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Chemical equipment running sick like playing with fire
In recent years, numerous safety incidents have occurred due to aging chemical equipment, highlighting the critical need for improved maintenance and management practices. Oil and chemical equipment often operate under extreme conditions—high temperatures, high pressures, and in corrosive or toxic environments. When such equipment fails, the consequences can be catastrophic, leading to significant loss of life, environmental damage, and economic losses. For instance, the 2004 chlorine gas explosion at Chongqing Tianyuan Chemical Factory resulted in nine deaths, three injuries, and the evacuation of over 150,000 people. Although classified as an accident, the root cause was traced back to a perforated chlorine condenser, which experts attributed to outdated and deteriorating equipment.
The petroleum and chemical industries rely on a wide array of equipment, including distillation towers, heat exchangers, compressors, pressure vessels, and pipelines. To prevent accidents caused by faulty or aging machinery, the concept of "failure control" has emerged as a crucial strategy. Failure control is a multidisciplinary field that combines elements of materials science, engineering, chemistry, and mechanics. It involves analyzing failure mechanisms, predicting potential issues, and implementing preventive measures. Techniques like fracture analysis, non-destructive testing, and component analysis are commonly used to identify early signs of wear or structural weakness.
To address these challenges, specialized agencies have been established to conduct failure analysis and prevention. For example, Sinopec operates several research centers dedicated to equipment failure analysis, helping oil and chemical companies detect and resolve equipment problems before they escalate into disasters. These centers play a vital role in improving equipment management, enhancing operational safety, and ensuring long-term reliability.
According to officials from the Special Equipment Safety Supervision Bureau under the General Administration of Quality Supervision, Inspection, and Quarantine, effective risk control is essential for maintaining safe operations. This includes strict registration procedures, regular inspections, and comprehensive record-keeping. Equipment that fails to meet safety standards must be repaired or retired, and decommissioned equipment should undergo proper evaluation before being reused.
Furthermore, users of chemical equipment are required to maintain detailed technical files, including design documents, inspection reports, and maintenance records. However, many small enterprises struggle with poor documentation and frequent staff turnover, leading to lost or incomplete records. To address this, better data management systems and regular audits are necessary.
Finally, regulatory authorities must enforce strict oversight of both equipment operators and inspection agencies. Violations of safety regulations should be met with appropriate penalties, and unlicensed entities involved in equipment production or testing must be held accountable. By combining proactive maintenance, rigorous inspections, and strong regulatory enforcement, the industry can significantly reduce the risk of future accidents.