Safety knowledge of oil refining and chemical equipment maintenance?

Maintenance of refining equipment is the basic guarantee for normal production in refining industry. The quality of overhaul and the level of safety and reliability not only directly affect the "safe, stable, long, full and excellent" operation of refining and chemical plants, but also endanger the lives and property of the broad masses of people. Today, Xiaoqi will lead you to know how to ensure the safety of petrochemical equipment maintenance and repair.

I. Overview of 0 1 refining unit and equipment

Refinery and chemical plant is composed of various equipments according to certain technological requirements. Therefore, the performance of refining equipment is the key to affect the production level of the unit. Different refining enterprises use different devices, but according to their functions, refining equipment can be divided into six types, namely: fluid conveying equipment, heating equipment, heat exchange equipment, mass transfer equipment, reaction equipment and containers. Fluid conveying equipment mainly includes various pumps, compressors, blowers, pipes, fittings and valves; Heating equipment mainly includes heating furnace, heating kettle, etc. There are also heat exchange equipment (such as air coolers and heat exchangers), various towers (reaction and fractionation) and storage tanks (crude oil, light oil and lubricating oil).

2. Main risk factors of oil refining and chemical plant: fire and explosion ①.

(1) Material channeling causes explosion. Most substances in production have the properties of combustion and explosion. Therefore, when substances cross each other, such as oxygen escaping into combustible gas, combustible gas escaping into air (oxygen), or escaping into equipment maintenance, explosions can be caused under fire sources with sufficient energy.

(2) Illegal hot work causes explosion. Failure to take necessary safety measures before overhaul and illegal hot work are one of the main causes of explosion accidents.

(3) Scrubbing equipment with volatile liquids such as gasoline will cause explosion. In petrochemical enterprises, cleaning agents are used to clean up pollution when equipment is overhauled, but some employees use volatile flammable liquids such as gasoline as cleaning agents, which leads to many major fire and explosion accidents.

(4) Explosion caused by working under pressure. Working under pressure is widely used in petrochemical enterprises, especially in old equipment. Because of aging equipment, running, running, dripping and leaking often occur. In order to ensure normal production, practical safety measures should be taken as far as possible, and plugging with pressure is allowed and safe. However, some enterprises often cause explosion accidents by tightening bolts, eliminating leakage and replacing gaskets without decompression.

Occupational poisoning ②

In the production of oil refining and chemical industry, there are many sources of toxic and harmful substances: some of them appear in the form of raw materials, by-products, finished products, auxiliary raw materials, reaction products or wastes, such as mixed benzene, catalysts, hydrogen sulfide and ammonia. , and the toxic and harmful dust, smoke, fog, steam, gas, etc. generated during maintenance. Most of the ways to invade the human body are inhalation, cannibalism or skin absorption, which leads to poisoning of maintenance personnel and workers.

Other factors ③

In addition to the above-mentioned main dangers and hazards, there are injuries caused by falling people or objects, electric shock injuries caused by electrical equipment or lines, mechanical injuries caused by rotating equipment, high-temperature medium burns, low-temperature medium frostbite, noise hazards, etc.

II. Requirements for maintenance characteristics of refining equipment 1 maintenance characteristics.

(1) complexity. If the residual raw materials and products in petrochemical process units are not thoroughly cleaned and purged, fires, explosions and poisoning will occur; The tower of the device is tens of meters high, the pipes are criss-crossed, all kinds of equipment are spread all over every corner, and all kinds of workers cross-operate.

(2) systematic. The process unit is a huge system composed of various equipments according to the process requirements, and the maintenance is carried out at different levels according to the system structure.

(3) normality. The placement of maintenance equipment, safety facilities, fire fighting equipment, machines and tools, the disassembly and installation of various equipment and facilities in process devices, the posting and hanging of safety signs and warning clauses, and the provision and use of labor protection articles and appliances should be standardized and standardized, and must conform to the provisions of safety technical specifications.

(4) Reliability. During maintenance and debugging, the quality must reach the standard, so that the device can achieve the operation goal of "safety, stability, long, full and excellent".

