健康、安全与环境管理体系.doc

DOCUMENT TITLE HSE MANAGEMENT SYSTEM SECTION 3 STANDARD CONTROL SHEETS DOC NO JA MFHS 0000 0002REV 08FUNCTION MF SUBMISSION DATE 3 Dec 10PAGE 1 OF 90DOC LEVEL 2 CSPC MS SECURITY CLASSIFICATION Restricted The Controlled Copy of this document is in electronic format and is stored in DCC All hardcopies are uncontrolled This copy is last printed on 8 1月 20 9 12 上午 HSE MANAGEMENT SYSTEM 健康 安全与环境管理体系 SECTION 3 第三部分第三部分 STANDARD CONTROL SHEETS 标准控制单标准控制单 DOCUMENT NO JA MFHS 0000 0002 DOCUMENT AUTHOR DOCUMENT REVIEWER DOCUMENT APPROVAL REVAMENDMENT DESCRIPTIONISSUED DATE MFHS 11MFHSMF06 Revised SCS1 1 3 12 main changes highlighted in yellow 5 Aug 09 MFHS 10MFEM DMFHS07 Revised SCS1 4 added HPWJ full body protection suit requirement 20 Jul 10 MFHS 11MFHSMF08 Revised SCS1 1 1 5 2 1 3 1 3 2 3 4 4 3 Replaced SCS3 6 3 7 4 2 with SCS2 4 most changes highlighted in blue 3 Dec 10 DOCUMENT TITLE HSE MANAGEMENT SYSTEM SECTION 3 STANDARD CONTROL SHEETS DOC NO JA MFHS 0000 0002REV 08FUNCTION MF SUBMISSION DATE 3 Dec 10PAGE 1 OF 90DOC LEVEL 2 CSPC MS SECURITY CLASSIFICATION Restricted The Controlled Copy of this document is in electronic format and is stored in DCC All hardcopies are uncontrolled This copy is last printed on 8 1月 20 9 12 上午 Metadata Unit No AllEquipment No All Reference Document PR MFHS 0000 0003 Permit to Work Regulations GD MFHS 0000 0001 GD MFHS 0000 0009 Safety Regulations Retention Period Plant life Distribution List IndicatorNameE H Copy MFE MFOE MFHSQE MFLOE MFSPE MFUTE MFEO POE MFPE MFOME MFTEE MFESE MFEME MFLO 9Zhao TongqianE MFSP 3Ouyang FengrongE MFUT 3Li ChangguoE MFPO 3Li LinlinE MFPP 3Chen BaozhongE MFLD 3Liang ZifeiE MFOM 4Zhong FeiE MFDM 3Zhang ChunyuanE Content 1 1Entry into confined space 1 2Hot work on pipelines isolated with twin tyred hydro plugs 1 3Opening up large process lines containing flammable toxic asphyxiant or pyrophoric material 1 4High pressure water jetting outside permanent cleaning bays 150 to 2 500 Barg 1 5Welding flame cutting and grinding in or adjacent to zone classified areas 1 6Excavations 2 1Opening systems that have contained flammable toxic asphyxiant or pyrophoric material 2 2Blast cleaning 2 3Use of air power saws and drills to cut drill pipes Repair modify Inspect Process Unit Unit Area Equipment Number Road number Previous Contents Safety Certificate Number Emergency contact number Panel Tel 1 An Emergency plan must be included and understood by the users 2 A Plot plan with the detail work location and emergency mustering point shall be submitted with the Emergency Plan for use by CSPC Fire Brigade 3 CSPC Fire Brigade must carry out an assessment of the access and egress of the Confined Space EMERGENCY CO ORDINATION Rescue shall be co ordinated and implemented by Fire Brigade EMERGENCY IN THE CONFINED SPACE 1 Confined Space Attendant shall notify by radio contact direct to the relevant Unit Control Room If necessary he could also notify the Fire Brigade by Orange Button on the radio set 