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AQ/T 3012-2008 PDF in English


AQ/T 3012-2008 (AQ/T3012-2008, AQT 3012-2008, AQT3012-2008)
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AQ/T 3012-2008: PDF in English (AQT 3012-2008)

AQ/T 3012-2008 AQ SAFE PRODUCTION INDUSTRY STANDARD OF THE PEOPLE’S REPUBLIC OF CHINA ICS 13.100 E 09 Registration number. 25427-2009 Guideline of safety management system implementation for petrochemical corporation ISSUED ON. NOVEMBER 19, 2008 IMPLEMENTED ON. JANUARY 01, 2009 Issued by. State Administration of Work Safety Table of Contents Foreword ... 3  Introduction ... 4  1 Scope ... 5  2 Terms and definitions ... 5  3 Safety commitments, policy objectives and responsibilities ... 8  4 Organization, responsibilities and resources... 9  5 Risk assessment and management of hidden danger ... 15  6 Management of legal and regulatory compliance ... 20  7 Management of contractor and vendor ... 21  8 Design and construction of facilities ... 24  9 Operational control ... 25  10 Change management ... 29  11 Customers, communities and interested parties ... 31  12 Emergency management ... 32  13 Handling and prevention of accident ... 33  14 Inspection, assessment and improvement ... 35  Appendix A (Informative) Example of application of the guideline of safety management system implementation for petrochemical corporation ... 39  Guideline of safety management system implementation for petrochemical corporation 1 Scope This standard specifies the guidelines for the safety management modes and management methods of petrochemical enterprises. This standard applies to the safety management of the entire process of petrochemical enterprises. The enterprise can select the applicable content according to the actual situation and ensure that it meets the requirements of relevant laws-regulations and standards. 2 Terms and definitions The following terms and definitions apply to this standard. 2.1 Element Key factors in safety, environmental and health management. 2.2 Accident Unexpected circumstances that cause death, illness, injury, property damage, or environmental damage. 2.3 Hazard The source or state that may cause injury, illness, property damage, damage to the work environment, or a combination of these conditions. 2.4 Hazard identification The process of identifying the presence of a hazard and determining its characteristics. Interested parties Individuals or groups that are related to or affected by enterprise’s safety management performance. 2.19 Petrochemical corporation A production enterprise that uses petroleum and natural gas as raw materials. 3 Safety commitments, policy objectives and responsibilities 3.1 General Enterprises shall have clear commitments and documented policy objectives for safety management. Enterprise leaders continuously improve their safety performance by providing resources as well as assessments and audits. 3.2 Safety commitment Enterprise leaders shall provide strong leadership and top-down commitments, establish a safety guarantee system. Enterprise’s commitments shall demonstrate the importance of safety in action. Managers at all levels of the enterprise and management organizations shall make written commitments. 3.3 Policy objectives The policy objectives are the guiding ideology and strategic goals of the enterprise in safety management, as well as the embodiment of pursuing good safety performance. The enterprise’s policy objectives shall reflect the following principles. a) All production and operation activities of the enterprise shall meet the requirements of safety management; b) It keeps consistency with other enterprise’s policies and has equal importance; c) It can be implemented by organizations at all levels; d) It is easily accessible by the public; e) It meets or exceeds the requirements of relevant laws and regulations; unions; b) The enterprise shall, in accordance with relevant national laws, regulations and industry standards, establish the requirements of safety responsibilities for the top management, management appointees, top management members, and personnel at all levels; c) The enterprise shall provide necessary resource support for the functional departments and personnel at all levels who have safety management responsibilities; d) The company shall appoint a senior management appointee to be responsible for the health and safety of all employees, be responsible to implement the relevant health and safety provisions; e) The enterprise shall assist the grassroots employees to select their own representatives, to communicate with the enterprise leaders on matters related to this standard; f) Every employee of the enterprise has a safety responsibility, and shall perform safety duties no matter where they are; g) Conduct regular inspections to ensure that all responsibilities are fully implemented, use review and assessment to continuously improve the safety performance of enterprise. 