2 Maintenance requirements

In the maintenance stage, it often involves electrician operation, blasting operation, hot work, ground breaking operation, aerial work, welding operation, hoisting operation, entering equipment, etc. Therefore, all relevant regulations should be strictly implemented to ensure the smooth progress of maintenance work. Limited to space, the following only introduces the safety requirements of hot work and operation in the equipment.

Hot work ①

(1) Fix the hot work area and the no-fire area. The "fixed hot work area" shall be defined according to the fire danger degree and the needs of production, maintenance and construction, after the application of the user and the registration and approval of the factory safety and fire prevention department. No hot work area is allowed except the fixed hot work area.

(2) Hot work and classification. Welding and cutting operations in fire-forbidden areas and temporary operations that may produce flames, sparks or hot surfaces in inflammable and explosive places belong to hot work. Hot work is divided into three categories: special hot work, first-class hot work and second-class hot work. Hot work must be carried out after hot work analysis and qualification.

(3) hot work safety certificate system.

① When hot work is carried out in the no-fire area, a "hot work safety certificate" shall be obtained, and the application, review and approval procedures shall be strictly implemented. (2) The hot work personnel shall check all contents in detail after receiving the hot work permit. If it is found that it does not meet the safety requirements for hot work, it has the right to refuse hot work and report to the fire department of the unit. Hot work personnel should carry a hot work permit with them, and it is forbidden to work without a license or incomplete procedures. (3) Before hot work, the hot work personnel shall submit the hot work certificate to the person in charge of the site for inspection, and after confirming that the safety measures have been correctly implemented, hot work can be carried out at the specified time, place and content. (4) When the location or content of hot work changes, the certificate examination formalities shall be handled again; Otherwise, hot work is not allowed. ⑤ When hot work is carried out at heights and in equipment, in addition to hot work safety certificates, hot work safety certificates and equipment safety certificates must also be handled.

(4) Analysis and standard of hot work. Hot work must be carried out after hot work analysis and qualification.

Hot work analysis shall meet the following requirements:

① The sampling shall be representative, and the analysis samples of special hot work shall be kept until the end of hot work.

(2) The sampling time and hot work time shall not exceed 30min. If this interval is exceeded or the hot work stop time exceeds 30min, it must be re-sampled and analyzed.

③ Analysis standard of hot work: If explosion detector is used, the gas or steam concentration of the tested object should be less than or equal to 20% of the lower explosion limit (volume ratio, the same below); If other chemical analysis methods are adopted, when the lower explosion limit of the gas or vapor to be measured is greater than or equal to 10%, its concentration should be less than1%; When the lower explosion limit is less than 10% and greater than or equal to 4%, its concentration should be less than 0.5%; When the lower explosion limit is less than 4% and greater than or equal to 1%, its concentration should be less than 0.2%. When there are more than two kinds of mixed combustible gases, the lower explosion limit shall prevail.

(4) when hot work is carried out in the equipment, the contents of toxic and harmful gases and oxygen in the air must be analyzed and determined. The content of toxic and harmful gases shall not exceed the maximum allowable concentration specified in Hygienic Standard for Design of Industrial Enterprises (GBZ1-2002), and the oxygen content shall be 18% ~ 22%.

Operation ② in the equipment

(1) Equipment operation and its danger. The operation of tanks, towers, kettles, tanks, balls, furnaces, barrels, pipes, containers, basements, underground wells, pits, sewers or other closed places entering the petrochemical production area is called in-plant operation.

(2) Key points of equipment operation safety:

① When working in equipment, you must apply for the "Safety Operation Certificate in Equipment" and strictly perform the examination and approval procedures.

(2) Before entering the equipment, the equipment must be safely isolated from other equipment (adding a blind plate or removing a section of pipeline, which is not allowed to be replaced by other methods) and cleaned and replaced.

(3) 30 minutes before entering the equipment, samples must be taken for analysis, and the concentration and oxygen content of combustible gas and toxic gas should be strictly controlled within the safety index. Only after passing the analysis can you enter the equipment for operation.

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, and the operation in wet containers and narrow containers should be less than or equal to 12v. Lamps and electric tools must meet the safety requirements of moisture-proof and explosion-proof.

