催化裂化装置火灾及爆炸事故后果分析

对石油化工企业典型生产装置--催化裂化装置发生火灾及爆炸事故后果进行分析,研究分析了催化裂化装置油浆泵泄漏引发池火灾和石油气泄漏引发无约束蒸气云爆炸两种事故的后果情况,给出这两种事故的各种伤亡半径,从而直观的为企业提供了事故后果情况,为企业的事故预防工作提供依据.     

加氢装置主要危险性分析

本文对某厂加氢工艺装置进行分析'确定该装置的主要危险性为火灾爆炸危险性,其中包括劳料的火灾爆炸:危险性致、工艺设备的火灾危险性、爆炸性气体环境分区;该装置的主要危险性还包括设备腐蚀危险.通过对主要危险性进行分析,为该装置的安全生产保障措施的制定、初步设计及施工图的绘制,提供了重要的参考依据.     

乌江构皮滩隧洞LNG动力船LNG泄漏数值模拟

为了研究LNG动力船在通航隧洞这一新型半封闭空间结构船舶通航设施中的航行安全问题,以贵州乌江构皮滩隧洞中LNG动力船发生泄漏事故为研究对象,通过建立仿真模型,利用Fluent对LNG动力船的LNG燃料在有风和无风2种状态下发生阀门泄漏、管系泄漏和罐体破损的气体扩散过程进行模拟,分别计算得出LNG泄漏造成人员窒息、火灾、爆炸等后果的影响范围和程度.结果表明:无风状态下的泄漏危害高于有风状态下的泄漏危害,泄漏点孔径与危害范围呈正相关关系;在人员窒息、爆炸、火灾3种危害中,火灾危险范围最广,其次为爆炸危险范围,最小为人员窒息危险范围,无风状态下罐体发生泄漏造成火灾面积可达609.942 0 m2,有风状态下阀门发生泄漏可导致人员窒息的危险范围面积仅0.008 0 m2.以此为依据,从LNG动力船和通航隧洞两方面分别提出了安全保障措施.     

FSRU作业过程火灾爆炸危险性评估研究

浮式储存和再气化装置（FSRU）运行过程中易导致火灾爆炸等事故的发生,为有效评估FSRU作业过程火灾爆炸危险性,采用火灾爆炸危险指数评估法,对运用FSRU的某浮式LNG接收终端进行危险性评估;选取LNG运输船与FSRU装料作业等9个单元,研究确定了一般工艺危险性系数、特殊工艺危险性系数、安全措施补偿系数等参数,得出了补偿前后的火灾爆炸危险性指数,有效评估了FSRU作业过程火灾爆炸危险性,并基于研究结果提出了保障FSRU作业安全的对策措施与建议。研究结果表明,安全措施补偿前,缘于LNG/NG本身的火灾危险性和数量较大,能量高度集中,LNG运输船与FSRU装料作业等单元的火灾爆炸危险等级均达到了“非常大”;在采取了一系列的安全措施补偿后,火灾爆炸危险指数降低了3/5左右。这对系统深入地研究FSRU作业安全具有较重要的理论意义和实际应用价值。     

碳酸二甲酯生产装置危险性分析

从物料分子结构与火灾爆炸性质、化学反应机理、工艺生产过程等学科逐层次对碳酸二甲酯(DMC)生产装置危险有害因素进行定性分析;采用道化学火灾爆炸危险指数法、危险度评价法对装置进行固有危险程度分析;采用挪威DNV公司PHAST软件对环氧乙烷、环氧丙烷等泄漏事故后果进行模拟;提出碳酸二甲酯生产装置安全对策建议措施。     

基于PHAST的甲醇储罐定量风险分析

基于甲醇在储存中可能存在的各种泄漏事故类型,结合挪威船级社(DNV)定量风险分析软件SAFETI中的PHAST模块,分析了甲醇的危险特性以及储存中泄漏事故危险性,并运用PHAST对甲醇储罐发生泄漏后的火灾、爆炸事故后果及风险进行定量风险评价,模拟预测事故后果及风险。通过模拟分析,得出事故影响程度的计算机模拟图表和报告,并提出了防止和减轻事故危害的措施,从而为甲醇罐区的安全提供指导。     

道化学火灾、爆炸危险指数法在1,3丁二烯聚合安全性评价中的应用

道化学火灾、爆炸危险指数法是在化工领域中广泛应用的一种评价方法,根据该法制定的指数选取规则,可对工艺单元火灾爆炸危险性进行量化和分级.以某化工厂3000t/a三聚体生产项目为背景,从工艺过程、危险物质、安全设施设计等方面,对1,3丁二烯聚合过程火灾、爆炸危险性进行分析;定量评价工艺装置及所含物料潜在危险性,得出主装置区、储罐区固有危险等级,分析不同状态下安全补偿系数对降低危险等级的影响,提出相应安全对策措施.     