4.3 Personnel, training and behavior 4.3.1 Confirmation of capability Enterprise shall carefully select the staffs on the position, clarify their responsibilities, conduct systematic training, establish procedures for assessing their skills and abilities. The enterprise shall ensure that all employees are regularly subjected to safety training, which shall be documented, meanwhile provide re-training for the new and transferred employees, to make them have the following safety awareness and capabilities. a) Be responsible for their work and obey the rules; b) In an emergency situation, can make decisive disposal, have strong capability of production processing and accident response; c) Can correctly analyze and solve the problems on production operation and process equipment; d) Have a strong sense of safety, environment and health, be conscious of doing safe work; 4.3.3 Training plan The training plan is as follows. a) Enterprises shall, according to the needs of safety management work, prepare annual training and assessment plans; b) The training plan shall include the implementation organization of the training, the methods and contents, the training targets, the schedule, the training materials, the expected results achieved, etc.; c) The safety authority shall regularly supervise and inspect the implementation of the training plan. 4.3.4 Training records and files Enterprises shall establish safety training records and files as required, including at least. a) Safety training plan; b) Records of safety training assessment; c) Record of the qualification certificate obtained after the safety training assessment; d) Files of three-level safety education for new employees; e) Files of training assessment for the safety management qualification of leading cadres; f) Files of training and qualification of special work personnel; g) Files of professional training for safety management personnel; h) Safety education file of contractors; i) Safety education file of training personnel, internship, etc. 4.4 Financial and material resources 4.4.1 Funds Enterprises shall prioritize funds for safety, to ensure the effective operation of the safety management system. The sources of funds include funds for safety and technical measures, labor protection funds, special funds for occupational safety and health as well as environmental protection facilities of construction (engineering) projects, funds for equipment overhaul and renewal, etc. Establish a management system of safety production cost, collect the safety f) Education office facilities; g) Communication equipment and transportation means; h) Health food and beverages, etc. The enterprise shall guarantee the material conditions necessary for the safety management system, to ensure the smooth progress of key tasks such as rescue and disaster relief as well as hidden danger management. Provide necessary testing equipment, protection equipment and educational office facilities for the safety management department to carry out work. 4.5 Safety meeting Enterprises shall hold regular safety work meetings at all levels, summarize safety management work in a timely manner, deploy the next-step work, communicate the requirements of the state and interested parties. According to its organizational form and management level, enterprises determine the form and requirements of the safety meetings at all levels and establish relevant records. 4.6 Management of file 4.6.1 Requirements for file control Enterprises shall control the safety management documents, to ensure that. a) Adapt to the activities of the enterprise; b) Regular review, and revision if necessary, approval by the authorized person before release; c) The current version is readily available when needed; d) It can be recovered from the issuing point and the use place in time when it fails. 4.6.2 Scope of document control Scope of document control is as follows. a) Enterprise overview; b) Organization and responsibilities; c) Safety policy, goals; d) Risk assessment record; 5.2.1 Scope and method of hazard identification Enterprises shall systematically determine the hazards and impacts of production activities, product transportation and after-sales services, the scope shall cover the entire process from putting into production to product sales. At least it shall consider. a) Design defects, process defects, equipment defects and human factors that lead to the occurrence of accidents and spreading of hazards; b) Various energy injuries during building, construction and overhauling; c) Leaks, fires, explosions, poisoning that may occur during shutdown, startup, production phases; d) The working environment and working conditions that may cause occupational diseases or occupational poisoning; e) Significant pollution that may result from operating activities in sensitive water areas. f) Accidents and potential emergencies, including. 1) Defects in the transportation and use of raw materials and products; 2) Equipment failure; 3) Climate, earthquakes and other natural disasters; 4) Violation of the operating procedures. g) Discarding, demolition and disposal activities. 1) Demolition of the discarded device and equipment; 2) Disposal of wasted hazardous chemicals. h) Activities, processes, products and services that may cause environmental pollution and ecological damage; i) Residual risks left over from past production and operation activities. Enterprises shall, when conducting hazard identification, consider the operational experience, risk characteristics and personnel capabilities, to determine the applicable hazard identification methods. 5.2.2 Risk assessment criteria The risk assessment criteria are the basis for determining the hazard and its d) Technical guarantees and services. 