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Chemical equipment running sick like playing with fire
In recent years, numerous safety incidents have occurred due to the use of outdated chemical equipment. Given that oil and chemical equipment operates under high temperatures, high pressures, and in corrosive and toxic environments, any malfunction can lead to severe consequences, including significant property loss and major casualties. For instance, the 2004 chlorine gas explosion at Chongqing Tianyuan Chemical Factory resulted in 9 deaths, 3 injuries, and the evacuation of over 150,000 people. Although the incident was classified as an accident, it was ultimately traced back to a perforation in the chlorine condenser. Experts concluded that the root cause was the aging and obsolete chlorine tanks and related equipment.
The petroleum and chemical industries rely on a wide range of equipment, such as distillation towers, heating furnaces, heat exchangers, condensers, compressors, steam turbines, pumps, pressure vessels, and pipelines. To prevent accidents caused by faulty or aging equipment, experts emphasize the importance of "failure control." This concept, also known as failure analysis and prevention, is a multidisciplinary field that combines reliability engineering, materials science, mechanics, chemistry, corrosion protection, and more. Techniques like fracture analysis, non-destructive testing, and metallurgical examination are commonly used to identify and mitigate potential failures before they occur.
To address these challenges, specialized agencies have emerged to conduct failure analysis and prevention. For example, Sinopec has established research centers in Shanghai, Shenyang, and Nanjing, which focus on identifying and solving equipment issues through advanced analytical methods. These centers play a crucial role in improving equipment management, ensuring safe operations, and reducing the risk of accidents.
According to officials from the Special Equipment Safety Supervision Bureau under the General Administration of Quality Supervision, Inspection, and Quarantine, ensuring the safe operation of chemical equipment requires effective risk control. The regulations mandate that all equipment be registered and issued with usage permits, and that their status be monitored through dynamic computer systems. Any equipment found to have safety hazards must be managed accordingly, and those that cannot meet safety standards must be repaired or scrapped within a specified timeframe. Additionally, decommissioned equipment must undergo proper testing and evaluation before being reused.
Furthermore, users of chemical equipment should maintain detailed safety technical files. These records should include design documents, inspection reports, maintenance logs, and records of past failures. However, many small enterprises lack proper record-keeping, leading to frequent file losses due to personnel turnover. Measures must be taken to improve this situation. Regular inspections, at least once a month, should also be conducted and documented.
Lastly, safety supervision authorities must strictly enforce their oversight responsibilities. They should not only inspect equipment in use but also monitor production units and testing agencies. Violations of safety regulations should result in appropriate penalties. Units operating without proper licenses or registrations must be legally banned or punished. Through these comprehensive measures, the industry can significantly reduce the risks associated with aging and faulty equipment, ensuring safer and more reliable operations.