Latest Basis: Detailed Version of Major Production Safety Accident Hazard Determination Standards

1. The chairman and general manager have not obtained the safety training assessment certificate after 6 months in office, judged as a major hazard.

2. Personnel in the enterprise safety management appointment documents have not obtained the safety training assessment certificate after 6 months in office, judged as a major hazard.

3. The main person in charge and safety management personnel have participated in training within 6 months of taking office but have not yet obtained the certificate; if they have obtained a certificate of passing the training assessment from the training institution, it is not judged as a major hazard. If the proof only shows participation in training without clearly indicating passing the assessment, it is judged as a major hazard.

4. The main person in charge and safety management personnel have obtained the training qualification certificate but have not participated in annual retraining and passed the assessment, judged as a major hazard; if the local government does not require annual retraining, it is not judged as a major hazard.

II. Special operation personnel are not certified to work.             

1. According to Order No. 30, enterprises should obtain but have not obtained special operation personnel operation certificates, judged as a major hazard. It should be noted that chemical automation control instrument installation, maintenance, and repair personnel whose certification has expired and not reviewed are considered uncertified.

2. Special operation personnel who have participated in training and obtained a certificate of passing the training assessment from the training institution are not judged as a major hazard.

3. If the local safety supervision department has not carried out relevant training and certification work, it is not judged as a major hazard.

III. The external safety protection distance of production units and storage facilities involving "two key points and one major" does not meet national standard requirements.

1. The external safety protection distance of production units and storage facilities involving "two key points and one major" that does not meet the external protection distance in the personal acceptable risk and social acceptable risk assessment report is judged as a major hazard. If no personal acceptable risk and social acceptable risk assessment has been conducted, it is raised as an issue but not judged as a major hazard.

2. The production units and storage facilities involving "two key points and one major" that do not meet the external fire protection distance requirements of standards such as "Petrochemical Enterprise Fire Protection Design Code" (GB50160-2008) and "Building Design Fire Protection Code" (GB50016-2014) are judged as a major hazard.

IV. Devices involving key regulated hazardous chemical processes have not achieved automated control; the system has not realized emergency shutdown functions; the equipped automated control system and emergency shutdown system have not been put into use.

1. Devices involving key regulated hazardous chemical processes have not achieved automated control and the system has not realized emergency shutdown functions, judged as a major hazard.

2. The equipped automated control system and emergency shutdown system have not been put into use; on-site control valves and emergency shut-off valves have not been put into operation or bypass valves are open; related interlocks have been disabled for a long time (more than 1 month, except during major equipment overhauls and special reasons), judged as a major hazard.

3. Devices involving key regulated hazardous chemical processes have not achieved automated control and the system has not realized emergency shutdown functions but are undergoing automation transformation, not judged as a major hazard.

V. Hazardous chemical tank areas constituting level one and level two major hazard sources have not realized emergency

shut-off functions; hazardous chemical tank areas constituting level one and level two major hazard sources involving toxic gases, liquefied gases, and highly toxic liquids have not been equipped with independent safety instrumented systems.

1. Hazardous chemical tank areas constituting level one and level two major hazard sources must have emergency shut-off valves installed at the inlet and outlet of each storage tank; otherwise, it is judged as a major hazard.

2. Hazardous chemical tank areas constituting level one and level two major hazard sources have a main emergency shut-off valve on the main inlet and outlet pipeline of the tank area, but individual storage tanks are not equipped with separate valves, judged as a major hazard.

3. Hazardous chemical tank areas constituting level one and level two major hazard sources have emergency switching methods set between different storage tanks of the same purpose to prevent consequences such as over-liquid level and overpressure, not judged as a major hazard.

4. Hazardous chemical tank areas constituting level one and level two major hazard sources have storage tanks without emergency shut-off functions, but the enterprise has conducted HAZOP analysis and SIL assessment, and the results meet safety requirements, so it may not be judged as a major hazard.

5. Hazardous chemical tank areas constituting level one and level two major hazard sources involving toxic gases, liquefied gases, and highly toxic liquids are not equipped with independent safety instrumented systems, judged as a major hazard.

