In chemical production, there are many safety hazards associated with chemical plants, are you aware of them all? This article provides an inventory of 300 hazards, from facilities and equipment to production sites, so check yourself!
Equipment and facilities
Reactors and reactors
1) Abnormal noise from speed reducer
2) Oil stains on the speed reducer or frame
3) Hot melt deformation of the plastic airfoil of the speed reducer
4) Lack of oil on machine seal and reducer
5) Gasket leakage
6) Damaged anti-static earth wire, not installed
7) Safety valve not inspected annually, leaking, no account established
8) Thermometer not inspected annually, damaged
9) Pressure gauge not inspected annually, damaged or blocked by material
10) The key
Reactor does not adopt double sets of temperature and pressure display and record alarm
11) Rupture discs not replaced when due, leaking, no account established
12) Rupture disc lower valve not opened
13) Rupture discs not installed in reactors with explosion hazard
14) High temperature, interruption of stirring, etc., abnormal pressure increase or material flushing
15) The bottom valve is easily blocked when discharging material
16) Acid corrosion in stainless steel or carbon steel kettle
17) Overloading of the kettle, e.g. with a charge exceeding the prescribed limit
18) The enamel in the kettle is broken and still used in corrosive, flammable and explosive places
19) The inner liner of the reactor is damaged by erosion at the steam inlet of the jacket
20) The pressure vessel is older than its service life, poor manufacturing quality and still leaks after repeated repairs
21) Pressure vessel without nameplate
22) Missing or unclear identification of position number
23) Failure to effectively isolate explosion-sensitive reactors
24) No safety checklist for critical equipment
25) Lack of spare parts or spares for critical equipment
Storage Tanks, tank farms, tankers
1) Ambiguous or damaged or blocked level gauges
2) Loose or unconnected electrostatic earth wire
3) Leakage at flange gasket
4) High level storage tanks such as small platforms not effectively secured
5) Safety seal levels not meeting requirements
6) Atmospheric tanks are used under pressure
7) Charges exceeding specified limits
8) non-temperature tanks not fitted with thermometers
9) Cracked vessels still in use
10) frequent vacuum and nitrogen alternating loads break the tank
11) low boiling point solvent or liquefied gas tanks exposed to direct sunlight
12) Danger of impact by transport vehicles etc. in outdoor storage tanks etc.
13) Holes in the cofferdam of hazardous goods tanks are not closed
14) Inadequate sealing of dikes in hazardous chemical tank areas and arbitrary opening of rainwater drainage holes
15) The shut-off valve to the drainage pipe is in an unsafe condition such as normally open
16) The outlet pipeline of combustible or corrosive materials in the hazardous chemical tank area is not provided with suspended spring compensation measures or directly connected with flexible short pipes.
17) Dangerous chemical tank areas are not equipped with various warning signs such as no mobile phone, no fire source, height and speed limit
18) No leakage, feeding operation records and daily inspection in the hazardous chemical tank area
19) Tractors enter the dangerous goods tank area at will
20) Open fire or forest fire around the DG tank farm
21) Use of electric stove, electric teakettle, electric hot plate and other illegal electricity in the operation room of DG tank area
22) No grounding device for tanker trucks at loading and unloading locations
23) No measures to prevent the operator from falling from the tanker
24) Failure to fit effective flame arresters and substandard condition (damaged lighting or faulty brakes) of tankers entering the tank farm
25) Safety accessories (pressure gauges, thermometers, safety valves) on tanker tanks without inspection dates or with failures
26) Tanker body not marked with the next inspection date of the pressure vessel
27) No electrostatic drag chains, anti-toxic equipment or leaking valves on the tank
28) Grounding not left to stand for more than 10 minutes before and after unloading
29) The driver and escort leave the unloading site when the tanker is unloaded and there is no on-site supervisor
30) Open and splash discharges are used
31) Tank exceeding standard level or overflowing full of material when discharging
32) Leakage from hoses or flanges when discharging vinyl chloride tankers
33) Full tank when transporting and feeding vinyl chloride
34) repeated transport and unloading in the plant when the tanker is not fully loaded
35) starting the vehicle with the engine off and hand brake or in the middle of unloading
36) Unloading operations during high lightning and lightning strikes
37) Tank contact points are not available at 2 locations
38) when loading or unloading gasoline or toluene, the operator does not wear anti-static work clothes and anti-static shoes
39) No accident weir and emergency spraying and dilution facilities were provided in the storage area of liquid ammonia and other storage tanks
40) No emergency spraying and eyewash facilities on site
41) No measures to prevent misloading of materials e.g. ethyl acetate into gasoline tanks
42) Welding while standing on gasoline drums
43) Cutting gasoline drums or welding tanks without cleaning
44) Overfilling of liquid ammonia and vinyl chloride storage tanks
45) Blocking fire escapes and encroaching on access roads when unloading tankers
46) Receivers leaving the unloading site
47) Use of iron, plastic or other spark-prone tools at the loading and unloading site
48) No records of the operation of material tanks sent from the tank farm to the workshop
Condensers, reboilers
1) Leakage caused by corrosion, ageing of gaskets etc.
