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| GB 19041-2024 | English | 515 |
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Safety specifications for the production of phosgene and phosgenation products
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| GB 19041-2003 | English | 259 |
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GB 19041-2024: Safety specifications for the production of phosgene and phosgenation products---This is an excerpt. Full copy of true-PDF in English version (including equations, symbols, images, flow-chart, tables, and figures etc.), auto-downloaded/delivered in 9 seconds, can be purchased online: https://www.ChineseStandard.net/PDF.aspx/GB19041-2024
GB
NATIONAL STANDARD OF THE
PEOPLE’S REPUBLIC OF CHINA
ICS 71.020
CCS G 09
Replacing GB 19041-2003, GB 13548-1992
Safety specifications for the production of phosgene and
phosgenation products
Issued on: AUGUST 23, 2024
Implemented on: MARCH 01, 2025
Issued by. Status Administration for Market Regulation;
National Standardization Administration.
Table of Contents
Foreword... 3
1 Scope... 5
2 Normative references... 5
3 Terms and definitions... 7
4 Planning and layout... 8
5 Design... 10
6 Production operations... 22
7 Emergency response... 25
8 Safety requirements for phosgenation product production using diphosgene and
triphosgene... 27
Appendix A (Informative) Major hazardous characteristics of phosgene and some
phosgenation products... 30
Appendix B (Informative) First aid kit contents... 41
References... 42
Safety specifications for the production of phosgene and
phosgenation products
1 Scope
This document specifies the planning, layout, design, production and operation,
emergency response, safety requirements for phosgene and phosgenation product
production facilities, as well as the production of phosgenation products using
diphosgene and triphosgene.
This document applies to the production of phosgene and phosgenation products, as
well as newly built, expanded, renovated, existing facilities producing phosgenation
products using diphosgene and triphosgene.
2 Normative references
The contents of the following documents, through normative references, constitute
essential provisions of this document. For dated references, only the version
corresponding to that date applies to this document. For undated references, the latest
version (including all amendments) applies to this document.
GB 2894 Safety signs and guideline for the use
GB 12158 General requirements for preventing electrostatic accidents
GB 16297 Integrated emission standard of air pollutants
GB 17945 Fire emergency lighting and evacuate indicating system
GB/T 20801 (all parts) Pressure piping code - Industrial piping
GB/T 29639 Guidelines for enterprises to develop emergency response plan for
work place accidents
GB 30000.18 Rules for classification and labelling of chemicals - Part 18.Acute
toxicity
GB 30077 Requirements on emergency rescue materials equipment for hazardous
chemical enterprises
GB 31571 Emission standard of pollutants for petroleum chemistry industry
AQ 3009 Safety criterion for electrical apparatus in hazardous areas
AQ/T 3034 Guidelines for chemical process safety management
AQ 3047 The rule of precautionary label for chemicals in workplace
AQ 8001 General principle of safety assessment
SH/T 3097 Specification for design of static electricity earthing in petrochemical
industry
SH/T 3153 Petrochemical telecommunications design code
TSG 21 Supervision regulation on safety technology for stationary pressure vessel
TSG D0001 Pressure pipe safety technology supervision regulation for industrial
pressure pipe
3 Terms and definitions
The following terms and definitions apply to this document.
3.1
Key access path
Expressways, first-class highways, second-class highways, railway and waterway
trunk lines, urban expressways, and other transportation routes.
3.2
Safety distance
The minimum permissible distance -- BETWEEN the boundary of the phosgene and
phosgenation product production unit (the outermost axis of the unit) AND the
relative concentration areas.
3.3
Phosgenation products
Products produced by the chemical reaction of phosgene with one or more chemical
substances.
3.4
The relative concentration areas
Areas where people gather, such as public facilities including residential areas,
schools, hospitals, nursing homes, cultural venues, commercial venues, passenger
ports, passenger terminals, passenger stations, passenger airports, parks, stadiums,
amusement parks, as well as labor-intensive workplaces (workshops or factories
with more than 100 workers at any one time), employee dormitories (including shift
dormitories).
3.5
Phosgene badge
A test paper that indicates a person's exposure to phosgene (the product of exposure
concentration and time), by which it can read the exposure dosage using a
colorimetric chart.
Note. Phosgene badges are also called phosgene cards or phosgene signboards.
3.6
Fluid containing phosgene
A gaseous medium containing at least 0.2% phosgene by volume, or a liquid medium
containing at least 1% phosgene by mass.
4 Planning and layout
4.1 Basic requirements
4.1.1 Safety facilities for newly built, expanded, renovated projects shall be designed,
constructed, put into production, used simultaneously with the main project.
4.1.2 Phosgene and phosgenation plants shall be designed by an organization with Class
A comprehensive engineering design qualification or Class A professional qualification
in the chemical, petrochemical, pharmaceutical industries.
