate in Limited Spaces" , "Temporary Electricity Management Regulations" and other rules and regulations.
②. Safety technical measures at the maintenance site
(1) After the device is shut down and purged, the pipelines connected to other production devices and the oil tank area must be blocked by blind plates. And a dedicated person must be assigned to mark it, and register and sign in a unified manner according to the blind plate blocking position, blind plate number, installation and disassembly date, person in charge, etc., and no omissions shall be allowed. Sewer wells and floor drain trenches should be cleaned with steam purging and sealed tightly to prevent fire and explosion accidents. After the device is shut down and the purging work is completed, the workshop leader will organize a comprehensive inspection and submit it to the maintenance leading group for acceptance. Only after it is confirmed to be safe and correct can it be delivered to the construction unit.
(2) For equipment maintenance projects, "five fixes" must be achieved, that is, maintenance plans for major maintenance projects must be determined, and safety measures must be discussed and approved by the factory director or safety director.
(3) Maintenance equipment must be placed according to the layout of the headquarters to ensure that the entrance and exit of the device and internal roads are smooth. The safety protection and grounding facilities of the machine are complete, flexible and easy to use.
(4) All maintenance personnel must wear personal protective equipment when entering the construction site.
(5) The fire usage system must be strict during maintenance. Smoking is strictly prohibited at the construction site. No fire is allowed without a fire ticket; temporary electrical facilities or lighting should comply with electrical safety technical requirements; it is prohibited to use gasoline or volatile solvents to wash machines, accessories or work clothes; motor vehicles entering the maintenance site must strictly abide by the "Vehicle "Ten Safety Orders".
(6) Anyone who enters toxic and harmful parts must be equipped with suitable gas masks, air respirators and other special protective equipment to prevent poisoning; when entering towers, cauldrons, storage tanks, containers, sewers, and underground For maintenance operations in pits, furnaces, flues or other closed equipment, special operation safety tickets must be issued, and dedicated personnel should be assigned to the site for safety monitoring and ventilation.
(7) Electrical safety regulations and relevant regulations must be strictly followed in the maintenance of electrical equipment.
(8) During maintenance and hoisting operations, relevant national safety regulations should be strictly implemented; for high-altitude operations, national regulations on working at heights must be strictly implemented.
3 Maintenance accident emergency plan
①. Purpose of maintenance accident emergency plan
Once an accident occurs, the danger source can be controlled promptly and effectively to avoid the expansion of the accident. , and where possible, accidents can be eliminated. It can minimize the loss of people and property caused by accidents.
②. Contents of the accident emergency response plan
Establishing a strong emergency response organization is the key to implementing the accident emergency response plan. A sound emergency organization should include the on-site leadership agency for handling emergencies, professional and voluntary rescue teams, and other necessary agencies and personnel such as medical care, information, logistics, and security. Emergency measures are the core content of the accident emergency response plan, including: accident emergency handling methods and training, accident and disaster self-rescue and mutual rescue and drills, accident and disaster relief equipment and equipment, accident and disaster reporting procedures, etc.
4 Maintenance Implementation Plan
①. Three Handlings of Safety Work
Whether it is a common type of work or a special type of work, when handing over work tasks, you must carry out Safety "three explanations" (namely, explaining the location of the work, explaining the nature of the work, and explaining the safety of the work). First of all, it is necessary to make it clear where the work is to be carried out. What levels of fire prevention areas and levels of toxic and hazardous places are the workplaces? What safety procedures should be carried out and what safety protection measures should be taken must be clearly explained to the operators; secondly, what is the operation? What kind of operation is it? Is it an operation in a limited space or an operation at high altitude? Is it a welding operation, a lifting operation or other special operations? What safety protection measures should the operator take? What kind of operation tickets should be issued? All of them must be issued to the operator. Personnel should explain clearly; at the same time, they must also explain what safety precautions are taken during the operation, and how to deal with the emergency and avoid danger if an unexpected situation occurs during the operation. Finally, the handing over personnel and operating personnel will perform the signing procedures respectively, so that the three handing over work can be traced.
②. Implement "three checks" during operations
In actual operations, some jobs last for a long time, and operators can easily relax their safety vigilance. At this time, "three checks" are carried out "Especially important. First, check whether the safety measures are implemented, whether the required safety belts, safety helmets, goggles, protective clothing, and air breathing apparatus are worn, whether the required tickets for various special operations have been issued, and whether the required guardians are in place. No; secondly, check whether there are any new safety hazards at the work site, such as whether there are new toxic and harmful gases, whether there are flammable and explosive liquids emerging from unknown places, whether there are loose scaffolding fixing bolts, etc.; thirdly, check Are there any violations of regulations and operations among operators? Sometimes, in order to rush for progress and deadlines, individual personnel become overheated, and illegal instructions and risky operations quietly appear. Sometimes, operators take a chance and relax the strict implementation of safety regulations and measures, etc. wait. Through irregular "three inspections" during construction operations, potential safety hazards are eliminated in the bud, thus preventing the occurrence of safety accidents during maintenance and repair operations.
③. "Three pipes" after the operation is completed
After the maintenance and repair work is completed, the "three pipes" must be carried out to see whether the first pipe operation meets the relevant standards and process requirements.
Although the maintenance standards and process requirements to be implemented have been clearly stated in the HSE operation plan, during the operation, due to many factors (skill level of the operator, etc.), the process and quality of the specific operation may not necessarily meet the maintenance standard process requirements. Some even have major process hazards. Through this management, it is ensured that the construction operations meet the standards and do not leave any consequences for the production safety of the equipment. Whether there are any human hazards during the second pipe operation, the entire maintenance operation must be "completed, materials used up, and on-site." "Clean" to prevent operators from accidentally leaving metal and silk fabrics in pipelines, containers, and towers due to negligence, blocking the flow of liquid media and causing hidden dangers and accidents; after the completion of the third pipeline, is there an acceptance signature from the installation management unit? Separate responsibilities and traceability of safety work.
Since the refining and chemical plant is a high-temperature and high-pressure device, flammable, explosive, toxic and harmful products will be produced during the production process. Therefore, the temperature resistance, pressure resistance, corrosion resistance and sealing of the device have high requirements. At the same time, it also puts forward higher requirements for the maintenance and repair of refining and chemical equipment. It is not only necessary to ensure that maintenance and repair operations do not leave hidden dangers for the equipment, but also to ensure the safety of personnel and machinery and equipment during the maintenance and repair operations. This requires Maintenance and inspection operations must be foolproof.
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