The Regulation of Hazardous Operation Approval Procedure and Safety Management.doc

Management System DocumentsSAF-008-PRThe Regulation of Hazardous Operation Approval Procedure and Safety ManagementRevision Status： 2.0Distribution No.：Control Flags：Establishment： Reviewer： Approved By： 2009-08-25 Issued 2009-08-25 Implemented The Regulation of Hazardous Operation Approval Procedure and Safety ManagementDocument Change ListNo.PageModified DateImplemented DateClauseAbstractsModifierReviewerApproved By文件编号： SAF-008-PR 修订状态：2.0 修订日期：2009/08/25 页码：1 / 11. PurposeIn order to enhance the management of hazardous operation, avoid happing accidents, protect people in safety, we formulated this regulation.2. Scope2.1 This regulation ruled all hazardous operations (including hot work, operation in equipment, High Altitude Operation and so on) approving, requirements & managements of safety.2.2 This regulation is applicable to all hazardous operations.3. Reference3.1 Fire Prevention Law of the Peoples Republic of China (May 1, 2009, implemented).3.2 Safety Regulations of Lifting Operations in Chemical Production Unit (AQ3021-2008).3.3 Safety Regulations of Fire Operation in Chemical Production Unit (AQ3022-2008)3.4 Safety Regulations of Groundbreaking Operation in Chemical Production Unit (AQ3023-2008).3.5 Safety Regulations of Circuit Operation in Chemical Production Unit (AQ3024-2008).3.6 Safety Regulations of High Altitude Operation in Chemical Production Unit (AQ3025-2008).3.7 Safety Regulations of Blank off flange pumping Operation in Chemical Production Unit (AQ3027-2008).3.8 Safety Regulations of Restricted Space Operation in Chemical Production Unit (AQ3028-2008).4. Terms and definitions4.1 Primary Fire OperationIt means these work which are easy to cause human casualties accidents, dangerous for the operators, other people and / or facilities.4.2 Secondary Fire OperationIt means these people who involved in special work directly.4.3 Tertiary Fire Operation4.4 Restricted Space OperationDid4.5 Groundbreaking Operation4.6 High Altitude Operation4.7 Reference Surface distance from Falling4.8 High or Low Temperature Work at Height4.9 Work at Height with Electric4.10 Interrupt the Traffic Operation4.11 Lifting Operation4.12 Blank off flange pumping Operation5. Duties5.1 Safety Department is the competent authorities of this regulation. It is responsible for inspecting of hazardous operations, and stopping, doing fine any illegal operation.5.2 Safety department and Maintenance Center are responsible for informing all suppliers with requirements in this regulation. Otherwise, any operation is illegal.5.3 Each plant is responsible for inspecting and managing of hazardous operations in its own plant or area. It has the right to prevent any illegal operation.5.4 The department who applied for hazardous operation is also responsible for inspecting.6. Procedure6.1 Approval Procedure of Fire Operation6.1.1 The following operations in the area of potential fire or explosion, must obey the requirements of Fire Operation Management.a) Welding and Cutting;b) Blowtorch, Stove, LPG Stove, Electric Stove;c) Burning, Baking, Bending Pipe, or other operation which is easy to sparks;d) Temporary electricity, Un-explosion-proof electrical equipment;e) Automotive vehicle entrance to tanks area;f) Blasting Operation.6.1.2 The department who applied for hazardous operation must get permit.6.1.3 Grades of Fire Operation and AreasFire Operation includes three grades: Primary, Secondary and Tertiary.1) Primary Fire Operation Areas including Board Line (except wet part), Pulp Drier (except wet part), NCG System and Pipes, Chemical Plant, H2O2 Tanks, Turbine Oil Station and facilities, Heavy Oil Tanks (including pumps), Lubricating oil Warehouse, Chemical Warehouse, Chip Yard (including Conveyor), and other dangerous areas.2) Secondary Fire Operation Areas including Voltage Transformer House, Cable Interlayer, Power Distribution Room, O2 making and delivering facilities, light Oil Tanks, Recovery Boiler, Cooling Tower, Paper Cutter, Palletizer, Electric Generator, Coal Conveyor Belt, Coal Yard, Finished Goods Warehouse, Muti-productions Warehouse, and other areas.3) Tertiary Fire Operation Areas mean the areas that are not included in the primary and secondary areas.6.1.4 Qualification and Authority of Fire Operator1) Welding & Cutting Operators must be trained specially, and get the license;2) Fire Operators must obey the rules of fire operation: no permit, no guardian, no fire-proof measures, and no fire operation;3) Fire Operators have the right to refuse fire operation if who breaks the rule of fire operation.6.1.5 Qualification and Duty of Fire Operation Guardian1) Qualification of Fire Operation Guardian. The guardian of primary & secondary fire operation must be sent from fire operation application department. The guardian of tertiary fire operation could be sent from application department or operating department. The guardian must know production process and facilities well. High responsibility and ability are also being required. Knowing how to deal with emergency is the basic requirement.2) Duty of Fire Operation Guardian. After receiving the permit of fire operation, the guardian must check out fire-proof measures（including condition of site, preventive measures）with the guidance of safety engineer or head of unit. The guardian must wear a mark, and forbidden to leave during fire operation.3) Authority of Fire Operation Guardian. Guardian has the right to stop the fire operation when there are some illegal operations or operation not be accorded with the permit. If the operator refuses to obey the guardian order, the guardian has the right to cancel the