2 The Process Panel operator will contact Fire Brigade by hotline or telephone 368 8119 3 Personnel will leave the Confined Space if they are able to do so 4 Confined Space Attendant attempts rescue from OUTSIDE the confined space if single person attached to life line winch 5 The Confined Space Attendant will carry out a head count to account for each person 6 All mobile equipment associated with the activity except Breathing Air supply 维修 改造 检查 生产装置 工艺单元 区域 设备编号 道路编号 原有的物料 安全作业单编号 紧急联络紧急联络 控制室电话控制室电话 1 必须编制应急计划 并且使用者必须理解应急计划 2 显示具体作业位置和现场 临时 紧急集合点的平面图应附在本应急计划中供消防队使用 3 CSPC 消防队必须对受限空间的出入口作出评价 紧急营救紧急营救 营救应由消防队协调执行 在受限空间的紧急反应在受限空间的紧急反应 1 受限空间看护人应通过对讲机直接通知相关装置的控制室 如果必要 他也可以通过对讲机上 桔红色的按钮直接通知消防队 2 控制室操作人员通过热线电话或电话 3688119 联系消防队 3 如果情况允许 受限空间内的人应自己出来 4 受限空间的看护人应尝试从外面营救 如果单个人系在救生绳上或绞盘上 5 受限空间的看护人应清点人数 6 所有与活动有关的移动设备 除呼吸器供气管线和临时照明外 应关掉 7 消防人员一到现场 受限空间看守人应向他们简要介绍情况 受限空间外的紧急反应受限空间外的紧急反应 1 如果受限空间外面发生紧急情况 作业人员将通过现场警报 装置警报或受限空间看护人的空气 哨获得通知 2 作业人员应尽快离开受限空间 3 受限空间看护人应清点人数 4 工作人员离开后 如果可能 所有的移动式设备应停止 5 所有的人员应撤离至指定的集合点待命 工作人员与看护人的沟通工作人员与看护人的沟通 1 受限空间的看护人应配备空气哨 在紧急情况下用来报警 2 听到空气哨声 作业人员应撤离受限空间 3 作业人员也应配备空气哨以便他们在受限空间内发生紧急情况时报警 CSPC Standard Control Sheets 标准控制单标准控制单 Ver 版本 08 Page 12 of 90 受限空间的尺寸和描述受限空间的尺寸和描述 描述 尺寸 m3 高度 m 宽度 m 长度 m 进入受限空间的通道进入受限空间的通道 开孔数 开孔大小 至少 575mm 开孔位置 请打勾选择 并标注在图纸上 底部 中部 顶部 最多进入人数 简要的工作描述简要的工作描述 包括其它可协助消防队实施援救的信息 申请人申请人 姓名 申请日期 预期开工日期 消防队批准消防队批准 姓名 签名 日期 受限空间看护人的职责受限空间看护人的职责 1 紧急情况下报警 2 在现场采取行动之前应联系确认 3 协助实施援救但不得进入受限空间 4 使用受限空间登记表记录所有进入人员名单 5 当不可能进行持续的观察 视线受阻 时 受限空间看护人必须遵循交给他的书面程序上的要 求与受限空间内作业人员进行沟通 6 与进入受限空间的人员保持联络 7 保持出入口畅通并持续监控 8 理解现场报警和装置报警 必要时撤回受限空间作业人员 9 移动设备附近放置灭火器 10 监视周围区域的变化 例如 风向和风力 留意移动设备 确保废气排放远离人孔 通风系统连续运行 排放系统是否异常 附近是否有泄漏或排放 附近是否有其它有冲突的工作 当周围环境变得不安全时 如有必要 停止工作并撤离 当周围环境变得不安全时 如有必要 停止工作并撤离 受限空间看护人必须能胜任工作且身体条件符合要求受限空间看护人必须能胜任工作且身体条件符合要求 CSPC Standard Control Sheets 标准控制单标准控制单 Ver 版本 08 Page 13 of 90 SCS1 2Hotwork on Pipes Isolated with Twin tyred Hydro Plugs CSPC PTW Regulations This Standard Control Sheet must be attached to the copy of the Safety Certificate issued to the Applicant 1 Scope 1 1 This Standard Control Sheet covers the following hazards of hot work on pipelines that are isolated using twin tyred hydro plugs TTH plugs Potential release of flammable or toxic material due to failure of plug seal due to internal conditions of pipeline Release of flammable or toxic material due to build up of pressure inside the pipeline Errors of the work party will have serious consequences Work party may not be familiar with the equipment 1 2 A job specific Method Statement must be prepared that covers the minimum requirements of this Standard Control Sheet 1 3 A Safety Certificate and Fire Permit must be obtained that cover the minimum requirements of this Standard Control Sheet before a Clearance Certificate can be issued for this activity 1 4 If it is not possible to comply with this Standard Control Sheet the method of work must be approved by a Fire Permit Signatory FPS 1 5 The use of sewer plugs balloons or pipe freeze plugs is