Strengthen guidance on chemical safety instrument system management
2023-11-04 15:40:51
In order to strengthen the management of chemical safety instrumentation systems and prevent and reduce the occurrence of hazardous chemical accidents, the following guidance is proposed:
I. Fully understand the importance of strengthening the management of chemical safety instrumentation systems
(1) The chemical safety instrument system (SIS) includes a safety interlock system, an emergency stop system, and a toxic and harmful flammable gas and fire detection protection system. The safety instrumentation system is independent of the process control system (such as a decentralized control system, etc.), and is in a dormant or stationary state when the production is normal. Once the production device or facility is in a situation that may cause a safety accident, it can be instantaneously and accurately acted to safely stop the production process. Or automatically import a predetermined security state, must have high reliability (ie, functional safety) and standard maintenance management, if the safety instrument system fails, it will often lead to serious safety accidents. In recent years, major chemical industry in developed countries (danger Most chemical accidents are related to the failure or improper setting of safety instruments. According to the consequences and risks of failure of safety instrument functions, the safety instrument functions are divided into different safety integrity levels (SIL 1-4, up to 4). Different grades of safety instrument loops have different technical requirements in terms of design, manufacture, installation, commissioning and operation and maintenance.
At present, China's safety instrumented systems and related safety protection measures in the design, installation, operation, maintenance and management and other life cycle stages, there are insufficient risk and risk analysis, improper design selection, irrational structure of redundant fault-tolerant, lack of clear Inspection and testing cycle, preventive maintenance strategies are not targeted and other issues, and the management of safety instrumented systems needs to be strengthened. With the large-scale production of chemical installations and hazardous chemical storage facilities in China and the gradual increase in the automation level of production processes, it is urgent and necessary to simultaneously strengthen and standardize the management of safety instrument systems.
Second, strengthen the basic work of chemical safety instrument system management
(b) Accelerate the development of functional safety related technology and management personnel in safety instrumented systems. Chemical engineering design, construction units and hazardous chemical production and storage units shall organize relevant technical personnel such as responsible persons, crafts and instrumentation to carry out professional safety instrument training, popularize functional safety related knowledge, and learn relevant standards and specifications. It is necessary to provide targeted training for design, installation, commissioning and operation and maintenance personnel for different parts of the life cycle of safety instrumented systems, so that relevant personnel can master relevant safety technology systems, risk analysis and control, risk reduction and related professional technologies. . Each chemical design unit should use one year or so to cultivate a technical backbone team that is competent for the functional safety design of safety instrument systems. Chemical companies and hazardous chemical storage units that involve “two important priorities and one major†(ie, major hazardous chemicals, which focus on the supervision of hazardous chemical processes and major hazards of hazardous chemicals) shall accelerate personnel training and cultivate a batch of Engineers and technicians with professional technical capabilities and relevant standards and standards are required to meet and strengthen the functional safety management of chemical safety instrumentation systems.
(C) Further improve the chemical safety instrumentation system technical standards and certification system. Speed ​​up the revision and revision of the chemical safety instrumentation system technical standard system. To organize the research and planning of China's chemical functional safety technical standards system, relevant departments and units shall formulate work plans and organize the formulation of functional safety-related technical standards and application guidelines that are consistent with the current state of safety development in China's chemical industry. Promote the establishment and improvement of functional safety certification system mechanisms that are in line with China's national conditions. Based on the "Functional Safety of Electrical, Electronic, and Programmable Electronic Safety-related Systems" (GB/T20438) and "Functional Safety of Safety Instrumented Systems in the Process Industry" (GB/T21109), the related functional safety of personnel, products, and organizations is gradually established. Certification service system.
Third, further strengthen the safety instrumentation system life cycle management
(D) Before designing the safety instrument system, it is necessary to clarify the process safety requirements, design intent and basis of the safety instrument system. It is necessary to fully identify dangerous and dangerous events through process hazard analysis, scientifically determine necessary safety instrument functions, and assess safety risks according to national laws, regulations and standards, and determine the necessary risk reduction requirements. According to the functional and integrity requirements of all safety instrument functions, technical documents for the safety requirements of safety instrument systems are prepared.
(E) Regulate the design of chemical safety instrumentation systems. The safety instrument function is designed and implemented in strict accordance with the safety instrument system safety requirements technical documentation. Through rational selection of instrumentation equipment, structural constraints (redundancy and fault tolerance), inspection and test cycles, and diagnostic techniques, the safety instrument function design is optimized to ensure that the risk reduction requirements are achieved. To properly determine the safety instrumentation function (or subsystem) inspection test cycle, when online testing is required, online testing methods and related measures must be designed. The detailed design stage should clarify the requirements of each safety instrument function (or subsystem) inspection test cycle and test methods.