2) High material temperature after condensation
3) blockage of the heat exchange media layer by sludge and microorganisms
4) Unprotected high temperature surfaces
5) Cooling water inlet and outlet valves are not open when cooling high temperature liquids (e.g. 150°C), or the cooling water volume is not sufficient
6) Evaporator etc. heats up rapidly when first used
7) The heat exchanger is not protected against vibrations, which can cause the pipes connected to it to loosen and leak.
Pipes and fittings
1) The pipes are not cleaned of welding slag or other foreign objects after installation
2) The sight glass is not clean or damaged
3) Improper installation of the sight glass due to improper pressure and temperature resistance of the selected sight glass material
4) The sight glass is broken or used under pressure for a long time
5) Damaged anti-static earth wire
6) Serious corrosion or rupture of pipes, flanges or bolts
7) High temperature pipes not insulated
8) Explosion relief pipe made into an elbow
9) unclear identification of pipeline material and flow direction
10) unclear colour coding of pipes
11) commissioning of different materials in series with the valve is not blind dead
12) Abandoned pipes are not cleaned in time
13) low installation position of pipe and valve, easy to hit the head or difficult to operate
14) Corrosive material pipelines, flanges and other leaky places are not taken protective measures
15) The possibility of water, nitrogen, air, steam, etc. entering the material pipeline
16) Iron or plastic drums of flammable and explosive materials are placed beside high temperature pipelines
17) unreasonable choice of materials for pipes or fittings, easy to corrode
18) Glass tube level meter without protective measures
19) No protective metal mesh is installed at the glass of the sight glass where it may explode
20) Check valves are not flexible or fail to operate
21) Electric valves without power or pneumatic valves without air
22) Pressure piping, such as hydrogen, is not regularly maintained or is operating with illness
23) Operators are not trained or licensed to work with pressure piping
24) Maintenance personnel are not qualified to repair or modify pressure piping
25) Poor welding quality of pressure piping, with welding defects such as galling, porosity, slagging and failure to weld through
26) Pressure pipelines are not equipped with safety accessories in accordance with the provisions or safety accessories are overdue for calibration
27) Pressure pipelines are not established files, operating procedures
28) Glass-lined pipes are hit by steel pipes etc.
29) Existing pipeline valves are used even after the production process medium has changed without considering material adaptability
30) Nitrogen pipes are connected in series with air pipes
31) Brine and cooling water pipes connected in series
Transfer pumps, vacuum pumps
1) Pump leakage
2) abnormal noise
3) Coupling without shield
4) Pump outlet without pressure gauge or non-return valve
5) Long-term disuse without draining the pump and piping of liquid, resulting in corrosion or freezing
6) Volumetric pumps operating with the outlet valve closed or without a safety return valve
7) Small pump inlet pipe diameter or long pipeline or many bends
8) Centrifugal pumps installed at a higher height than the suction height
9) No anti-static belt used
Centrifuges
1) Solvent dumping, not filled with nitrogen or blocked nitrogen piping or no flow meter on site to show
2) Oxygen meter and alarm device not installed when centrifuges are used for solvent filtration in fine drying packages
3) fast braking or braking with auxiliary tools (e.g. iron bars)
4) centrifuges not effectively earthed
5) anti-static belts not used in the explosion-proof area
6) abnormal vibration when the centrifuge is in operation
Source: Reproduced
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