considered as non standard methods Guidance on isolation can be found in the CSPC Safety Regulations Section 02 2 Risk Assessment Checklist 2 1 Use of TTH plugs must only be considered when conventional methods such as positive isolation and gas freeing are not practicable 2 2 The Authorised Engineer AE and Authorised Safety Inspector ASI must ensure the Method Statement covers TTH plug specification which must be selected from an Approved list of Manufacturers Location of the plug Method of use of the plug which must be in accordance with the manufacturer s recommendations Requirements for isolation purging and gas freeing before the hot work is started Gas testing requirements 3 Installation of the TTH plug 3 1 The AE must ensure that the pipeline mechanical condition is acceptable for the proposed TTH plug with regard to ovality and loss of thickness 3 2 The ASI must select the position for the TTH plug and ensure that the pipeline has been thoroughly cleaned and or de scaled in the area of the proposed hot work and as far into the line as possible 3 3 The AE must ensure that there is adequate bonding between pipe and TTH plug and organise testing by a Authorised Electrical Person in order to avoid the potential of a spark occurring on the upstream side of the TTH plug 4 Carrying out Hot Work 4 1 There must be a pre job discussion involving the Work Party its Supervisor the ASI the AE and the AGT During the discussion the following issues will be addressed as a minimum TTH plug manufacturer s instructions for operation including tyre pressure and water fill between the tyres Monitoring of pressure gauges and vents Gas testing requirements during the work including frequency location and who is responsible 4 2 There must be adequate access to and escape from the work area in case of emergencies 4 3 There must be a standby person who is an AGT He must be in radio contact with the Control Centre 4 4 The work party and others working in the immediate vicinity must wear flame retardant clothes and flame retardant hood 4 5 If the pipeline may have contained toxic material all people in the vicinity must carry escape sets CSPC Standard Control Sheets 标准控制单标准控制单 Ver 版本 08 Page 14 of 90 SCS1 2在采用双气垫液压塞隔离的管线上进行动火作业在采用双气垫液压塞隔离的管线上进行动火作业CSPC 作业许可证制度作业许可证制度 本标准控制单必须与签发给申请人的安全作业单附在一起使用本标准控制单必须与签发给申请人的安全作业单附在一起使用 1 1 本标准控制单涵盖下列在采用双气垫液压塞 TTH塞 隔离的管线上进行动火作业时存在的危险 由于管线内部条件引起塞封失去作用而导致易燃或有毒物质泄漏的可能性 由于管线内部压力积聚引起的易燃或有毒物质泄漏 作业方的错误将导致严重后果 作业方对设备不熟悉 1 2 必须编制涵盖本标准控制单之最低要求的 针对具体作业的施工方案 1 3 在签发本项工作的作业许可单之前 必须办领其中满足本标准控制单之最低要求的安全作业单和动火单动火单 1 4 如果无法遵守本标准控制单之要求 作业施工方案必须经动火单签署人 FPS 批准 1 5 采用污水管管塞 气囊或管道防冻塞均视为非标准方法非标准方法 有关本项作业的隔离指南 参见CSPC安全规定 第二部分 2 风险评估检查表风险评估检查表 2 1 只有在常规方法 诸如绝对隔离和清除有害气体等方法不可行时 才可考虑使用TTH塞 双气垫液压 塞 2 2 授权工程师 AE 和授权安全检查员 ASI 必须保证施工方案包括如下内容 TTH 塞规格 必须从经批准的制造厂商清单中选择 填塞的位置 TTH 塞的使用方法 必须按照制造厂商的推荐方法 开始动火作业之前的隔离 吹扫和清除有害气体 气体检测要求 3 TTH塞的安装塞的安装 3 1 AE必须保证管线的机械条件满足建议的TTH塞在椭圆度和厚度方面的要求 3 2 ASI必须选择TTH塞的安装位置并保证拟进行动火作业的管线部位已经经过彻底清洁和 或除垢 尽可能深 入管线内部 3 3 AE必须保证在管线与TTH塞之间充分接触并由称职的电气人员组织进行检测 