Strengthen the safety risk assessment of fine chemical reaction

对备份数据和日志保留的期限政策,可得平衡考虑备查的便利以及防泄漏的成本,留存太久不仅成本高昂,而且泄露的风险也高,保存时间不够。
国家安全监管总局关于加强精细化工反应
State Administration of safety supervision on strengthening fine chemical reaction
安全风险评估工作的指导意见
Guiding opinions on safety risk assessment
安监总管三〔2017〕1号
Safety 2017 No. 1 duct three
各省、自治区、直辖市及新疆生产建设兵团安全生产监督管理局,有关中央企业:

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The safe production supervision and administration bureaus of all provinces, autonomous regions, municipalities directly under the central government and the Xinjiang production and construction corps:
为加强精细化工企业(以下简称企业)安全生产管理,进一步落实企业安全生产主体责任,强化安全风险辨识和管控,提升本质安全水平,提高企业安全生产保障能力,有效防范事故,现就加强精细化工反应安全风险评估工作提出如下指导意见:
In order to strengthen the fine chemical enterprises (hereinafter referred to as enterprises) production safety management, to further implement the safety responsibility, strengthen the safety risk identification and control, enhance the essential safety level, improve the safety protection ability of the enterprise, effective prevention of accidents, we hereby put forward the following guiding opinions on strengthening the security risk assessment of fine chemical reaction:
一、充分认识开展精细化工反应安全风险评估的意义
First, fully understand the significance of carrying out safety risk assessment of fine chemical reaction
精细化工生产中反应失控是发生事故的重要原因,开展精细化工反应安全风险评估、确定风险等级并采取有效管控措施,对于保障企业安全生产意义重大。开展反应安全风险评估也是企业获取安全生产信息,实施化工过程安全管理的基础工作,加强企业安全生产管理的必然要求。当前精细化工生产多以间歇和半间歇操作为主,工艺复杂多变,自动化控制水平低,现场操作人员多,部分企业对反应安全风险认识不足,对工艺控制要点不掌握或认识不科学,容易因反应失控导致火灾、爆炸、中毒事故,造成群死群伤。通过开展精细化工反应安全风险评估,确定反应工艺危险度,以此改进安全设施设计,完善风险控制措施,能提升企业本质安全水平,有效防范事故发生。
In the production of fine chemical reaction is an important cause of the accident is out of control, carry out the fine chemical reaction safety risk assessment, determine the risk level and take effective control measures for safety production guarantee enterprise is significant. To carry out the safety risk assessment of the reaction is also the basic work for the enterprise to get the information of production safety and the safety management of chemical process. The fine chemical production in batch and semi batch operation, the process is complex, low level of automation, field operations personnel, some enterprises lack of understanding of the reaction of the security risk, process control or do not grasp the understanding of science, due to runaway reaction cause fire, explosion and poisoning accidents qunsiqunshang. Through the development of fine chemical reaction safety risk assessment, determine the risk degree of reaction process, in order to improve the design of safety facilities, improve risk control measures, can improve the level of intrinsic safety, effectively prevent accidents.
二、准确把握精细化工反应安全风险评估范围和内容
Two, accurately grasp the scope and content of safety risk assessment
(一)企业中涉及重点监管危险化工工艺和金属有机物合成反应(包括格氏反应)的间歇和半间歇反应,有以下情形之一的,要开展反应安全风险评估:
(a) involving key regulatory hazardous chemical process and metal organic synthesis enterprise (including Grignard reaction) batch and semi batch reaction, one of the following circumstances, to carry out the reaction safety risk assessment:
1.国内首次使用的新工艺、新配方投入工业化生产的以及国外首次引进的新工艺且未进行过反应安全风险评估的;
1 the first time the new technology and new formula used in China are put into industrial production and the new technology introduced in foreign countries for the first time and has not been carried out to evaluate the safety risk;
2.现有的工艺路线、工艺参数或装置能力发生变更,且没有反应安全风险评估报告的;
2 changes in the existing process route, process parameters or device capability, and no response to the safety risk assessment report;
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3.因反应工艺问题,发生过生产安全事故的。
3 because of the reaction process, the production safety accidents.
(二)精细化工生产的主要安全风险来自于工艺反应的热风险。开展精细化工反应安全风险评估,要根据《精细化工反应安全风险评估导则(试行)》(见附件)的要求,对反应中涉及的原料、中间物料、产品等化学品进行热稳定测试,对化学反应过程开展热力学和动力学分析。根据反应热、绝热温升等参数评估反应的危险等级,根据最大反应速率到达时间等参数评估反应失控的可能性,结合相关反应温度参数进行多因素危险度评估,确定反应工艺危险度等级。根据反应工艺危险度等级,明确安全操作条件,从工艺设计、仪表控制、报警与紧急干预(安全仪表系统)、物料释放后的收集与保护,厂区和周边区域的应急响应等方面提出有关安全风险防控建议。
