Development of a new chemical process-industry accident database to assist in past accident analysis

Past accident analysis (PAA) is one of the most potent and oft-used exercises for gaining insights into the reasons why accidents occur in chemical process industry (CPI) and the damage they cause. PAA provides invaluable ‘wisdom of hindsight’ with which strategies to prevent accidents or cushion the impact of inevitable accidents can be developed.A number of databases maintain record of past accidents in CPI. The most comprehensive of the existing databases include Major Hazard Incident Data Service (MHIDAS), Major Accident Reporting System (MARS), and Failure and Accidents Technical Information Systems (FACTS). But each of these databases have some limitations. For example MHIDAS can be accessed only after paying a substantial fee. Moreover, as detailed in the paper, it is not infallible and has some inaccuracies. Other databases, besides having similar problems, are seldom confined to accidents in chemical process industries but also cover accidents from other domains such as nuclear power plants, construction industry, and natural disasters. This makes them difficult to use for PAA relating to CPI. Operational injuries not related to loss of containment, are also often included. Moreover, the detailing of events doesn’t follow a consistent pattern or classification; a good deal of relevant information is either missing or is misclassified.The present work is an attempt to develop a comprehensive open-source database to assist PAA. To this end, information on about 8000 accidents, available in different open-source clearing houses has been brought into a new database named by us PUPAD (Pondicherry University Process-industry Accident Database). Multiple and overlapping accident records have been carefully eliminated and a search engine has been developed for retrieval of the records on the basis of appropriate classification. PUPAD doesn’t aim to replace or substitute the well established databases such as MHIDAS and MARS but, rather, aims to compliment them.     

Underground parallel pipelines domino effect: An analysis based on pipeline crater models and historical accidents

This paper focuses on the analysis of the possibility of domino effect in underground parallel pipelines relying on historical accident data and pipeline crater models. An underground pipeline can be considered as safe following an accident with an adjacent gas or liquefied pipeline when it remains outside the ground crater generated. In order to prevent the domino effect in these cases, the design of parallel pipelines has to consider adequate pipeline separations based on the crater width, which is one of the widely used methods in engineering applications. The objective of this work is the analysis of underground petroleum product pipelines ruptures with the formation of a ground crater as well as the evaluation of possible domino effects in these cases. A detailed literature survey has been carried out to review existing crater models along with a historical analysis of past accidents. A FORTRAN code has been implemented to assess the performance of the Gasunie, the Batelle and the Advantica crater models. In addition to this, a novel Accident-Based crater model has been presented, which allows the prediction of the crater width as a function of the relevant design pipeline parameters as well as the soil density. Modifications have also been made to the Batelle and Accident-Based models in order to overcome the underestimation of the crater width. The calculated crater widths have been compared with real accident data and the performance evaluation showed that the proposed Accident-Based model has a better performance compared to other models studied in this work. The analysis of forty-eight past accidents indicated a major potential of underground parallel pipelines domino effect which is proven by two real cases taken from the literature. Relying on the investigated accidents, the crater width was smaller than or equal to 20 m in most cases indicating that the definition of underground pipeline separations at around 10 m would be sufficient to ensure a small probability of the domino effect.     

Improved models of failure time for atmospheric tanks under the coupling effect of multiple pool fires

Fire accidents of chemical installations may cause domino effects in atmospheric tank farms, where a large amount of hazardous substances are stored or processed. Pool fire is a major form of fire accidents, and the thermal radiation from pool fire is the primary hazard of domino accidents. The coupling of multiple pool fires is a realistic and important accident phenomenon that enhances the propagation of domino accidents. However, previous research has mostly focused on the escalation of domino accidents induced by a single pool fire. To overcome the drawback, in this study, the failure of a storage tank under the coupling effect of multiple pool fires was studied in view of spatial and temporal synergistic process. The historical accident statistics indicated that the accident scenario of two-pool fires accounted for 30.6% in pool fires. The domino accident scenario involving three tanks is analyzed, and the typical layout of tanks is isosceles right triangle based on Chinese standard “GB50341-2014”. The thermal response and damage of a target tank heated by pool fires were numerically investigated. The volume of 500 m³, 3000 m³, 5000 m³ and 10000 m³ were selected. Flame temperature was obtained by FDS, and then was input onto the finite element model. The temperature field and stress field of target tanks were simulated by ABAQUS. The results showed that the temperature rise rate of the target tanks under multiple pool fires was higher than that under a single pool fire. The failure time of the tank under the coupling effect of multiple fires was lower than that under the superposition of multiple fires without the first stage. The stress and yield strength were compared to judge the failure of the target tank. The model of failure time for the tank under the coupling effect of pool fires was established. Through the verification, the deviation of this model is 4.02%, which is better than the deviation of 15.76% with Cozzani's model.     