以消除在TTH塞的上游一 侧产生火花的可能性 4 进行动火作业进行动火作业 4 1 作业开始之前 必须在涉及到的作业方 作业方的监督人员 ASI AE和AGT之间展开讨论 在此讨论过 程中 至少要澄清如下几个问题 TTH 塞制造厂商关于操作 包括气垫压力和气垫之间的充水问题 的说明 对压力表和排放的监测 作业过程中的气体检测要求 包括频率 位置等 以及谁来负责的问题 4 2 必须有适当的进入作业区的通道和在紧急情况下撤离的通道 4 3 必须有一名授权气体检测员 AGT 现场待命 他必须通过对讲机与控制中心联系 4 4 作业人员以及在紧邻作业区工作的其他人员均必须穿戴阻燃服装和阻燃头罩 4 5 如果管线中可能含有有毒材料 所有临近人员均必须配有救生装备 CSPC Standard Control Sheets 标准控制单标准控制单 Ver 版本 08 Page 15 of 90 SCS1 3Opening up large process lines containing flammable toxic asphyxiant or pyrophoric material where isolation cannot be verified CSPC PTW Regulations This Standard Control Sheet must be attached to the copy of the Safety Certificate issued to the Applicant 1 Scope 1 1 This Standard Control Sheet covers the opening of systems containing flammable flash point 65oC toxic asphyxiant or pyrophoric material where isolation valves have been proven to be passing OR the opening diameter is greater than 8 and the only means of proving the isolation valve integrity is by gapping a flange for systems of 8 or less Standard Control Sheet 2 1 can be used Where isolation valve integrity can be verified by via a vent valve Standard Control Sheet 2 1 is applicable regardless of system size Flare gas and fuel gas systems must always be treated as toxic first and foremost 1 2 This Standard Control Sheet covers the following hazards of opening these systems Potential release of flammable toxic asphyxiant or pyrophoric material due to failure of isolation Decisions made by the person confirming isolation are critical to the safety of the work party Competence in use of breathing apparatus BA is essential 1 3 A job specific Method Statement must be prepared that covers the minimum requirements of this Standard Control Sheet 1 4 A Safety Certificate and Fire Permit signed by Fire Permit Signatory must be obtained that cover the minimum requirements of this Standard Control Sheet before a Clearance Certificate can be issued for this activity 1 5 The concentration of toxic materials defined as Immediately Dangerous to Life and Health IDHL are recorded in the respective MSDS For Hydrogen Sulphide H2S the IDLH is 1000ppm volume 2 Risk Assessment Checklist 2 1 All other reasonably practical alternatives to opening up a system containing hazardous materials without confirmed isolation must have been considered 2 2 The ASI and Maintenance Supervision must prepare a job specific Method Statement covering The hazardous nature of the materials inside the system to be opened The method of isolation and hazard freeing to be used The method of testing to be used to confirm isolation Required engineering preparations including replacing bolts on flanges before opening Tool selection is critical with regard to spark production Personal Protective Equipment PPE requirements Location of standby personnel whilst the work is ongoing Method of communications to be maintained during the work Access and escape routes to the work site Two independent routes must be provided Level of Supervision