火灾爆炸危险指数评价法在催化裂化装置中的运用

本文以大庆石化总厂140万吨/年重油催化裂化装置为例,运用美国道化学公司火灾、爆炸危险指数评价法对该装置进行安全性评价,分析装置各单元固有的火灾爆炸危险性.根据火灾爆炸危险指数大小给工艺单元划分危险等级,评价其潜在的火灾爆炸危险,确定安全补偿系数.通过量化其危险性因素,从生产设备、工艺操作、安全管理等方面综合分析该装置的危险性、生产过程存在的火灾爆炸危险性和发生事故的可能性,评价发生事故的严重程度,找出主要危险因素力求从技术、工艺、设备、原材料、安全管理等方面采取措施,以减少火灾爆炸事故的发生或降低事故损失.本文为石化企业采取有针对性的火灾爆炸预防措施,从而降低事故的发生概率,提高装置运行的稳定性和可靠性,减少损失,保证生产安全进行提供了科学依据.     

道化学火灾、爆炸危险指数分析法在油库安全监管中的应用

<正>用道化学火灾、爆炸危险指数分析法对油库石脑油储罐进行风险分析,得出对其采取安全措施补偿前后的火灾、爆炸指数(F&EI),以及暴露半径和面积、危害系数、危险等级等指数,为安全监管提供理论依据,找准安全隐患位置和关键点,以便采取有效的安全防护措施。道化学(DOW)火灾、爆炸危险指数分析法是依据以往所发生事故的统计资料、物质的潜在能量和现行安全防灾措施的状况,按逐步推算的方法,对工艺装置及所含物料     

MTBE装置潜在危险性分析及物料泄漏扩散后果模拟研究

MTBE装置处理的物料（混合C4、甲醇）具有易燃易爆性,若发生物料泄漏,将导致装置发生火灾爆炸。为了确保装置安全平稳、长周期运行,基于MTBE装置工艺技术特点,全面系统分析了装置的潜在危险性,总结出导致装置发生火灾爆炸事故的主要因素-物料泄漏;在此基础上,采用挪威DNV公司的SAFETI定量风险评价软件,建立混合C4、甲醇泄漏扩散模型,对物料泄漏导致的主要事故类型（喷射火、池火等）进行模拟,得出泄漏扩散引发火灾爆炸事故的危害范围。结果表明：该模拟研究能够反映出泄漏扩散过程和破坏范围,取得了较真实的事故影响范围曲线图,可以为设计人员更加详细了解MTBE装置发生事故的危害性及企业加强重点部位监控、制定防范措施、编制事故应急预案提供重要参考依据。     

Cushioning the impact of toxic release from runaway industrial accidents with greenbelts

The three aspects of accidents in chemical process industries which cause most serious damage—explosions, fires, and toxic releases—can all be controlled to some extent if greenbelts are present around the affected industry. We have recently developed and validated a system of methodologies for greenbelt design. In this paper we present the application of these models in designing greenbelts and forecasting their role in cushioning the impact of accidental release of toxic gases. With properly located and designed greenbelts as much as 33% of the accidental release of SO₂, 43% of H₂S, and 51% of NH₃ under stable atmospheric conditions (in which the dispersion is very slow and the release thus has maximum toxic impact) can be absorbed.     

Applications of dust explosion hazard and disaster prevention technology

Powdered materials are widely used in industrial processes, chemical processing, and nanoscience. Because most flammable powders and chemicals are not pure substances, their flammability and self-heating characteristics cannot be accurately identified using safety data sheets. Therefore, site staff can easily underestimate the risks they pose. Flammable dust accidents are frequent and force industrial process managers to pay attention to the characteristics of flammable powders and create inherently safer designs.This study verified that although the flammable powders used by petrochemical plants have been tested, some powders have different minimum ignition energies (MIEs) before and after drying, whereas some of the powders are released of flammable gases. These hazard characteristics are usually neglected, leading to the neglect of preventive parameters for fires and explosions, such as dust particle size specified by NFPA-654, MIE, the minimum ignition temperature of the dust cloud, the minimum ignition temperature of the dust layer, and limiting oxygen concentration. Unless these parameters are fully integrated into process hazard analysis and process safety management, the risks cannot be fully identified, and the reliability of process hazard analysis cannot be improved to facilitate the development of appropriate countermeasures. Preventing the underestimation of process risk severity due to the fire and explosion parameters of unknown flammable dusts and overestimation of existing safety measures is crucial for effective accident prevention.     