The significance of domino effect in chemical accidents

A historical survey was performed on 330 accidents involving domino effect, occurred in process/storage plants and in the transportation of hazardous materials; only accidents occurred after 1st-January-1961 have been considered. The main features – geographical location, type of accident, materials involved, origin and causes, consequences, domino sequences – were analyzed, with special consideration to the situation in the developing countries and compared to those from other previous surveys. Among the involved substances, LPG was the most frequent one, followed by liquid hydrocarbons. Process plants (38.5% of cases) and storage areas (33%) were the most common settings; 10.6% of past domino accidents occurred in transfer operations. The ratio between “two-step” and “three-step” domino accidents was found to be 6. A specific analysis of the accidents (84) occurred in the 21st century was performed, comparing them with the total set of accidents. Finally, a set of specific recommendations inferred from the results is provided.     

多米诺效应的风险分析方法

介绍与分析多米诺效应的相关研究,并针对多米诺效应的定量风险分析,建立了从多米诺场景辨识到后果分析的多米诺效应定量分析方法.通过分析初始事故带来的物理效应对邻近设备的影响,计算了二次设备的损坏概率;分析了多米诺场景,计算了多米诺事故频率,并根据多米诺事故的后果得到个人风险和社会风险曲线.多米诺效应的风险是工业区一个潜在的严重风险,加强多米诺效应的研究对工厂和工业区的安全管理与规划都有重要意义.     

Application of domino effect quantitative risk assessment to an extended industrial area

Escalation of primary accidental scenarios triggering a “domino effect” have caused extremely severe accidental events in the chemical and process industry. The identification of possible escalation events is required in the safety assessment of sites where relevant quantities of hazardous substances are stored or handled. In the European Union, “Seveso-II” Directive requires the assessment of on-site and off-site possible escalation scenarios in sites falling under the obligations of the Directive. In the present study, a methodology developed for the quantitative assessment of risk due to domino effect was applied to the analysis of an extended industrial area. Recently developed equipment damage probability models were applied for the identification of the final scenarios and for escalation probability assessment. The domino package of the Aripar-GIS software was used for risk recomposition. The results evidence that quantitative risk assessment of escalation hazard is of fundamental importance in order to identify critical equipment and to address prevention and protection actions.     

A model for estimating the impact of the domino effect on accident frequencies in quantitative risk assessments of storage facilities

It is well known that the domino effect can have a major impact on accidents in storage facilities, as it can increase the consequences of an initial event considerably. However, quantitative risk assessments (QRAs) do not usually take the domino effect into account in a detailed, systematic way, mostly because of its complexity and the difficulties involved in its incorporation. We have developed a simple method to include the domino effect in QRAs of storage facilities, by estimating the frequency with which new accidents will occur due to this phenomenon. The method has been programmed and implemented in two case studies. The results show that it can indeed be used to include the possibility of domino effect occurrence in a QRA. Furthermore, depending on the design of a facility, the domino effect can have a significant effect on the associated risk.     

Modern accident investigation - Four major challenges

Nowadays, ‘investigation’ is a very commonly advocated approach and consequently is becoming an umbrella concept. ‘Investigation’ includes many types of approaches on different system levels. Originating from transport accidents and crime scenes, ‘investigation’ ranges from genocide, natural disasters, via discrimination, health care to crime fighting, economic fraud and ethical questions in engineering and management. In such a changing operating environment and widespread applications, accident investigation must reassess its distinctive role, purposes and operating conditions. It must clarify and communicate its specific aims and functions and performance to such an extent that it maintains its credibility, capability and quality in the eye of professionals, politicians as well as the public. Based on an assessment of the past performance of leading investigation agencies, practical experiences during major ad hoc accident investigations and changes in the operating environment, a SWOT analysis identified several issues as internal and external challenges in the future conduct of major investigations. Finally, the article proposes several priorities, challenging each stakeholder and expert in the investigation community to contribute from its own perspective to improve accident investigation theory and practices.     