during the work Any hold points in the work where Supervision have to be informed Containment of spills and fire mitigation 2 3 Potential exposure to hazardous substances must comply with the requirements of MSDS CSPC Standard Control Sheets 标准控制单标准控制单 Ver 版本 08 Page 16 of 90 3 Opening a System containing flammable toxic asphyxiant and or pyrophoric material where isolation valves have been proven to be passing OR where the integrity of isolation valves cannot be confirmed except by gapping flanges above 8 diameter Live Line Working 3 1 The ASI must prepare a Method Statement to take account of the hazard freeing problems The Method Statement must also include plans for rescue mitigation against fire and plans for loss of containment 3 2 The Method Statement must include a de bolting strategy as devised by the Authorised Engineer such that percussive tools that can produce sparks are not used at the point of breach 3 3 The Method Statement must be approved by the Fire Permit Signatory 3 4 A method of containment must be established large enough to accommodate possible spillage 3 5 A method of removing spillage must be determined 3 6 A method of mitigating against fire must be agreed with the CSPC Fire Brigade taking into account the quantity of flammable material that may be released This may require CSPC Fire Brigade to stand by For toxic or asphyxiant systems the following additional controls apply 3 8 Immediately before starting work the ASI must hold a pre job discussion with a competent person from the CSPC Fire Brigade and the work party to ensure everyone involved understands fully the method of work the hazards that may be encountered and the steps required to recover from problems encountered whilst performing the work 3 9 If the work involves connections into the CSPC Site Flare Main the ASI must inform the Flare System guardians LOP Unit 3 10 The ASI must ensure that an exclusion zone has been set up to prevent inadvertent access to the area liable to be affected by the toxic material The size of the exclusion zone must be based on material concentration size of opening and weather conditions 3 11Every person entering the exclusion zone must wear Breathing Apparatus BA They must have attended the BA course and have up to date authorisation from the CSPC Fire Brigade They must not remove their BA until they have left the exclusion zone 3 12 The ASI must start off the work 3 13 The ASI must standby or nominate an AGT to standby throughout the period when the line is open 3 14 A competent person must standby throughout the work to ensure adequate supply of breathing air 3 15The exclusion zone cannot be removed until the ASI or nominated AGT has confirmed that all flanges which had been disturbed before are gas tight and the area is confirmed to be gas free CSPC Standard Control Sheets 标准控制单标准控制单 Ver 版本 08 Page 17 of 90 SCS1 3打开其中含有易燃 有毒 窒息性或自燃物质的打开其中含有易燃 有毒 窒息性或自燃物质的 大规格工艺管线 而且隔离可靠性无法证实大规格工艺管线 而且隔离可靠性无法证实 CSPC 作业许可证制度作业许可证制度 