5.3.2.2 Technical measures for risk control. a) Measures to eliminate risks; b) Measures to reduce risks; c) Measures to control risks. 5.3.2.3 Management measures for risk control. a) Improve the management procedures and operating procedures; b) Implement the risk monitoring and management measures; c) Implement the emergency plan; d) Strengthen the safety education and training for employees; e) Establish the inspection supervision and reward & punishment mechanisms. 5.3.3 Implement risk control measures After the risk control measures are determined, it shall organize the implementation work in a timely manner, including. a) Develop an implementation plan for risk control measures; b) Determine the funding sources; c) Determine the progress and time schedule; d) Determine the project leader; e) Formulate methods and standards for assessment and acceptance; f) Organize the assessment and acceptance. 5.4 Management of hidden danger 5.4.1 Scope of management of hidden danger Enterprises shall assess the hidden dangers as exposed in risk assessment, safety inspection, production operations, formulate and implement hidden danger management and rectification plans. 5.4.2 Assessment of hidden risk i) International conventions, etc. Enterprises shall establish channels and procedures for obtaining these requirements, update them in a timely manner. 6.3 Regulatory review In the process of identifying laws and regulations as well as other statutory requirements, determine how these requirements apply to the enterprise's risk control and conduct compliance reviews. The specific practices include. a) Regularly review whether the enterprise’s management requirements and practices meet regulatory requirements; b) Establish and save the review record; c) Track the continued applicability and compliance of regulations. 7 Management of contractor and vendor 7.1 General Contractors, vendors and interested parties are important to the safety performance of the enterprise. It shall assess their safety performance, conduct safety supervision and performance assessment of the contractor, thereby reducing and controlling the risks arising from the contracting process. It shall verify the vendor’s products and after-sales services, to ensure they comply with the enterprise’s safety management provisions. 7.2 Management of contractor 7.2.1 Prequalification The enterprise shall establish the prequalification criteria or requirements for the contractor; establish a list of contractors recognized by the enterprise through the review of the contractor, maintain relevant contractor information and documents. The review can either be in written form or a combination of written review and on-site review. Prequalification of contractor’s qualifications includes but is not limited to. a) Service type, business scope, qualification certificate; b) Safety production (construction) license; c) Safety, health and environmental organization and management system; d) Past safety performance; The enterprise shall establish a coordination and contact system with the contractor, to enable the contractor to keep abreast of the safety requirements of the enterprise and the matters that need to be coordinated by the owner. The contractor shall establish a written emergency plan. The emergency plan shall include the emergency handling procedures, the designated muster areas, the escape routes, the methods for counting the number of people in the accident; provide emergency training for their employees and keep the training records. The contractor shall report to the safety management department and relevant departments of the enterprise all incidents and near miss incidents as related to the contractor's on-site work. 7.2.6 Assessment of contractor’s safety performance The enterprise shall regularly review and record the contractor's safety performance and feed the opinions back to the contractor, to urge and encourage the contractor to develop its own safety improvement plan. If necessary, it may organize the audit of the contractor's safety management system. The enterprise shall document the safety performance of the contractor during the working period, use it as an important basis for selecting the contractor in the future. 7.3 Management of vendors 7.3.1 Prequalification Enterprises shall establish a certification and assessment system for the vendor’s qualification, formulate prequalification, selection and renewal criteria, regularly conduct qualification examinations on the quality and after-sales service of materials (equipment) as supplied by vendors, regularly adjust and eliminate the vendors which fail to comply with requirements. The technical documentation of the materials and equipment supplied by the vendor as required shall include. a) Statutory qualification certificate; b) Manufacturing license for equipment, product certificate, instruction manual, production license for explosion-proof equipment, production license for measuring instruments, etc.; c) Safety labels of hazardous chemical goods, safety technical specifications of hazardous chemical goods, etc. The design, construction, and construction organizations shall, based on the characteristics of each stage and each trade, organize the risk assessment activities for various stages of feasibility study, design, construction, startup. Take effective risk reduction measures, to prevention and reduce the occurrence of all kinds of accidents and occupational diseases to the maximum extent, meanwhile reduce the hazard as caused to the environment. 