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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 from happening again.
Enterprises shall advocate a prevention-focused management concept,
strengthen the management of near miss accidents (incidents), reduce the
eliminate unsafe factors;
b) Educational measures. Through safety education in different forms and
ways, improve the awareness and skills of employees in preventing
accidents and standardize the safety behavior of employees;
c) Management measures. Improve the safety management system,
operating procedures, etc.
The enterprise shall, according to the regulations as well as the requirements
of its own management, determine the procedures for the handling of the
accident, the form of the review, the requirements of the results.
13.5 Accident statistics and experience sharing
Enterprises shall, according to the laws and regulations as well as the
requirements for their own management, determine the content and
requirements of statistics as well as the scope of information transmission, in
order to learn lessons and prevent similar accidents from happening again.
14 Inspection, assessment and improvement
14.1 General
Enterprises shall regularly inspect and supervise the operation of the safety
management system, establish a regular inspection and supervision system;
through implementing internal audit and management review, to ensure the
realization of the policies and objectives as well as the effective operation of the
safety management system.
14.2 Inspection supervision
14.2.1 Form an......
 
Source: Above contents are excerpted from the PDF -- translated/reviewed by: www.chinesestandard.net / Wayne Zheng et al.