本标准控制单必须与签发给申请人的安全作业单附在一起使用本标准控制单必须与签发给申请人的安全作业单附在一起使用 1 范围范围 1 1 本标准控制单涵盖在下述情况下打开含有易燃 闪点 65oC 有毒 窒息性或自燃物质的系统 已经确认隔离阀内漏 或 打开直径大于 8 的管线 并且只能通过法兰开缝核实隔离阀的可靠性 对于核实隔离阀的可靠性 对于 8 及小于 8 的系统 可采用标准控制单 2 1 对于隔离阀可靠性可以通过排放阀来证实的系统 无论系统尺寸大小 均采用标准控制单2 1 火炬气和燃料气系统必须作为有毒系统作为有毒系统 毒性是其最主要的特征 1 2 本标准控制单包括打开上述系统时的下列危险 由于隔离失败引起易燃 有毒 窒息性或自燃物质泄漏的可能性 确认隔离的人员作出的决定对作业方的安全至关重要 使用自给式呼吸装置 BA 的能力很重要 1 3 必须编制包括本标准控制单之最低要求的 针对具体作业的作业施工方案 1 4 在签发本项工作的作业许可单之前 必须办领其中包括本标准控制单之最低要求的经动火单签署人签署 的安全作业单和动火单 1 5 有毒物质的 直接危害生命和健康 IDLH 浓度记录在物质安全数据表 MSDS 中 硫化氢的IDLH是 1000ppm 体积比 2 风险评估检查表风险评估检查表 2 1 对其它所有合理可行的 不需要在无法确认隔离的情况下打开含有有害物质的系统的备选方案均必须加 以考虑 2 2 ASI和维修监督人员必须编制针对具体作业的作业施工方案 其中包括如下内容 待打开系统中所含物料的危险特征 待采用的隔离方法和消除危害的方法 用于确认隔离的检测方法 所需工程准备 包括打开之前更换法兰上的螺栓 所选择的工具是否会产生火星 这一点很重要 个人防护用品 PPE 要求 进行作业时看护人员的位置 进行作业时保持通讯的方法 作业现场的进出和逃生路线 必须提供两条独立的路线 进行作业时监督的程度和要求 必须通知监督人员的作业的任何 保留点 未确定因素 泄漏的收集方案 灭火计划 2 3 在可能接触有害物质的情况下 必须遵守MSDS的要求 3 在下述情况下在下述情况下打开含有易燃 闪点 65oC 有毒 窒息性或自燃物质的系统 也称作 在线作业 已经确认隔离阀内漏 或 打开直径大于8 的管线 并且只能通过法兰开缝核实隔离阀的可靠性核实隔离阀的可靠性 3 1 ASI 必须就如何排除危害制定作业施工方案 该方案方案必须包含救援计划 灭火方案和和泄漏时的收集计划 CSPC Standard Control Sheets 标准控制单标准控制单 Ver 版本 08 Page 18 of 90 3 2 该作业施工方案必须包含由AE制定的拆卸螺栓的策略 包括在法兰打开口不可以使用产生火星的敲击工 具 3 3 施工方案必须经动火单签署人动火单签署人批准 3 4 必须建立收集方案收集方案 收集设施必须能够充分应付可能发生的泄漏 3 5 必须确定移走泄漏物的方法 3 6 必须同CSPC消防队商定灭火方案 其中应考虑到可能泄漏的易燃物数量 这也许要求CSPC消防队待 命 打开其中含有有毒 窒息性物质的系统 要采用以下附加控制 打开其中含有有毒 窒息性物质的系统 要采用以下附加控制 3 8 ASI 必须在开始作业之前与CSPC消防队的一名合格人员会同作业方召开一次作业前的讨论会作业前的讨论会 旨在确保 每一名与作业相关的人员均充分理解作业施工方案和可能遭遇到的危险 3 9 如果作业涉及到CSPC主火炬火炬 ASI 必须通知火炬系统管理者 LOP装置 3 10 ASI 必须确保根据物料浓度 设备 管线 开口大小和气候条件已经建立了一个隔离区 以防止他人无 意中进入将受到有毒物质影响的区域 3 11 进入隔离区的每个人均必须佩带自给式呼吸装置 BA 他们必须参加过BA培训并从CSPC消防队办领 有效授权 他们在离开隔离区之前一定不得取掉BA 3 12 ASI 必须在作业现场发出开始工作指令 3 13 在管线打开过程中 ASI 必须必须一直在作业现场或指定一名AGT现场待命在场 3 14 在整个作业期间 一名合格人员必须在场保证充足的呼吸空气供应 3 15 在ASI 或其指定的AGT确认所有 以前动过的 法兰均达到气密程度且作业区域无有害气体之前 不得 拆除隔离区 CSPC Standard Control Sheets 标准控制单标准控制单 Ver 版本 08 Page 19 of 90 SCS1 4High Pressure Water Jetting outside permanent cleaning bays 150 to 2500 Barg pressure 2250 psig to 37500 psig CSPC PTW Regulations This Standard Control Sheet must be attached to the copy of the Safety Certificate issued to the Applicant 1 Scope 1 1 This Standard Control Sheet covers the following hazards in the cleaning of equipment using High Pressure Water Jetting by approved Contractors Potential for water jet and flying debris to cause physical injury Formation of mist or spray containing hazardous materials removed from the equipment being cleaned Difficult communication because of the noise from the equipment and hearing impairment from PPE Potential for static electricity acting as an ignition source 1 2 A Method Statement and Risk Assessment must be prepared that cover the minimum requirements of this Standard Control Sheet and must be accepted and signed by the Authorised Engineer AE who has a good understanding of High Pressure Water Jetting operations 1 3 A Safety Certificate must be obtained that covers the minimum requirements of this Standard Control Sheet 1 4 High Pressure Water jetting inside permanent cleaning bays is