8.4 Pre-startup review The enterprise shall formulate a pre-startup inspection procedure for the newly- built, rebuilt, or expanded devices (facilities), form a document. The content of the review includes verifying whether the device (facility) is consistent with the design requirements; whether the safety precautions are in place; whether the employee training is completed; whether the rules and regulations and operating procedures are established, etc. After the review, it shall form a recoding document. 8.5 Actual deviation The actual deviations in the design, construction, installation, trial production processes must be confirmed and approved. Meanwhile documents shall be kept. 9 Operational control 9.1 General Enterprises shall establish the management procedures in production operations, equipment management, occupational health, environmental protection, etc., implement the systematic management in terms of production organization, process integrity, equipment integrity, operational safety, to ensure the realization of the policies and objectives. 9.2 Production organization The production organization is as follows. a) The enterprise shall establish and improve various rules and regulations of production management and safety management, check and examine the implementation of the systems; b) The enterprise shall establish a department which is responsible for scheduling of production organization; c) The dispatching department for production organization shall conscientiously perform its safety duties, scientifically and rationally arrange the mutual supply, balance and production connection of the maintenance criteria of equipment and facilities, to determine the maintenance items and cycles, thereby ensuring the integrity and safety of equipment and facilities. For deviations between the equipment in the operation and maintenance process and the criteria, the enterprise shall carry out assessment, find the causes of the deviation, determine the measures to correct deviations, form document. Meanwhile it shall. a) According to the national and enterprise codes, standards, regulations, systems on equipment safety, develop and improve the management systems and provisions of equipment safety, as well as the equipment safety operating procedures; b) Establish a preventive maintenance inspection and control system, conduct regular analysis, keep completeness and normal operation of equipment and facilities. c) Strengthen the management of key equipment, to ensure that the equipment is in a safe and reliable state; d) Manage the pressure vessels, pressure pipes, special equipment; conduct detection and maintenance in time; e) Establish relevant files and ledgers. 9.5 Safe work management The enterprise shall establish and maintain procedures, to control the activities that may pose risks to operators or production operations; to implement operation permit management for operational activities with obvious risks, such as. hot work, confined space, excavation, work at height, temporary power use, lifting, radiation, access to explosion-proof areas, etc.; to clarify the work procedures and control guidelines. It shall make inspection supervision of the work process, make corrections in time when finding problems. 9.6 Occupational health management 9.6.1 Occupational health monitoring Enterprises shall identify and determine various physical and chemical occupational hazard factors which are arising from the production process. According to the requirements of laws and regulations, determine the scope and requirements for the monitoring of the hazard factors of occupational disease in enterprises, determine the content and frequency of monitoring, clarify the control requirements of qualifications, personnel, instruments, determine the requirements for preservation and publication of monitoring results. gas, use the total amount control means of pollutants to establish the target indicators of the discharge device of each pollutant source, use cleaner processes and facilities, to gradually reduce or lower the negative environmental impacts. The enterprise shall establish a management procedure for solid waste disposal, determine the classification criteria and disposal procedures according to the regulations and their own situations, to ensure compliance with regulatory requirements. For the disposal of waste, it shall establish and keep the relevant records, such as the final destination of the waste, the qualification of the hazard-elimination organization, the quantity and classification of the waste. Enterprises shall consider the control of such periods as abnormal production, overflow or leakage, out-of-control of equipment control system, or of such pollution sources as the waste liquid, exhaust gas, or contaminated fire water during maintenance period, to avoid damage to the environment. 9.7.3 Conservation of energy and resources Enterprises shall establish the use and control objectives of resources and energy, take engineering technology and management methods, actively promote clean production audits, continuously reduce the consumption of resources and energy, improve the utilization of resources and energy. 