How to implement the "Four Clearances" of the fine chemical enterprise rectification task

The rectification tasks of fine chemical enterprises are "four clearings", namely: "clearing" the response safety risk assessment, "clearing" the automation control equipment transformation, "clearing" the educational qualifications of employees who do not meet the standards, "clearing" the relocation and transformation of densely populated places.
Zero" is one of the tasks of the three-year campaign for the safety rectification of hazardous chemicals, one of the tasks of centralized management of the safety risks of hazardous chemicals across the country, and one of the important tasks of the special rectification for the transfer of the hazardous chemicals industry
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So, how to implement the "four clearings" for the rectification task of fine chemical enterprises? The author believes that the first is to correctly understand the meaning of "four clears"; the second is to achieve dynamic clearing
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Dynamic clearing is the biggest difficulty, and it is also close to 100% when statistics companies clear data in many regions, but every time they check again, they can find the reason for not clearing
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Changes such as process optimization, device transformation, and personnel adjustment in the production process of the enterprise.
If the change management is not strictly implemented or the supporting upgrade is not timely, the clearing task achieved in the early stage will be in vain
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Next, the author would like to elaborate on the specific circumstances of the "four clearings"
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First, for the "zeroing" of reaction safety risk assessment, the emphasis is on the batch and semi-batch reactions involving key regulatory hazardous chemical processes and metal organic compound synthesis reactions (including Grignard reactions) in fine chemical enterprises
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In one of the following situations, a reaction safety risk assessment shall be carried out: a new process used for the first time in China, a new formula that has been put into industrial production, or a new process introduced abroad for the first time without a reaction safety risk assessment; existing process routes, Process parameters or device capabilities have been changed, and there is no response safety risk assessment report; production safety accidents have occurred due to reaction process problems
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It is particularly important to emphasize that, through the risk assessment of the reaction, the risk of the reaction process should be determined, the design of safety facilities should be improved, and risk control measures should be improved
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Among them, the application of reaction safety risk assessment results is the core
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In order to achieve the dynamic clearing of reaction safety risk assessment, it must be recognized that when the enterprise optimizes the process or changes the raw materials and auxiliary materials, because the process control conditions, raw materials or auxiliary materials have changed at this time, the enterprise must start the reaction safety again.
risk assessment
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When an accident occurs in the operation of a similar process in the industry, the enterprise should analyze the root cause of the accident, and evaluate whether the risk of the existing process conditions is acceptable through reaction safety risk assessment or material thermal stability test for the exposed process problems
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Second, the "clearing" of automation control equipment transformation contains two meanings, one is that the automation control system equipment (setup/construction) rate is 100%, and the second is that the automation system equipment commissioning/utilization rate reaches 100%
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Among them, the commissioning/utilization rate of automation system equipment reaches 100%, which is the key to whether the "four clearing" can be completed
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This requires that the control system set according to the design scheme can be put into use normally, such as various control interlocks can be put into use normally, the alarm values ​​and interlock values ​​of the control parameters are set reasonably and can play a role, and the interlock logic relationship in the control system The settings are reasonable
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The main reasons for the difficulty of dynamic clearing in the transformation of the automation control system are as follows
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First, the transformation and upgrading plan of the automation control system is unreasonable, and the supporting process has not been optimized and transformed
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Second, after the control system is reformed, the operators are not suitable, especially the old employees who have been in these positions for a long time.
They are accustomed to manual operation on site and cannot control the DCS, and it is difficult for the enterprise to recruit operators who meet the requirements.
Lock removal
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Third, when the control system fails or the interlock needs to be removed due to special working conditions, no approval procedures are carried out, and there is no corresponding plan even if the approval is carried out
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Fourth, many fine chemical enterprises are small in scale, and it is difficult to equip automatic instrument technicians to meet the requirements.
They can only rely on social forces or technical personnel from suppliers, and it is difficult to solve abnormal working conditions that may occur at any time in the production process
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Fifth, the transformation and improvement of the automatic control system of hazardous chemical enterprises has been concentrated in recent years, and the technical talents of instrument automation in the whole society cannot meet the needs seriously, and the training of talents is difficult to "synchronize"
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Third, the relocation and transformation of densely populated places will be "cleared", which involves the control room, shift shift, office, restroom, external exercise room, and inspection room
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Among them, there are many discussions on the Internet about "whether the control room in the installation area must be moved out" and "reinforcement after anti-explosion assessment"
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The author believes that the control room is the safest place for people to gather in the production area.
What needs to be considered is that when the production device has a potential explosion of maximum power, or a serious gas leakage occurs in the device, and the gas diffusion reaches the maximum distance and then an explosion occurs, the control room should be controlled.
The chamber can withstand the maximum shock wave without being destroyed
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Uncertain factors such as how far the gas diffuses and where the ignition source is, determine the risk uncertainties of the non-explosion-resistant structure control room
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Therefore, under the premise of meeting the requirements of fire separation distance, the control room with anti-explosion structure is the first choice for the relocation and transformation of the control room
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Fourth, for the “clearing” of employees’ academic qualifications, enterprises should not only carry out safety skills improvement training for on-the-job employees in accordance with the implementation of the action plan for safety skills improvement in high-risk industries; to boost
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However, at present, some companies are slow to act and do not pay enough attention to this requirement, and there are still problems such as lax checks on new employees and personnel transfer, resulting in the phenomenon that the clearing does not meet the standard
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All in all, the rectification task of fine chemical enterprises "four zeros" is a long-term and arduous task, which requires long-term efforts and the joint efforts of the whole society
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First, the enterprise should implement the main responsibility of the "four zeros" for the rectification task of fine chemical enterprises, and take the "four zeros" as the starting point to improve the intrinsic safety level of production equipment, improve the quality of employees, and minimize the consequences of accidents
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Second, governments at all levels should strengthen supervision and, in accordance with the arrangements of the emergency management department, organize and carry out the "four clearing" of the fine chemical enterprise rectification task to look back and promote the safe development of the fine chemical industry in the region
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The third is that third-party institutions must be self-disciplined.
The completion of various tasks such as response security risk assessment, automation control system transformation, personnel-intensive place transformation, and employee education improvement all require the active investment and promotion of third-party institutions.
Therefore, third-party institutions must adhere to the The red line and bottom line of safe production
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The fourth is to strengthen the training of talents, especially the training of instrument automation technical talents.
It is necessary to make full use of the work-related accident prevention ability of hazardous chemical enterprises to improve the training project plan and improve the professional quality of employees
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(Author: Cheng Changjin, Chief Engineer of China Chemical Safety Association)