(6) Strict installation and commissioning of safety instrumentation systems and joint confirmation. A complete installation and commissioning and joint verification plan should be formulated and ensured to be effectively implemented. Detailed records of commissioning (single instrument commissioning and loop debugging), confirmation of the process and results, and the establishment of a management file. After the construction unit completes the installation and commissioning of the design documents, the company shall, before putting into operation, review and jointly confirm the safety instrumentation system in accordance with national laws and regulations, standards and regulations, industrial and corporate safety management regulations, and safety requirements technical documents to ensure safety instruments. The function has the established function and satisfies the integrity requirement, has the safe investment condition.
(7) Strengthen the operation and maintenance management of safety instrumentation systems in chemical companies. Chemical companies shall compile safety instrument system operation and maintenance plans and procedures to ensure that the safety instrument systems can reliably perform all safety instrument functions and achieve functional safety.
According to the inspection and test cycle that meets the requirements for safety integrity, the safety instrument function should be tested and tested regularly, and the test process and results recorded in detail. It is necessary to strengthen the management of equipment failures (including equipment failures, interlocking actions, malfunctions, etc.) and analysis processing of safety instrumented systems, and gradually establish a failure database of relevant equipment. It is necessary to standardize the selection of relevant equipment for safety instrumented systems, establish a system for the access and review of safety instrumentation equipment, and a change approval system, and constantly revise and perfect the company's application and equipment failures.
(8) Gradually improve the safety instrument system management system and internal regulations. Enterprises should formulate and improve safety instrument system-related management systems or internal technical specifications, integrate functional safety management into the corporate safety management system, and continuously improve the level of process safety management.
Fourth, attach great importance to the management of other related instrument protection measures
(9) Strengthen process alarm management, formulate enterprise alarm management system and strictly enforce it. Alarms related to the safety and integrity requirements of the safety instrument function can be managed and tested with reference to safety instrument functions.
(10) Strengthen the management of basic process control systems, control loops related to safety integrity requirements, refer to safety instrument functions for management and inspection tests, and ensure the automatic control loop commissioning rate.
(11) The toxic and hazardous gas detection and protection system shall be designed and implemented in strict accordance with the relevant standards. To ensure its reliable function, the relevant systems shall be independent of the basic process control system.
V. Accelerating the management of new project safety instrumentation system from the source
(Xii) From January 1, 2016, large-scale and wholly-owned foreign-funded joint ventures and other qualified chemical companies shall establish new chemical plants and hazardous chemical storage facilities that involve “two priorities and one majorâ€, and shall design in accordance with the requirements of this guidance. Safety instrument system that complies with relevant standards.
(13) Starting from January 1, 2018, all new chemical installations and hazardous chemical storage facilities that involve “two priorities and one major†should design a safety instrument system that meets the requirements. Other new chemical installations and safety instrumentation systems for hazardous chemical storage facilities, starting from January 1, 2020, should implement functional safety-related standards and design safety instrumentation systems that meet the requirements.
VI. Actively promote in-service safety instrumentation system assessment
(14) Chemical companies and hazardous chemical storage units that involve “two important and one important†production equipment or facilities in service shall be determined through risk analysis based on comprehensive analysis of process hazards (such as hazard and operability analysis). Safety instrument function and its risk reduction requirements, and assess whether the existing safety instrument function meets the risk reduction requirements as soon as possible.
(15) Based on the assessment, the company shall formulate a safety instrument system management plan and periodic inspection and test plan. For safety instrument functions that do not meet the requirements, relevant maintenance plans and rectification plans must be formulated, and safety instrumentation systems should be evaluated and improved before the end of 2019. Other chemical installations and hazardous chemical storage facilities shall be implemented in accordance with the requirements of this opinion.
VII. Work requirements
(16) All relevant enterprises and units shall, in accordance with the requirements of relevant laws and regulations, standards and regulations, and the requirements of this guidance, improve the management system and system of the company's safety instrumentation system, increase capital investment, and ensure that the new device safety instrumentation system meets the functional safety standards. Claim. Those failing to meet functional safety requirements for in-service device safety instrumented systems must be included in the rectification plan for a limited time to rectify, work hard to eliminate potential accident hazards, reduce the risk of accidents, curb accidents, and earnestly improve the level of intrinsic safety of the company.
(17) Local security supervisory departments at various levels shall carry out investigations and studies as soon as possible, formulate work goals, determine pilot units, specify progress requirements, guide and urge enterprises to strengthen the management of chemical process safety instrumentation systems and related safety protection measures. The functional safety assessment of safety instrumentation systems, the implementation of the safety instrumentation system management system, personnel training and development should be included in the safety supervision and inspection content. The provincial safety supervision bureau shall summarize the relevant inspections every year and report them to the State Securities Regulatory Bureau for supervision and control before the end of February each year.