9.8 Security The enterprise shall determine the safety and security requirements for entering the plant and the work site; implement the access control, to check the entry personnel and vehicles, etc., to confirm that it meets the safety requirements. Enterprises shall determine the key points for safety and security in accordance with laws and regulations and their own management requirements, arrange personnel patrol, equip safety monitoring facilities, to ensure safety. Safety monitoring facilities shall be inspected and tested regularly, to ensure that they are in good condition; meanwhile keep the inspection and test records. 10 Change management 10.1 General Change management refers to the planned control of permanent or temporary changes in personnel, work processes, work procedures, technologies, facilities, etc., to ensure that the hazards caused by changes are fully identified and risks are effectively controlled. The enterprise shall establish a change document, timely notify the results of change to relevant departments and relevant personnel. Timely train relevant personnel, to make them master new work procedures or methods of operation. 10.5 Management of change data After passing the acceptance of the change, according to the document management requirements, timely revise the operating procedures and process control parameters, establish and improve the management system. The new document data is timely sent to the relevant department and personnel according to the relevant procedures. Then close the change. 11 Customers, communities and interested parties 11.1 General Enterprises shall establish and maintain appropriate procedures, to clarify the content and channels of communication among customers, communities and stakeholders. 11.2 Product safety and notification of hazard Enterprises shall communicate with customers and transportation contractors on the information involved in the product hazards, meanwhile keep relevant records. If the contract has such requirements, the enterprise shall provide interested parties with reasonable data and channel to obtain such information, for the purpose of determining whether the enterprise meets the requirements of this standard; if there are further requirements in the contract or agreement, the enterprise shall, through the provisions of the procurement contract, request the vendors and sub-contractors to provide the similar data and channels as above. 11.3 Communication of community Enterprises shall determine the channels and content of communication with the community, such as issuing the safety performance through issuing the safety reports or holding symposiums, communicating the emergency response procedures, regular publishing safety performance, proclaiming safety policies, etc. 11.4 Communication of stakeholder Enterprises shall determine the important risks in the production process as well as the way in which relevant information is communicated to the stakeholders, such as employees, contractors, social groups, etc., by the use such as emergency lighting; emergency communication system. After the emergency plan is formulated, it shall be reviewed and approved according to the responsibilities, reported to the local government department for filing according to the laws and regulations. 12.4 Drills, assessments and revisions of emergency plan The enterprise shall conduct regular inspections and drills on the emergency plan, including whether the communication system can operate normally during the accident, whether all kinds of ambulance facilities (supplies) are available and effective, whether the evacuation steps are appropriate, whether the accident disposal personnel can be in place in time. If necessary, it shall organize the contractors and external-personnel to participate in desktop or practical drills. After the drill, it shall review the emergency plan, to find out the shortcomings and make changes accordingly. The revised emergency plan shall be reviewed and approved according to the original approval procedure, meanwhile it shall notify the relevant departments and relevant personnel in time. 12.5 First-aid Enterprises shall regularly organize training, to enable employees in risk to master the following first-aid methods in life-critical situations. first-aid for electric shock, first-aid for burning injury, first-aid for drowning, first-aid for mechanical injury, first-aid for acute poisoning, cardiopulmonary resuscitation, etc. The enterprise is equipped with different first-aid medicines and medical equipment according to the nature of the workplace, carries out regular inspection and maintenance, to ensure that the first-aid supplies are in emergency state. 13 Handling and prevention of accident 13.1 General The enterprise shall establish a management procedure on the reporting, investigation, handling of accidents. The management procedures established shall ensure that the root cause of the accident (a near miss incident) can be investigated and confirmed in a timely manner. According to the cause of the accident, establish corresponding corrective and preventive measures, to prevent similar accidents fr...... ......
 
Source: Above contents are excerpted from the PDF -- translated/reviewed by: www.chinesestandard.net / Wayne Zheng et al.