VI. Full-pressure liquefied hydrocarbon storage tanks have not set water injection measures according to national standards.

1. Spherical storage tanks of propylene, propane, mixed C4, raffinate C4, and liquefied petroleum gas without water injection facilities are judged as a major hazard. (Water injection facilities are mainly required for normal temperature full-pressure liquefied hydrocarbon storage tanks; semi-refrigerated pressure liquefied hydrocarbon storage tanks (such as ethylene) and some water-reactive liquefied hydrocarbons (such as chloromethane) may not require water injection measures. Dimethyl ether storage tanks may not require water injection measures.)

2. Water injection measures for storage tanks without remote control valves with manual function are judged as a major hazard.

3. Water injection measures for storage tanks cannot ensure sufficient water source and injection pressure, judged as a major hazard.

4. Horizontal full-pressure storage tanks without water injection facilities are not judged as a major hazard.

VII. Filling of flammable, explosive, toxic, and harmful liquefied gases such as liquefied hydrocarbons, liquid ammonia, and liquid chlorine does not use a universal pipeline filling system.

VIII. Pipelines of highly toxic gases such as phosgene, chlorine, and hydrogen sulfide pass through public areas outside the plant area (including chemical parks and industrial parks).

IX. Regional overhead power lines (35KV and above) pass through production areas and do not meet national standard requirements.

X. In-service chemical devices have not been formally designed and have not undergone safety design diagnosis.

1. In-service chemical devices that have not been formally designed and have not undergone safety design diagnosis are judged as a major hazard.

2. Units conducting safety design diagnosis of in-service chemical devices lack corresponding qualifications and relevant design experience, judged as a major hazard.

Eleven Use processes and equipment listed in the catalog of outdated and eliminated safety technologies and equipment.

12. Places involving leakage of flammable and toxic harmful gases have not installed detection and alarm devices according to national standards, and explosion hazard areas have not installed and used explosion-proof electrical equipment according to national standards.

1. According to GB/T 50493, major emission sources in enterprises that may leak flammable and toxic harmful gases have not set detection alarms, which is determined as a major hazard.

2. The types of flammable and toxic harmful gas detection alarms set by the enterprise are incorrect (such as wrong detection targets, wrong flammable or toxic types, etc.), regarded as not set, and determined as a major hazard.

3. The main emission sources in the enterprise that may leak flammable and toxic harmful gases have set detection alarms, but the alarms are not in normal working condition (faulty, not powered, data seriously deviated, etc.), which is determined as a major hazard.

4. The following situations are not determined as major hazards:

1) Flammable and toxic harmful gas detection alarms lack audible and visual alarm devices;

2) Alarm signals from flammable and toxic harmful gas detection alarms are not sent to a 24-hour manned duty room or control room;

3) Installation height of flammable and toxic harmful gas detection alarms does not meet specification requirements;

4) Alarm value numbers, grading, etc., of flammable and toxic harmful gas detection alarms do not meet requirements;

5) Alarm information of flammable and toxic harmful gas detection alarms is not continuously recorded;

6) Flammable and toxic harmful gas detection alarms are temporarily removed due to calibration, and the enterprise has formulated corresponding safety control measures;

7) Flammable and toxic harmful gas detection alarms are not regularly calibrated, but no obvious problems with the alarms are found.

5. Using non-explosion-proof electrical equipment in explosion hazard areas is determined as a major hazard.

6. Explosion-proof electrical equipment used in explosion hazard areas with explosion-proof levels not meeting requirements is determined as a major hazard.

7. Temporary loss of explosion-proof function of explosion-proof electrical equipment in explosion hazard areas due to missing bolts, missing seals, etc., is not determined as a major hazard.

13. Control rooms or cabinet rooms facing devices with fire and explosion hazards do not meet national standards for fire and explosion prevention.

1. Control rooms or cabinet rooms located within explosion hazard zones or with fire separation distances not meeting requirements are determined as major hazards.

2. Control rooms or cabinet rooms facing the side with fire and explosion hazard devices (with no other buildings between; including oblique directions, e.g., control room windows facing due south but fire and explosion hazard devices on the southwest side; distance to devices is not considered) have doors or window openings on the outer wall; or have no doors or window openings but the wall is not a non-combustible solid wall with a fire resistance limit of not less than 3 hours, which is determined as a major hazard.