I. Fully understand the importance of strengthening the management of chemical safety instrumentation systems
(1) The chemical safety instrument system (SIS) includes a safety interlock system, an emergency stop system, and a toxic and harmful flammable gas and fire detection protection system. The safety instrumentation system is independent of the process control system (such as a decentralized control system, etc.), and is in a dormant or stationary state when the production is normal. Once the production device or facility is in a situation that may cause a safety accident, it can be instantaneously and accurately acted to safely stop the production process. Or automatically import a predetermined security state, must have high reliability (ie, functional safety) and standard maintenance management, if the safety instrument system fails, it will often lead to serious safety accidents. In recent years, major chemical industry in developed countries (danger Most chemical accidents are related to the failure or improper setting of safety instruments. According to the consequences and risks of failure of safety instrument functions, the safety instrument functions are divided into different safety integrity levels (SIL 1-4, up to 4). Different grades of safety instrument loops have different technical requirements in terms of design, manufacture, installation, commissioning and operation and maintenance.
At present, China's safety instrumented systems and related safety protection measures in the design, installation, operation, maintenance and management and other life cycle stages, there are insufficient risk and risk analysis, improper design selection, irrational structure of redundant fault-tolerant, lack of clear Inspection and testing cycle, preventive maintenance strategies are not targeted and other issues, and the management of safety instrumented systems needs to be strengthened. With the large-scale production of chemical installations and hazardous chemical storage facilities in China and the gradual increase in the automation level of production processes, it is urgent and necessary to simultaneously strengthen and standardize the management of safety instrument systems.
Second, strengthen the basic work of chemical safety instrument system management
(b) Accelerate the development of functional safety related technology and management personnel in safety instrumented systems. Chemical engineering design, construction units and hazardous chemical production and storage units shall organize relevant technical personnel such as responsible persons, crafts and instrumentation to carry out professional safety instrument training, popularize functional safety related knowledge, and learn relevant standards and specifications. It is necessary to provide targeted training for design, installation, commissioning and operation and maintenance personnel for different parts of the life cycle of safety instrumented systems, so that relevant personnel can master relevant safety technology systems, risk analysis and control, risk reduction and related professional technologies. . Each chemical design unit should use one year or so to cultivate a technical backbone team that is competent for the functional safety design of safety instrument systems. Chemical companies and hazardous chemical storage units that involve “two important priorities and one major†(ie, major hazardous chemicals, which focus on the supervision of hazardous chemical processes and major hazards of hazardous chemicals) shall accelerate personnel training and cultivate a batch of Engineers and technicians with professional technical capabilities and relevant standards and standards are required to meet and strengthen the functional safety management of chemical safety instrumentation systems.
(C) Further improve the chemical safety instrumentation system technical standards and certification system. Speed ​​up the revision and revision of the chemical safety instrumentation system technical standard system. To organize the research and planning of China's chemical functional safety technical standards system, relevant departments and units shall formulate work plans and organize the formulation of functional safety-related technical standards and application guidelines that are consistent with the current state of safety development in China's chemical industry. Promote the establishment and improvement of functional safety certification system mechanisms that are in line with China's national conditions. Based on the "Functional Safety of Electrical, Electronic, and Programmable Electronic Safety-related Systems" (GB/T20438) and "Functional Safety of Safety Instrumented Systems in the Process Industry" (GB/T21109), the related functional safety of personnel, products, and organizations is gradually established. Certification service system.
Third, further strengthen the safety instrumentation system life cycle management
(D) Before designing the safety instrument system, it is necessary to clarify the process safety requirements, design intent and basis of the safety instrument system. It is necessary to fully identify dangerous and dangerous events through process hazard analysis, scientifically determine necessary safety instrument functions, and assess safety risks according to national laws, regulations and standards, and determine the necessary risk reduction requirements. According to the functional and integrity requirements of all safety instrument functions, technical documents for the safety requirements of safety instrument systems are prepared.
(E) Regulate the design of chemical safety instrumentation systems. The safety instrument function is designed and implemented in strict accordance with the safety instrument system safety requirements technical documentation. Through rational selection of instrumentation equipment, structural constraints (redundancy and fault tolerance), inspection and test cycles, and diagnostic techniques, the safety instrument function design is optimized to ensure that the risk reduction requirements are achieved. To properly determine the safety instrumentation function (or subsystem) inspection test cycle, when online testing is required, online testing methods and related measures must be designed. The detailed design stage should clarify the requirements of each safety instrument function (or subsystem) inspection test cycle and test methods.