(two) the main safety risk of fine chemical production comes from the hot air insurance of process reaction. To carry out the fine chemical reaction of security risk assessment, according to the fine chemical reaction safety risk assessment guidelines (Trial) (see Annex) the requirements of thermal stability test on the reaction involved in raw materials, intermediate materials, products and other chemicals, to carry out the analysis of thermodynamics and kinetics of chemical reaction process. According to the risk level of reaction heat, adiabatic reaction parameters such as evaluation, according to the maximum reaction rate of arrival time and other parameters to evaluate the possibility of runaway reaction, combined with the reaction temperature parameters of multi factor risk assessment, determine the risk level of reaction process. According to the reaction process of the risk level, ensure the safety operation conditions, from the process design, instrument control, alarm and emergency intervention (SIS), after the release of the material collection and protection, put forward relevant security risk prevention recommendations of plant and the surrounding regional emergency response.
三、强化精细化工反应安全风险评估结果运用,完善风险管控措施
Three, strengthen the use of fine chemical reaction safety risk assessment results, improve risk management measures
(一)涉及的反应工艺危险度被确定为2级及以上的,要根据危险度等级和评估建议,设置相应的安全设施和安全仪表系统;反应工艺危险度被确定为4级及以上的,在全面开展过程危险分析(如危险与可操作性分析)基础上,通过风险分析(如保护层分析)确定安全仪表的安全完整性等级,并依据要求配置安全仪表系统;对于反应工艺危险度被确定为5级的,相关装置应设置在由防爆墙隔离的独立空间中,并设计超压泄爆设施,反应过程中操作人员不应进入隔离区域。企业要优先通过开展工艺优化或改变工艺路线降低安全风险。
(a) the reaction process risk involved was identified as grade 2 and above, according to the risk level and assessment recommendations, setting up safety facilities and safety instrument system corresponding to the reaction process; risk was identified as grade 4 and above, in the process to carry out a comprehensive risk analysis (such as hazard and operability analysis) basis, through risk analysis (such as the layer of protection analysis) to determine the safety instrument safety integrity level, and based on the requirements of safety instrument system; the reaction process was identified as risk level 5, related device should be set up in the explosion-proof wall isolation independent space, and the design of overpressure venting facilities. In the reaction process of operating personnel should not enter the isolated area. Enterprises should give priority to the process optimization or change the process route to reduce security risk.
(二)企业要把反应安全风险评估作为安全管理的重要内容,新建项目要以反应安全风险评估结果为依据,开展工艺设计及安全设施设计,保证各项安全控制措施落实到位;相关在役装置要根据反应安全风险评估结果,补充和完善安全管控措施,及时审查和修订操作规程。
(two) enterprises to response security risk assessment as an important part of safety management, the new project to reactor safety risk assessment results as the basis, to carry out the process design and the design of safety facilities, ensure the safety control measures are in place; related equipment in use to evaluate the results according to the security risk, to supplement and improve the safety control measures. Timely review and revise operation rules.
(三)企业要保证设备设施满足反应工艺安全要求,根据反应安全风险评估情况,建立关键设备设施清单,定期开展检查、维护和维修,要确保泄放、冷却、降温等设施和安全仪表等系统的完好、可用。要开展有针对性的岗位操作培训,保证岗位操作人员熟练掌握本岗位反应安全风险,严格执行岗位操作规程,不断提升操作技能。要根据反应安全风险评估结果,制定岗位应急处置方案和事故专项应急预案,强化定期演练,提高应急处置能力。
(three) the enterprise to ensure that equipment and facilities to meet the safety requirements of reaction process, according to the security risk assessment, the establishment of key equipment list, regularly carry out inspection, maintenance and repair, to ensure the discharge, cooling, cooling and other facilities and safety instrumented system intact and available. To carry out targeted job training, to ensure that the operating personnel to master the post reaction safety risks, strict implementation of operating procedures, improve operating skills. According to the results of the reaction safety risk assessment, the development of contingency plans and emergency contingency plans, strengthen regular drills, improve emergency response capabilities.
四、工作要求