permit, and report it to superior leaders.6.1.6 The fire operation approver must go to operation place and check out the fire-proof measures before approving the operation.6.1.7 Contractor must obey this rule with the guidance of our internal staff.6.18 Approval Procedure of Fire Operation6.1.9 Approval of Primary Fire OperationIt can be signed and issued by chief or technical chief of the application department. And it must be audited by safety department, and approved by the head of production department. After those procedures, it can be taken into practice.6.1.10 Approval of Secondary Fire OperationIt can be signed and issued by chief or technical chief of the application department. And it must be approved by safety department. After those procedures, it can be taken into practice.6.1.11 Approval of Tertiary Fire OperationIt can be signed and issued by chief of section chief operator of the application department. It must be approved by the head of application department. After those procedures, it can be taken into practice.6.1.12 Fire-proof measure of fire operation confirmed must obey following instructions. You should mark out of the measures with“” in the application form. 1-4 measures must be confirmed by safety technician of application department. 5-8 measures must be confirmed by operating unit. Other measures will be confirmed by different people according to the duty dividing.6.1.13 Valid period of fire operation permit. Valid period of primary fire operation permit is no more than 8 hours. Valid period of daily fire operation in secondary fire operation permit is no more than 12 hours. Valid period of secondary fire operation in annual overhaul is no more than 3 days. Valid period of tertiary fire operation is no more than 5 days.6.1.14 Gas Analysis before Fire Operationn Fire Operation on tanks, pipes, equipment, or other space with combustible or toxic medium, gas analysis is necessary.n Gas analysis of secondary and tertiary fire operations will be decided by approver depending on the actual needs. If gas analysis is not necessary, the column of “gas analysis” be filled with “/”.n In 1 hour before fire operation to do sampling analysis. The analysis result will be filled in the permit form,. The analysis report will be filed with permit stub. In 1 hours, if the fire operation didnt happen, reanalysis the gas.n Gas analysis standards: when the LEL of combustible gas is greater than or equal to 4%, analysis result which is less than or equal to 0.5% is qualified. If LEL is less than 4%, the result which is less than or equal to 0.2% will be qualified.6.1.15 Basic Principles of Fire Operation1) All of fire operations below the producing, storage, delivering combustible matters equipment, pipes, it should cut off the supply sources with Blank off flanges, then blowing, cleaning, opening the manhole, ventilation, and gas analyzing. 2) If its possible, the equipment should be removed to safe place firstly, the do fire operation. Primary fire operation is controlled strictly. 3) Combustible and toxic matters should be removed off the equipment and cut off with Blank off flanges during annul overhaul or medium maintenance.4) Fire operation in the internal of equipment, should get the permit of operation internal of equipment. Working in height also needs height working permit.5) If the condition has changed, the approved fire operation should be canceled and stopping operation.6) The permit form of fire operation is in quadruplicate. The 1st page will be kept by fire operator. The 2ed page will be kept by guardian. The 3rd page will be kept by approver. One page of primary & secondary fire operation permit should be kept in safety department.6.2 Approval Procedure and Management of Operation in Restricted Space6.2.1 Approval Procedure of Operation in Restricted SpacePlant or department is responsible for applying for permit of operating in restricted space. All permits should be approved by safety department.6.2.2 Requirements for Guardiann Guardian should know the environment, process and facilities well. The ability of dealing with emergency is necessary.n When operating and equipment belongs different department, each department should send a person to be guardian.n Before entrancing the equipment, the operation unit is responsible for checking out the safety preventive measures. It has the right to refuse operating if the measures are useless.n Guardian should know the number of operators who entrance to the equipment. Keeping contacting with operator. If happen emergency affairs, guardian should interrupt operation immediately. n Without safety measures, entrancing to equipment and rescuing are forbidden.6.2.3 Requirements for Operatorn Before operating, getting permit.n Actual information is no accord with permit, operating is forbidden.n No guardian, no operating.n No PPE, no operating.n No safety measures, no operating.n The number of people and continued working time should be controlled strictly.6.2.4 Requirements for Approval1) All operations should get permits in the way of permit form. No permit, no operating.2) The leader of operators applies for permit to plant which owns the equipment.3) The leader of plant fills the permit form, checks out preventive measures (marking the measures related to this operation with “”, 1-10 measures should be confirmed by plant, 11-16 measures should be confirmed by leader of operators. Other measures also should be confirmed if exist), organizes gas analysis, sets guardian, tells the details about safety to operators, signs in permit with gas analysis report.4) Getting approval from safety department.6.2.5 Gas Analysis before entering into the Restricted Space1) O2 content