(6) Strict installation and commissioning of safety instrumentation systems and joint confirmation. A complete installation and commissioning and joint verification plan should be formulated and ensured to be effectively implemented. Detailed records of commissioning (single instrument commissioning and loop debugging), confirmation of the process and results, and the establishment of a management file. After the construction unit completes the installation and commissioning of the design documents, the company shall, before putting into operation, review and jointly confirm the safety instrumentation system in accordance with national laws and regulations, standards and regulations, industrial and corporate safety management regulations, and safety requirements technical documents to ensure safety instruments. The function has the established function and satisfies the integrity requirement, has the safe investment condition.
(7) Strengthen the operation and maintenance management of safety instrumentation systems in chemical companies. Chemical companies shall compile safety instrument system operation and maintenance plans and procedures to ensure that the safety instrument systems can reliably perform all safety instrument functions and achieve functional safety.
According to the inspection and test cycle that meets the requirements for safety integrity, the safety instrument function should be tested and tested regularly, and the test process and results recorded in detail. It is necessary to strengthen the management of equipment failures (including equipment failures, interlocking actions, malfunctions, etc.) and analysis processing of safety instrumented systems, and gradually establish a failure database of relevant equipment. It is necessary to standardize the selection of relevant equipment for safety instrumented systems, establish a system for the access and review of safety instrumentation equipment, and a change approval system, and constantly revise and perfect the company's application and equipment failures.
(8) Gradually improve the safety instrument system management system and internal regulations. Enterprises should formulate and improve safety instrument system-related management systems or internal technical specifications, integrate functional safety management into the corporate safety management system, and continuously improve the level of process safety management.
Fourth, attach great importance to the management of other related instrument protection measures
(9) Strengthen process alarm management, formulate enterprise alarm management system and strictly enforce it. Alarms related to the safety and integrity requirements of the safety instrument function can be managed and tested with reference to safety instrument functions.
(10) Strengthen the management of basic process control systems, control loops related to safety integrity requirements, refer to safety instrument functions for management and inspection tests, and ensure the automatic control loop commissioning rate.
(11) The toxic and hazardous gas detection and protection system shall be designed and implemented in strict accordance with the relevant standards. To ensure its reliable function, the relevant systems shall be independent of the basic process control system.
V. Accelerating the management of new project safety instrumentation system from the source
(Xii) From January 1, 2016, large-scale and wholly-owned foreign-funded joint ventures and other qualified chemical companies shall establish new chemical plants and hazardous chemical storage facilities that involve “two priorities and one majorâ€, and shall design in accordance with the requirements of this guidance. Safety instrument system that complies with relevant standards.
(13) Starting from January 1, 2018, all new chemical installations and hazardous chemical storage facilities that involve “two priorities and one major†should design a safety instrument system that meets the requirements. Other new chemical installations and safety instrumentation systems for hazardous chemical storage facilities, starting from January 1, 2020, should implement functional safety-related standards and design safety instrumentation systems that meet the requirements.
VI. Actively promote in-service safety instrumentation system assessment
(14) Chemical companies and hazardous chemical storage units that involve “two important and one important†production equipment or facilities in service shall be determined through risk analysis based on comprehensive analysis of process hazards (such as hazard and operability analysis). Safety instrument function and its risk reduction requirements, and assess whether the existing safety instrument function meets the risk reduction requirements as soon as possible.
(15) Based on the assessment, the company shall formulate a safety instrument system management plan and periodic inspection and test plan. For safety instrument functions that do not meet the requirements, relevant maintenance plans and rectification plans must be formulated, and safety instrumentation systems should be evaluated and improved before the end of 2019. Other chemical installations and hazardous chemical storage facilities shall be implemented in accordance with the requirements of this opinion.
VII. Work requirements
(16) All relevant enterprises and units shall, in accordance with the requirements of relevant laws and regulations, standards and regulations, and the requirements of this guidance, improve the management system and system of the company's safety instrumentation system, increase capital investment, and ensure that the new device safety instrumentation system meets the functional safety standards. Claim. Those failing to meet functional safety requirements for in-service device safety instrumented systems must be included in the rectification plan for a limited time to rectify, work hard to eliminate potential accident hazards, reduce the risk of accidents, curb accidents, and earnestly improve the level of intrinsic safety of the company.
(17) Local security supervisory departments at various levels shall carry out investigations and studies as soon as possible, formulate work goals, determine pilot units, specify progress requirements, guide and urge enterprises to strengthen the management of chemical process safety instrumentation systems and related safety protection measures. The functional safety assessment of safety instrumentation systems, the implementation of the safety instrumentation system management system, personnel training and development should be included in the safety supervision and inspection content. The provincial safety supervision bureau shall summarize the relevant inspections every year and report them to the State Securities Regulatory Bureau for supervision and control before the end of February each year.
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