化学工业重大事故的多米诺效应分析

针对化学工业重大事故多米诺效应的严重后果,进行重大事故多米诺效应发生规律的研究。在指出触发重大事故多米诺效应发生条件和发生模式的基础上,设计重大事故多米诺效应的研究程序。借助生成重大火灾爆炸事故场景和其后果分析方法,建立多米诺效应概率分析的数学模型,利用VB开发了多米诺效应计算软件DOMISOFWARE,解决较为复杂的重大事故多米诺效应概率的计算问题。研究表明,爆炸事故总是较火灾事故具有更高触发多米诺效应的可能性,并且火灾和爆炸触发加压设备发生多米诺效应的概率与常压设备相比随间距增大几乎呈线性下降;确定了爆炸和火灾触发多米诺效应的概率和临界距离。研究结果对于化工装置的安全设计和重大事故的预防控制具有重要的指导意义。     

FREEDOM II: An improved methodology to assess domino effect frequency using simulation techniques

The uncertainty and the complexity associated with the domino effect is a barrier to assessing the frequency of such accidents analytically. The use of simulation techniques, such as Monte Carlo, to examine the domino effect instead of analytical techniques has shown great promise. In this paper, a new method to assess the frequency of domino accidents is proposed—FREEDOM II—which is an improvement on the recent algorithm proposed by the authors (FREEDOM). The modifications on FREEDOM were carried out to overcome a limitation of the method and to extend its capabilities. A key shortcoming of the earlier method was its inability to handle multiple failure scenarios. This shortcoming has been overcome in FREEDOM II. A new and improved algorithm has been developed that carries out the simulation in a significantly shorter run time. The applicability of the new model is shown by performing a multi-scenario case study.     

Research on three-dimensional visualization system of Natech events triggered domino accidents in oil-gas depots

Natech events and domino accidents happen worldwide and usually lead to severe consequences, especially in hazardous areas such as Oil-Gas depots. With the continuous development of the Oil-Gas industry and information technology, it is essential to realize the three-dimensional management and monitoring of hazardous substances. To evaluate the consequences caused by Natech events triggered domino accidents (accident chain), a matrix loop method was proposed to calculate the probability and evolution path of the accident chain. The actual layout and the real-time data of the Oil-Gas depot are input into the evaluation method in matrices, thus making the results reliable and updated. Besides, a B/S architecture system is developed to present the evaluation consequences of the proposed method. The three-dimensional visualization effects of natural disasters, technological accidents and the dynamic propagation process of the accident chain are also realized in the system to enhance the user's experience. A system application regarding lightning-triggered domino accidents was carried out to demonstrate the feasibility and rapidity of the proposed evaluation method and perform the system's operation process and visualization effects. The application results show that the system can provide effective decision-making assistance to safety management workers before the accident and guidance for emergency rescue operations during the accident.     

基于蒙特卡洛模拟的多米诺事故风险量化管理*

为降低危化品相关的化工事故造成的人员伤亡和财产损失，以化工多米诺事故为研究对象，探讨由初始事故引发1个或多个次生事故的连锁反应机理与风险评估方法。提出应用蒙特卡洛模拟对多米诺事故风险进行动态量化的方法，梳理化工多米诺事故风险的识别、分析、评定、处理全周期管理流程，并以1个天然气压气站为案例，验证基于蒙卡模拟的化工多米诺事故风险量化方法的有效性。结果表明:该方法可以更准确地对化工多米诺事故风险进行定量评估。多米诺事故风险全周期管理流程的梳理能够有效指导化工企业开展安全管理、事故预防等工作。     

化工储罐区池火灾多米诺效应风险评估

化工储罐区储罐数量较多且集中,一旦发生事故很可能诱发多米诺效应造成灾难性的后果。在分析池火灾多米诺效应作用模式的基础上,建立了池火灾多米诺效应风险评估模型,并对某化工储罐区进行了实例计算,分析了单一储罐池火灾事故引发其他储罐池火灾的风险。分析结果表明,池火灾是诱发化工储罐多米诺事故的重要因素,且会造成风险的显著增加,但并非所有的池火灾事故都会诱发多米诺效应。此外,将多米诺效应评价方法应用于化工储罐池火灾事故风险评估中可有效地预测次生事故的发生概率和后果,从而提出针对性措施。     

Investigation of multiple domino scenarios caused by fragments

A model of multiple domino scenarios and the risk of the domino effect, which is a sequential chain escalating from the primary unit to the last unit, is presented in this paper. The trajectories of fragments from all units, the ground distribution of projectiles, and the risk of the sequential chain of the domino effect were calculated using Monte Carlo simulations. The results showed that the range affected by the fragments from each tank included the other tanks, meaning that fragments from one tank could hit the other tanks and cause multiple accidents, and that the sequential chain of the domino effect could indeed happen. The distributions of ground impacts showed that tank fragments were projected over long distances, up to 1200 m from the source. The spatial distribution of the kinetic energy at ground impact for tank fragments was also obtained. Moreover, the magnitudes of the probabilities of the primary, secondary, third, and fourth accidents in the domino chain were respectively about 10⁻⁷, 10⁻¹¹, 10⁻¹⁵, and 10⁻¹⁹. These results showed that for neighboring domino effect units in the same accident chain, the risk of the most recent domino effect was 10⁴ times that of the following domino effect.     