analysis.2) Combustibility and toxicity analysis when operating on related equipment.3) For equipment which are no combustible or toxic matters, you may no need to analysis the combustibility or toxicity. But you must make out this in the permit form.4) A representative sample is required. For huge equipment, you must sample from the top, middle and bottom of the equipment. Ensure the concentrations of the combustible gas and O2 are in safety range (when combustible gas LEL4%, target 0.5%. when LEL4%, target 0.2%. The O2 concentration between 19.5% and 23.5% is qualified). The concentration of hazardous matter in plant must be controlled and meets the state related regulation. The environment temperature of operation in equipment is in normal. During the period of operation, you must recheck every 4 hours. The samplers must be kept for 4 hours at least after getting the analysis results. Once one index of them is unqualified, operation must be intermitted. If the operation didnt happen in 1 hour you must reanalysis the gas.6.2.6 Valid period of restricted space operation permit: daily operation is no more than 1 day. Shut down operation is no more than 3 days. If operation is intermitted, reanalysis is need when reoperation. 6.2.7 Restricted space operation is forbidden to go with commissioning, pressure test, testing or other operations.6.2.8 Comprehensive Safety Measures of Operation in Restricted Space1) The training must be given to the guardian and operators, including safety knowledge, treatment method of emergency.2) All pipes must be closed with Blank off flanges. Cleaning the equipment is needed. All Blank off flanges must be marked and easy to be identified.3) The current of all motorized valves must be cut off and indentified. The gas source of air operated valves must be cut off too.4) Stopping rotating equipment, and then cut off the current with the signboard of “Maintenance is ongoing, forbid to open the power supply”. Guardian or taking off the fuse are also useful.5) Fire, lifting, and other hazardous operation must be in the extent of regulation permit.6) Before operating on polymer production equipment, polymer heating testing is necessary.7) Be sure of there is no blocks in the entrance and exit of the equipment.8) Under normal circumstances, delivery operator with winding engine or crane is forbidden. Under special circumstances, it must be approved by safety department.9) Safelight with safe voltage is needed in operation. If operation in metal or wet environment, the voltage of safelight is no more than 12 V, and with good insulation.10) All the operators, tools, materials must be registered. When finishing, operator has to check off them.11) Emergency rescue equipment and fire-fighting equipment are required for operation place.12) Emergency escape routs and methods must be made. To change operator or take a break while working for a long time.13) Forced ventilation is needed for operator breath and air flowing. But only O2 gas injection is forbidden strictly.14) Under special circumstances, wearing long tube mask, SCBA etc. are allowed. Guardian is necessary in this condition.15) If intoxication, asphyxia and other emergencies happen, rescue workers must wear isolated protective mask with entrancing the equipment. No less than 1 outside liaison is needed.16) All measures as above, If the condition has changed, operation should be terminated at once. When the condition meets the requirements, you can continue to operation. 6.2.9 Permit of Restricted Space1) The permit form of restricted space operation is in quadruplicate. The 1st page will be kept by operator. The 2ed page will be kept by guardian. The 3rd page will be kept in operation room. The 4th page will be kept by safety department.2) The permit is the license of entrance to equipment, couldnt be altered without permission. All the blanks no need to fill in will be mark with “/”.6.3 Approval Management of Groundbreaking Operation6.3.1 Safety Requirements of Groundbreaking Operation1) No groundbreaking operation permit, no groundbreaking.2) No safety training, technical telling, or guardian, no groundbreaking.3) The operating site needs to set fences, covers, and warning signs. Warning light is needed in light. After operation finished, roads and facilities need to be recovery.4) Operation is forbidden to exceed the content of permit. Otherwise, operation is illegal.5) The permit is the license groundbreaking operation, couldnt be altered without permission. To be lent is forbidden.6) If the cables, pipes, or other unknow objects are exposed during the guoundbreaking operation, the operation should be stopped at once. Protecting, reporting and waiting for the related department coming and getting approved. Then the operation can be continuted.7) When the operation is near to the hidden underground facilities, the groundbreaking should be done carefully. Operation with iron rod, pickmattock, or other mechanical machines is forbidden.8) When doing excavation of pits, tanks, wells, ditches and other operations, the following rules should be obeyed.a) The earth should be digged from the top to bottom. The earth digged should not be located in the sewer.b) When diging a nethermore pit, tank, well or ditche, climbling with a hole on the wall the them is forbidden. Wearing PPE during operation is necessary. Do not stand or walk on the edge of the pit.c) Safe slope or wall support should be set. The pile of earth is away from the edge of pit at least 0.8 meter. Height of earth pile is no more than 1.5 meters. After raining or thawing, examination of safe measures is necessary. If there is any problem, operation should be stopped until the perblem be solved.d) Paying a