4.1.3 A Hazard and Operability Analysis (HAZOP) shall be conducted during the basic
design phase for phosgene and phosgenation plants.
4.1.4 Safety assessments (pre-assessment, acceptance assessment, current safety
assessment) shall be conducted at different implementation stages for phosgene and
phosgenation plants. These safety assessments shall comply with the provisions of AQ
8001; their procedures and content shall adhere to relevant requirements.
4.1.5 Fire protection measures for phosgene and phosgenation product production
plants shall comply with the provisions of GB 55037 and GB 50016.Depending on the
type of enterprise, they shall also comply with the relevant provisions of GB 50160 and
GB 51283.
4.1.6 Exposure limits for toxic and hazardous substances in the workplace during
phosgene and phosgenation product production shall comply with the provisions of
GBZ 2.1.The overall layout, plant design, auxiliary room configuration shall comply
with the requirements of GBZ 1.
4.1.7 Phosgene and methyl isocyanate shall be used immediately upon production and
shall not be transported to other locations (including other production plants within the
industrial park) or transported via pipelines (including inter-plant pipelines).
4.2 Site layout
4.2.1 Phosgene and phosgenation product production projects shall be located within a
chemical park.
4.2.2 The project site layout shall comprehensively consider the total safe amount of
phosgene within the chemical park and the bearing capacity of the surrounding
environment.
4.2.3 Phosgene and phosgenation product production projects shall undergo risk
assessment and demonstration and, while complying with safety requirements, adhere
to the principles of industrial agglomeration, centralized layout, intensive land use.
4.3 Site selection
4.3.1 The site selection for phosgene and phosgenation production projects shall
comply with the requirements of the national industrial layout and local master plan.
4.3.2 Newly built, expanded, renovated projects must meet the following requirements.
a) They shall not be located in areas with a seismic fortification intensity of 8 degrees
or higher (inclusive);
b) They shall be located upwind of densely populated residential areas and towns
with the lowest annual wind frequency;
5 Design
5.1 Process
5.1.1 The water content of carbon monoxide and chlorine gas entering the phosgene
synthesis process shall not exceed 50 mg/m3.
5.1.2 Phosgene synthesis and phosgenation equipment and piping systems must be kept
dry; no moisture is permitted.
5.1.3 The following measures shall be implemented for cooling the phosgene and
phosgenation product production system.
a) Non-aqueous liquids that do not create secondary hazards upon contact with the
system media shall be used as coolants. If non-aqueous liquids do not meet
process requirements and water or aqueous solutions are necessary as coolants,
reliable protective measures shall be implemented to prevent water or aqueous
solutions from entering the process material side. In addition, process materials
shall be prevented from entering the coolant. An online pH (or conductivity)
analyzer with an alarm function shall be installed on the coolant side.
b) When water or aqueous solutions are used as coolants for storage tanks, cooling
coils shall not be installed within the tank.
c) When water or aqueous solutions are used as coolants for heat exchangers, shell-
and-tube heat exchangers shall utilize double tubesheets.
5.2 Equipment
5.2.1 The design, manufacture, installation, use, inspection and acceptance, repair,
modification of pressure vessels shall comply with TSG 21.
5.2.2 Fluid containing phosgene shall be transported by gravity or by leak-proof pumps
(such as canned or magnetic drive pumps). If the process requires a mechanical seal
pump, a double-end mechanical seal pump with seal flushing shall be used.
5.2.3 The sealing fluid used in pumps containing phosgene shall be compatible with the
process conditions; water or aqueous solutions shall not be used. The sealing fluid
pressure shall be higher than the process pressure. There shall also be a leak monitoring
system for the sealing fluid. Local negative pressure suction and exhaust ventilation
shall be installed near the pump, with the exhaust connected to the phosgene destruction
system.
5.2.4 The corrosion margin for equipment containing phosgene shall be determined
based on production conditions and material quality. The corrosion margin for carbon
steel or low-alloy steel shall not be less than 3 mm. Materials used in phosgenation
equipment shall be abrasion-resistant. 100% non-destructive testing shall be performed
on butt welds.
5.2.5 Sight glasses should not be used in equipment containing phosgene. If the process
requires them, sight glasses with protective covers shall be used; meanwhile local
negative pressure suction and exhaust ventilation shall be installed near the sight glasses,
with the exhaust connected to the phosgene destruction system.
5.2.6 Pressure vessels containing phosgene media shall be designed to be intrinsically
safe or adopt active safety measures to avoid overpressure. Safety relief devices shall
be installed according to the unit system. The safety relief devices shall discharge to the
emergency destruction treatment system in a closed manner and shall not be discharged
directly into the atmosphere.