Four, work requirements
(一)反应安全风险评估工作专业性强,技术要求高,各有关企业要高度重视,聘请具备相关专业能力的机构组织开展评估。企业要加大对工艺反应测试分析条件的投入,培育专业工程技术人员,逐步形成自身开展反应安全风险评估工作的能力。
(1) the response safety risk assessment work is highly professional and technical requirements, the relevant enterprises should attach great importance to employ the relevant professional ability of the organization to carry out assessment. Enterprises should increase investment in the process of reaction test analysis conditions, the development of professional engineering and technical personnel, and gradually form their own ability to carry out safety risk assessment work.
(二)有关企业要确保列入评估范围的新建装置在编制可行性研究报告或项目建议书前,完成反应安全风险评估。对相关在役装置要制定计划逐步开展,根据评估结果完善风险控制措施,努力降低安全风险。从2020年开始,凡列入评估范围,但未进行反应安全风险评估的精细化工生产装置,不得投入运行。

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(two) to ensure that the new equipment included in the scope of the assessment to complete the feasibility study report or project proposal before the completion of the reaction safety risk assessment. To develop the plan for the related equipment, and improve the risk control measures according to the results of the assessment. From the beginning of 2020, where included in the scope of assessment, but did not respond to safety risk assessment of fine chemical production equipment, shall not be put into operation.
(三)地方各级安全监管部门要结合本地区实际,指导和督促相关企业开展反应安全风险评估,积极跟踪评估结论,掌握并研判本地区有关企业的风险情况。积极培育具备条件的反应安全风险评估机构,鼓励具备条件的有关科研单位提供技术服务支持,加强技术人才队伍培养,配备完善实验测试设施,规范服务工作,提高反应安全风险评估能力和质量。
(three) local safety supervision departments at all levels should be combined with the local reality, guide and urge the relevant enterprises to carry out the reaction of security risk assessment, actively follow the conclusion of evaluation and risk analysis about enterprise grasp the region. Actively cultivate the reaction conditions of the safety risk assessment agencies, encourage the relevant scientific research units have the conditions to provide technical support services, strengthen technical personnel training, equipped with test facilities, standardized services, improve the response ability and quality safety risk assessment.
请各省级安全监管局及时将本指导意见精神传达至本辖区各级安全监管部门及有关企业。
Requests the Provincial Safety Supervision Bureau in a timely manner to convey the spirit of this guidance to the safety supervision departments at all levels and relevant enterprises.
国家安全监管总局
State Administration of safety supervision
2017年1月5日

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注意教育和培训员工遵守法律及商业操作规则,在发现安全事件时要及时报告主管高层,并注意保留相关证据,以便采取进一步响应措施。

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