14. Chemical production units have not set dual power supplies according to national standards, and automation control systems have not set uninterruptible power supplies.

1. Enterprises have not set dual power supplies for primary loads, which is determined as a major hazard.

2. DCS and other automation systems have not set uninterruptible power supplies (UPS), which is determined as a major hazard.

15. Safety accessories such as safety valves and rupture discs are not properly put into use.

1. Manual shut-off valves upstream and downstream of safety valves and rupture discs are closed, which is determined as a major hazard.

2. Manual shut-off valves upstream and downstream of safety valves and rupture discs are open but not sealed with lead seals, which is not determined as a major hazard.

3. Safety valve lead seals are damaged or calibration labels are missing, but valid calibration reports can be provided, which is not determined as a major hazard.

4. Rupture discs are not replaced regularly, which is not determined as a major hazard.

16. No establishment of a full-staff safety production responsibility system matching the posts or no formulation and implementation of production safety accident hazard investigation and management system.

1. No formulation of safety production responsibility system, which is determined as a major hazard.

2. The safety production responsibility system lacks safety responsibilities of the main person in charge of the enterprise, management, safety management organization or personnel, and key units related to production (safety, production technology, equipment, production workshop, etc.), which is determined as a major hazard. Lack of safety responsibilities of other units is not determined as a major hazard.

3. The safety responsibilities of the main person in charge and safety management organization or personnel have 1 to 2 items not meeting the requirements of the "Work Safety Law", and the safety responsibilities of other related units or personnel are incomplete or inconsistent with their administrative duties, which is not determined as a major hazard.

4. No formulation of production safety accident hazard investigation and management system, which is determined as a major hazard.

5. No implementation of hazard investigation and management work, which is determined as a major hazard.

6. The content of the production safety accident hazard investigation and management system is incomplete, or there are problems in hazard investigation and management work, which is not determined as a major hazard.

17. No formulation of operating procedures and process control indicators.

1. The enterprise has not formulated operating procedures, or the operating procedures are very vague, which is determined as a major hazard.

2. The enterprise has not clarified process control indicators, or the process control indicators seriously do not meet actual work, which is determined as a major hazard.

3. Data and process indicators in operating procedures, process cards, and post operation records are seriously inconsistent or have large deviations, which is determined as a major hazard.

4. The enterprise has formulated operating procedures and process control indicators but has not distributed them to grassroots posts, and grassroots employees are unclear about the content of operating procedures and process control indicators, which is determined as a major hazard.

5. The enterprise has not timely revised operating procedures and process cards after major changes, which is determined as a major hazard; failure to timely revise operating procedures and process cards after general changes is not determined as a major hazard.

6. If the enterprise has not formulated an operation procedure management system and has not prepared process cards (but has clarified process control indicators), it is not determined as a major hazard.

18. Failure to formulate special operation management systems such as hot work and confined space entry according to national standards, or failure to effectively implement the systems.

1. Failure to prepare special operation management systems is determined as a major hazard.

2. Conducting special operations without obtaining work permits is determined as a major hazard.

3. Conducting hot work (in flammable and explosive areas) or confined space entry operations without performing work analysis or hazard identification is determined as a major hazard.

4. Serious lack of safety control measures at special operation sites is determined as a major hazard.

5. Errors in special operation approval procedures (such as approving hot work before conducting hot work analysis; not referring to errors in related time entries) or falsification are determined as major hazards.

6. Incomplete content of special operation management systems, incomplete work permit content, or non-standard filling of work permits are not determined as major hazards.

19. Newly developed hazardous chemical production processes directly proceed to industrial production without pilot, pilot-scale, or industrial-scale tests; chemical processes used for the first time domestically have not undergone safety and reliability demonstration organized by relevant provincial government departments; new facilities have not formulated trial production plans for feeding and start-up; fine chemical enterprises have not conducted reaction safety risk assessments according to normative documents.

20. Failure to store hazardous chemicals according to national standards for zoning and classification; storing hazardous chemicals in excess quantity or variety; mixing incompatible substances together.