5.2.7 The number of equipment and the storage capacity of each storage tank for highly
toxic materials such as liquid phosgene, methyl isocyanate, methyl chloroformate (their
primary hazardous characteristics are described in Appendix A) shall be minimized and
meet the following requirements.
a) The total storage capacity of the storage tanks shall be controlled; the volume of
a single storage tank shall not exceed 5 m3;
b) The filling factor of a single storage tank shall be controlled below 75%;
c) An emergency collection tank of appropriate system capacity shall be provided;
d) The discharge pipe of the storage tank should not be connected to the side or
bottom;
e) The storage tank shall be equipped with a safety valve with a bursting disc
installed upstream of the safety valve. The safety valve outlet shall be connected
to the emergency rupture control system; an overpressure alarm shall be installed
between the bursting disc and the safety valve;
f) The material of the liquid phosgene storage tank shall be low-temperature resistant;
methyl isocyanate storage tanks shall not use equipment, instruments, or
components made of ordinary carbon steel or alloys containing copper, zinc, or
tin.
5.2.8 Heat exchangers and shell-and-tube phosgene synthesis reactors containing
phosgene must meet the following requirements.
a) Tube bundle vibration must be prevented during design;
b) Heat exchange tubes must be seamless steel tubes;
c) Expansion joints must not be used on the phosgene side of the heat exchanger;
d) Fin-tube heat exchangers and air coolers must not be used.
5.3 Pipelines
5.3.1 The design, manufacture, installation, use, inspection, testing, acceptance, repair,
modification of metal pipelines containing phosgene shall comply with the
requirements of TSG D0001 and GB/T 20801 (all parts).
5.3.2 Pipelines containing phosgene shall not be made of brittle materials; seamless
metal pipes are preferred. Pipeline branch connections shall use integrally reinforced
branch connection fittings or tees.
5.3.3 Phosgene-containing units within phosgene and phosgenation production plants
shall be isolated in sections. Emergency shut-off valves shall be installed to isolate and
partition the units, dividing the large unit into multiple sections. The gas phase of each
section shall be connected to the phosgene destruction system; the liquid phase shall be
connected to the emergency collection tank.
5.3.4 The installation and laying of pipelines transporting fluid containing phosgene
must comply with the following requirements.
a) Support and fixings must minimize stress, vibration, friction.
b) Pipelines passing through solid walls or floors must be installed within protective
casings.
c) Pipelines must not pass through living rooms, offices, transformer rooms,
evacuation stairwells, or unrelated process equipment, system units, or storage
tanks. They must not be directly buried or laid in trenches.
d) Gaseous phosgene pipelines must have measures to prevent phosgene liquefaction
and avoid gas-liquid two-phase flow in the pipelines, which could cause pipeline
vibration and erosion.
e) Pipelines transporting fluid containing phosgene shall not be installed adjacent to
pipelines carrying hot fluids or corrosive materials, nor shall they be installed
beneath pipelines carrying corrosive liquids.
5.3.5 Pipelines transporting fluid containing phosgene must be butt-welded, not
threaded. The weld joint inspection level must comply with Level I requirements in
GB/T 20801.
5.3.6 Pipelines containing phosgene shall not be jacketed with steam, hot water, or water.
5.3.7 Pipeline insulation shall be implemented to prevent moisture penetration
(especially from ocean air) that could cause corrosion.
5.3.8 Utility pipelines connected to pipelines containing phosgene shall be equipped
with backflow prevention measures. Utility pipelines used only during equipment
shutdown shall also be equipped with blind plates.
5.3.9 Pipeline accessories prone to leakage (such as metal bellows, sleeve compensators,
spherical compensators) shall not be installed on pipelines containing phosgene.
5.3.10 Sight glasses should not be used on pipelines containing phosgene. If sight
glasses are required for the process, they shall be protected with protective covers and
shut-off valves installed before and after the sight glasses. Local negative pressure
exhaust ventilation shall be installed near the sight glasses, with the exhaust connected
to the phosgene destruction system.
5.3.11 Sampling valves, mechanical seals, flanges, and other areas where phosgene may
leak shall be protected by local negative pressure exhaust systems, with the exhaust
connected to the phosgene destruction system.
5.3.12 Vent and drain valves in pipelines containing phosgene shall be installed in
accordance with the following requirements.
a) Exhaust materials shall be collected and treated in a centralized, sealed manner,
with the exhaust connected to the phosgene destruction system and the liquid
connected to an emergency collection tank;
b) Vent and drain valves shall utilize double shut-off valves;
c) Vent and drain valve outlets shall be equipped with local negative pressure suction
and exhaust facilities, with the exhaust connected to the phosgene destruction
system.
......
Source: Above contents are excerpted from the full-copy PDF -- translated/reviewed by: www.ChineseStandard.net / Wayne Zheng et al.
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