Safety management points in the process of chemical equipment maintenance

I. Safety requirements before overhaul
1.1 The inspection and construction unit shall carry out the inspection and construction work within the scope of its class licence.

1.2 When signing an equipment overhaul contract, a safety management agreement should be signed at the same time.

1.3 According to the requirements of the equipment overhaul project, the overhaul construction unit shall develop an equipment overhaul programme, which shall be audited by the equipment using unit. There should be safety technical measures in the overhaul programme and the person responsible for the safety of the overhaul project should be clearly defined. The overhaul construction unit shall designate a person to be responsible for the specific safety work during the whole overhaul operation.

1.4 Before the overhaul, the equipment using unit should participate in the safety education of the personnel of the overhaul operation, safety education mainly includes the following contents:

1) Safety rules and regulations on overhaul operations.
2) The risk factors and possible problems and countermeasures that exist at the overhaul site and during the overhaul process.
3) The use of personal protective equipment and precautions for its use during overhaul operations.
4) Relevant accident cases, experiences and lessons learned.
5)The maintenance site should be set up with appropriate safety signs in accordance with GB2894.
6)The person in charge of the overhaul project should organise the overhaul operators to the site for the overhaul programme handover
7) The construction unit should implement the overhaul organization, overhaul personnel and overhaul safety measures before the overhaul.
8) When the equipment overhaul involves high work, fire work, earth moving work, disconnection work, lifting work, extraction of blind work and restricted space work, should be implemented in accordance with the following seven provisions.
HG 30010 Safety regulations for fire moving operations in production areas
HG 30011 Safety norms for restricted space operations in production areas
HG 30012 Safety norms for blind plugging operations in the production area
HG 30013 Safety Code of Practice for Work at Height in the Production Area
HG 30011 Safety Code of Practice for Lifting Operations in the Production Area
HG 30015 Safety Code of Practice for Circuit Breaking Operations in the Production Area
HG 30016 Safety specification for earth moving operations in the production area
9) Temporary electricity shall be subject to electricity procedures and shall be installed and erected in accordance with the regulations.
10)The unit using the equipment shall be responsible for the isolation, cleaning and replacement of the equipment and shall be handed over after passing.
11) The person in charge of the overhaul project should check with the person in charge of the unit using the equipment to confirm that the equipment and process handling etc. meet the overhaul safety requirements.
12) The scaffolding, lifting machinery, electrical welding appliances and hand-held power tools used for overhaul operations should be checked Hand-held, mobile electrical appliances should be equipped with leakage protection devices. Any work apparatus that does not meet the safety requirements of the operation shall not be used.
13) For electrical power supply on the overhaul equipment, reliable disconnection measures should be taken and safety warning signs or locks should be set at the power switch after confirming the disconnection.
14) Gas protective equipment, fire-fighting equipment, communication equipment and lighting equipment used for overhaul operations should be inspected by special personnel to ensure that they are in good condition.
15) Ladders, railings, platforms, grates and covers at the maintenance site should be inspected to ensure safety.
16) The maintenance site with corrosive media should be equipped with emergency flushing water and corresponding protective equipment for personnel.
17) Effective protective measures should be taken for pits, wells, ditches and holes that may endanger safety, warning signs should be set up, and red lights should be set up at night to warn that the maintenance site is clean of items affecting maintenance safety.
18) Fire escapes and traffic lanes should be inspected and cleaned to ensure they are clear.
19) Lighting should be provided to meet the requirements of the workplace for night maintenance.
20) For radioactive sources involved in the maintenance site, appropriate disposal measures should be taken in advance to keep them in a safe condition.


Second, the safety requirements in the maintenance operation
2.1 Personnel participating in overhaul operations shall wear correct labour protection equipment according to regulations.

2.2 Overhaul operators should comply with the safety and technical operating procedures of the job.

2.3 Overhaul personnel engaged in special operations should hold special operation certificates.

2.4 When multiple jobs and multi-level crossover operations are carried out, they should be unified and coordinated, and appropriate protective measures should be taken.

2.5 When overhauling operations with radioactive substances, the relevant operation and overhaul personnel should be informed of the site to avoid, confirm the safety protection distance, set up obvious warning signs in accordance with the regulations, and set up special guardianship.

2.6 For night-time maintenance operations and maintenance operations in special weather, special persons shall be arranged for safety supervision.

2.7 When there is an abnormal situation in the production unit that may endanger the safety of the maintenance personnel, the equipment using unit shall immediately notify the maintenance personnel to stop the operation and quickly evacuate the workplace. After treatment, the abnormal situation is removed and safety is confirmed, the overhaul personnel can resume operation.



3. Safety requirements at the end of the overhaul
3.1 Safety facilities such as covers, grates, handrails, rails and guards removed for overhaul should be restored to their safe function. 3.2 Work appliances, scaffolding, temporary power supply and temporary lighting equipment used for overhaul should be withdrawn from the site in time.
3.3 Waste, debris, rubbish and oil left after the completion of maintenance should be cleaned up.
Source: Reproduced
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