⑥ When working in equipment with corrosive, asphyxiating, flammable, explosive and toxic substances, you must wear appropriate personal protective equipment and appliances as required.

⑦ When hot work is carried out in the equipment, the hot work permit and the prescribed procedures must be handled according to the regulations.

⑧ The operation in the equipment must be supervised by special personnel, and keep effective contact with the operators in the equipment.

Pet-name ruby in the maintenance operation conditions change, and may endanger the safety of workers, must immediately withdraw personnel; If it is necessary to continue the operation, it is necessary to go through the examination and approval procedures for equipment entry again.

Attending after the completion of the operation, maintenance personnel, guardians and * * *, head of the use department, check the inside of the equipment and confirm that there are no personnel, tools and sundries in the equipment before closing the equipment hole.

Three. Maintenance safety countermeasures 1 maintenance organization measures HSE maintenance management organization responsibility implementation and responsibilities

Set up a maintenance leading group, unified leadership and unified command of maintenance work. Its members should have a clear division of labor and take responsibility for each other. The maintenance leading group is divided into six professional groups. All professional groups should coordinate, cooperate, supervise and serve the front line of equipment maintenance. As an important member of the overhaul leading group, the overhaul HSE team arranges, inspects, summarizes and evaluates the safety work in the whole overhaul process. HSE supervisor is responsible for overall supervision and inspection of HSE management in all links during the whole overhaul process. Organize on-site safety inspection, report to the leading group immediately if potential safety hazards are found, and be responsible for making rectification plans and supervising on-site rectification. For workshops, teams, and decentralized operation groups, HSE inspectors should be assigned to be responsible for the safety control of on-site operations, so that the maintenance safety is always in a controllable state.

2 Maintenance safety technical measures

① overhaul HSE rules and regulations

Adhere to the safety policy of "safety first, prevention first" and implement the principle of "whoever is in charge is responsible". Strictly implement the rules and regulations such as Safety Regulations for Industrial Firework in Petroleum Enterprises, Regulations for Safety Management of Firework in Refinery and Chemical Enterprises of China Petroleum and Natural Gas Group Company, Regulations for Safety Management of Aerial Work in Refinery and Chemical Enterprises, Regulations for Limited Space Work in Refinery and Chemical Enterprises, and Regulations for Temporary Electricity Use.

(2), maintenance site safety technical measures

(1) After the unit is shut down and purged, the pipelines connected with other production units and the oil tank area must be blocked with blind plates and marked by special personnel. According to the blind plate sealing position, blind plate number, disassembly date, person in charge and other columns. , should be unified registration, signature, shall not be omitted. Drainage wells and floor drains should be cleaned and sealed with steam to prevent fire and explosion accidents. After the device is shut down and purged, the workshop leader shall organize a comprehensive inspection, submit it to the maintenance leading group for acceptance, and deliver it to the construction unit only after it is confirmed to be safe and correct.

(2) Equipment maintenance projects should be "five-fixed", that is, major maintenance projects should determine the maintenance plan, and safety measures should be discussed and approved by the director in charge or the person in charge of safety.

(3) Maintenance machines and tools must be placed according to the arrangement of the headquarters to ensure the smooth import and export of the device and the internal roads. The safety protection and grounding facilities of machines and tools are complete, intact, flexible and easy to use.

(4) All maintenance personnel must wear personal protective equipment when entering the construction site.

(5) Fire fighting system must be strictly used in maintenance. Smoking is strictly prohibited on the construction site. No hot work is allowed without hot work ticket; Temporary electricity facilities or lighting shall meet the technical requirements for electricity safety; It is forbidden to use steam or volatile solvents to clean machines, accessories or work clothes; When motor vehicles enter the maintenance site, they must strictly implement the Ten Orders on Vehicle Safety.

(6) Anyone who works in toxic and harmful parts must be equipped with appropriate gas masks, air respirator and other special protective equipment to prevent poisoning; When entering the tower, kettle, storage tank, container, sewer, pit, furnace, flue or other closed equipment for maintenance, it is necessary to obtain a special operation safety working ticket, and designate a special person to carry out safety monitoring at the scene and do a good job in ventilation.

(7) Electrical equipment maintenance should strictly implement the electrical safety work regulations and relevant regulations.