基于多米诺效应的输油管道重大事故后果分析

针对近年来不断发生的输油管道重大事故,引入多米诺效应理论分析输油管道事故后果。首先依据多米诺效应机理,建立输油管道重大事故多米诺效应模型,然后采用PHAST软件确定初始事故影响范围,运用设备损坏概率和人员伤亡概率模型计算初始事故对周围设备和个体的影响概率,从而可以从设备损坏、人员伤亡和事故影响范围三个方面定量分析输油管道的事故后果。研究结果对制定输油管道重大事故应急抢险方案,避免事故影响范围进一步扩大具有理论指导意义。     

质子交换膜燃料电池电站多米诺事故概率和风险研究*

为探究氢能电站火灾爆炸事故发展规律,采用多米诺效应对电站进行事故概率和风险研究,建立氢能电站多米诺效应定量风险分析模型。基于设备受损概率模型与多米诺理论基础,提出氢能电站多米诺效应概率计算方法,并将方法运用到实际案例,结合SAFETI软件对具体多米诺事故场景进行定量计算。研究结果表明:氢能电站易发生多米诺事故,考虑一级多米诺效应后人员潜在死亡概率增加56%。研究结果可为制定氢能电站安全防控措施以及降低火灾爆炸事故对人员和设备的危害提供依据。     

基于贝叶斯网络的事故多级多米诺效应计算方法研究

为了更合理地分析事故风险,提出了基于贝叶斯网络的多级多米诺效应计算方法及其计算步骤,并从个人风险和社会风险2个角度,定量分析了生产安全事故的多级多米诺效应。同时以某企业的2个汽油罐区为例,运用上述方法对其生产安全事故的多米诺效应进行定量计算,并将计算结果与未考虑多米诺效应、仅考虑一级多米诺效应时的计算结果进行比较。研究结果表明:基于贝叶斯网络的计算方法,同时考虑了多级多米诺效应和事故的协同效应,可以使计算的个人风险和社会风险更接近于实际。     

Application of a multi-plant QRA: A case study investigating the risk impact of the construction of a new plant on an existing chemical plant's risk levels

The construction of chemical clusters whereby a variety of chemical plants are located next to each other provides great economic benefits. However, in such clusters, due to the mere scale on which hazardous materials are processed, stored and handled, the potential of various accidents is much higher than in single companies. Furthermore, the close proximity of process installations and storage tanks in such areas gives rise to the risk of domino effects. Therefore, land use planning and layout design has always been a challenge within such clusters.In this paper, a Quantitative Risk Assessment (QRA) is carried out and used as a decision making tool to evaluate the acceptability of constructing a new chemical plant adjacent to an existing one. For this purpose, standard parameters such as individual risk and societal risk were quantified, before and after the new plant would come into operation. Given the experience of past accidents in the process industries, the likelihood of domino accidents in the two neighboring plants has also been analyzed.     

基于多米诺效应的定量风险评价研究

多米诺效应是引发化工重大事故的主要原因之一.本文综合国内外的研究成果,对火灾热辐射、冲击波超压等造成的多米诺效应进行了深入分析,建立基于多米诺效应的定量风险评价模型,其中包括了评价流程、传播概率、阈值距离计算、多米诺效应对事故频率的影响及后果分析的内容.最后利用Matlab7.1计算平台,以汽油储罐进行实例分析,结果表明该方法是一种适用于多米诺效应定量评价的良好方法,能够比较科学、有效的对危险单元进行风险评价,使重大事故风险评价更切合实际,为政府监管部门和化工企业进行事故的控制和预防提供决策技术.     

Overview of the relationship between organizational and workplace factors and injury rates

This paper summarizes data from ten studies examining the relationship between organizational and workplace factors and injury rates. The studies were identified from a systematic literature search, as well as from other sources, and were included if they reported comparisons among at least 20 workplaces. Factors that were examined in at least two studies were identified. Their relationship with injury rates was determined. It was not possible to make quantitative comparisons between studies. We looked for ‘consistency’ or ‘contradiction’ in the relationships. Among the variables ‘consistency’ associated with lower injury rates were: empowerment of the workforce (in general matters); delegation of safety activities; and an active role (in health and safety) of top management. Among the ‘contradictory’ variables were the level and use of discipline for safety violations; and several others that were contradictory only in subgroups of the same study. We discuss the limitations of synthesizing results from the diverse studies.