(8) Maintenance and lifting operations shall strictly implement the relevant national safety regulations; Aerial work, must strictly implement the provisions of the state on aerial work.

3 emergency plan for maintenance accidents

(1), the purpose of the emergency treatment plan for maintenance accidents

Once an accident occurs, it can effectively control the hazard source in time, avoid the accident from expanding and eliminate the accident as much as possible. It can minimize the loss of people and property caused by accidents.

(2), the contents of the accident emergency plan

Establishing a strong emergency organization is the key to implementing the accident emergency plan. A sound emergency organization should include on-site leading institutions dealing with emergencies, professional and voluntary rescue teams, and other necessary institutions and personnel such as medical care, information, logistics and security. Emergency measures are the core content of accident emergency plan, including: emergency handling methods and training, self-help and mutual rescue of accidents and disasters, accident and disaster rescue equipment and equipment, accident and disaster reporting procedures, etc.

4 Maintenance implementation plan

(1), three explanations of safety work

Whether it is an ordinary type of work or a special type of work, safety "three explanations" (that is, work place, work nature and work safety) must be carried out when explaining work tasks. First of all, where to work must be clear. The workplace is a multi-level fire zone and a multi-level toxic and harmful place. What safety operation procedures need to be handled and what safety protection measures should be taken must be clearly explained to the operators. Secondly, what is the nature of the operation? Do you work in a limited space or at high altitude? Is it welding operation, lifting operation or other special operations? What safety protection measures the operator should take and what working tickets should be handled must be clearly explained to the operator; At the same time, it is also necessary to explain what safety precautions are in the process of operation, and how to deal with emergencies and avoid risks in case of accidents during operation. Finally, the accounting personnel and the operating personnel perform the signing procedures respectively, so that the three accounting tasks can be traced back.

②. Implement "three inspections" in the operation.

In actual operation, some work lasts for a long time, so it is easy for operators to relax their safety vigilance. At this time, it is particularly important to carry out the "three inspections". Check whether safety measures are implemented, whether safety belts, safety helmets, goggles, protective clothing and air pagers are implemented, whether all kinds of special operation tickets in the office are handled, and whether guardians are in place; The second is to check whether there are new safety hazards on the job site, such as the appearance of new toxic and harmful gases, the appearance of flammable and explosive liquids in unknown places, and the loosening of scaffold fixing bolts; Third, check whether the operator has illegal command and operation. Sometimes, in order to seize the progress and time limit for a project, individual personnel are hot-headed, and illegal command and risky operations appear quietly. Sometimes, operators take chances and relax the strict implementation of safety rules and regulations and measures. Through the irregular "three inspections" in construction work, the potential safety hazards are eliminated in the bud, thus preventing the occurrence of safety accidents in maintenance work.

③ "three tubes" after operation.

After the overhaul operation, the "three pipes" must be carried out to see whether the operation of one pipe meets the relevant standards and process requirements. Although the maintenance standards and process requirements have been clearly implemented in the HSE operation plan, during the operation, due to many factors (the skill level of operators, etc. ), the process and quality of specific operations may not meet the requirements of maintenance standards, and some even have major process hidden dangers. Through this management, the construction work is ensured to meet the standard, leaving no future trouble for the safe production of the device. Whether there are man-made hidden dangers during the operation of the second pipe, the whole overhaul operation must be "finished, materials exhausted and cleaned on site" to prevent the operators from inadvertently leaving metal and silk products in the pipes, containers and towers, blocking the circulation of liquid media and causing hidden dangers; Whether there is an acceptance signature of the equipment management unit after the completion of the three pipes, so as to distinguish the responsibilities and trace the safety work.

Because the refining plant is a high-temperature and high-pressure plant, flammable, explosive, toxic and harmful products will be produced in the production process, there are high requirements for the temperature resistance, pressure resistance, corrosion resistance and sealing of the plant, and at the same time, there are high requirements for the maintenance and overhaul of the refining plant, not only to ensure that the overhaul operation does not leave hidden dangers for the factory, but also to ensure the safety of personnel, machines and equipment during the overhaul operation, which requires that the overhaul operation must be foolproof.

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