A quantitative risk management framework for dust and hybrid mixture explosions

Dust and hybrid-mixture explosions continue to occur in industrial processes that handle fine powders and flammable gases. Considerable research is therefore conducted throughout the world with the objective of both preventing the occurrence and mitigating the consequences of such events. In the current work, research has been undertaken to help move the field of dust explosion prevention and mitigation from its current emphasis on hazards (with an accompanying reliance on primarily engineered safety features) to a focus on risk (with an accompanying reliance on hierarchical, risk-based, decision-making tools). Employing the principles of quantitative risk assessment (QRA) of dust and hybrid-mixture explosions, a methodological framework for the management of these risks has been developed.The QRA framework is based on hazard identification via credible accident scenarios for dust explosions, followed by probabilistic fault-tree analysis (using Relex – Reliability Excellence – software) and consequence severity analysis (using DESC – Dust Explosion Simulation Code – software). Identification of risk reduction measures in the framework is accomplished in a hierarchical manner by considering inherent safety measures, passive and active engineered devices, and procedural measures (in that order). An industrial case study is presented to show how inherent safety measures such as dust minimization and dust/process moderation can be helpful in reducing dust and hybrid-mixture explosion consequences in a 400-m³ polyethylene storage silo.     

Leading and lagging: Process safety climate–incident relationships at one year

In order to evaluate the leading and lagging effects of process safety climate on incidents, we correlated safety climate survey data with organizational safety records from before and after the survey time period. We obtained data from a large, multinational organization with manufacturing operations involving a number of complex processes, chemicals, and hazardous substances. A total of 7728 employees from 62 sites responded to a safety climate survey in 2007. Individual responses were aggregated to the site-level and matched to site-level organizational records of process safety incidents 1 year before and 1 year after survey administration. Employees’ perceptions of good routine housekeeping were significantly related to environmental impact incidents as both a leading and a lagging indicator, as well as fires/explosions and property damage outcomes. Employees’ perceptions of systems to prevent backlogs and the extent to which health and safety problems are promptly corrected were also related to environmental releases and fires/explosions. Implications for process safety climate research, organizational survey strategies, and organizational climate change are discussed.     

Misoperation monitoring and early warning during startup and shutdown of petrochemical units

Most petrochemical units run under extreme conditions, such as high temperatures, pressures, and speeds. Consequently, the equipment operators may commit errors because the startup and shutdown processes usually involve complicated operation steps; moreover, the operators may lack experience in handling abnormal situations. Misoperation can lead to accidents, including fires and explosions. Thus, risk analysis for process operations and the development of preventive measures have become an effective means of avoiding misoperation-related accidents. However, it is challenging to ensure the comprehensiveness of risk-analysis results. In this paper, we present a method for misoperation monitoring and early warning in the startup and shutdown processes of petrochemical units. The mechanisms of misoperation occurrence are summarized based on investigations of serious accidents in the recent past. Knowledge regarding the mechanisms of misoperation is crucial for the risk analysis of petrochemical units. The potential risk information, such as causes, adverse consequences, key monitoring parameters, and prevention control solutions, should be acquired and be employed to construct an early-warning knowledge database. Furthermore, misoperation judgment rules need to be formulated to identify misoperations. The data obtained from the monitoring module, misoperation judgment rules, and analysis results can aid in developing schemes to avoid possible abnormal situations. This paper reports a misoperation monitoring and early-warning system for a hydrogenation unit. As demonstrated, conducting risk analysis to determine the potential operational risks and formulating misoperation judgment rules to analyze the process data are essential for enabling early warning. The application of this method will contribute to operational guidance, economic loss reduction, and accident avoidance.     

TORAP—a new tool for conducting rapid risk assessment in petroleum refineries and petrochemical industries

The use of a new computer-automated tool TORAP (TOol for Rapid risk Assessment in Petroleum refinery and petrochemical industries) is demonstrated through a rapid and quantitative risk assessment of a typical petroleum refinery. The package has been applied for an appraisal of the risks of accidents (fires, explosions, toxic release) posed by different units of the refinery, and to identify steps to prevent/manage accidents. The studies reveal that TORAP enables a user to quickly focus on the accidents likely to occur, and enables forecasting the nature and impacts of such accidents. This information is directly utilisable in identifying “soft” spots and in taking appropriate remedial measures to prevent or control accidents. The special attributes of TORAP are: (a) a wide range of applications—achieved by incorporating models capable of handling all types of industrial fires and explosions, (b) sophistication—brought about by including state-of-the-art models developed by these authors and others, (c) user-friendliness—achieved by incorporating on-line help, graphics, carefully formatted output, and, above all, an automatic module with which even a lay user can conduct risk assessment. The entire package, especially its automatic module, is supported by an extensive knowledge-base built into the software.     

Application of dynamic risk analysis in offshore drilling processes

Process safety is the common global language used to communicate the strategies of hazard identification, risk assessment and safety management. Process safety is identified as an integral part of process development and focuses on preventing and mitigating major process accidents such as fires, explosions, and toxic releases in process industries. Accident probability estimation is the most vital step to all quantitative risk assessment methods. Drilling process for oil is a hazardous operation and hence safety is one of the major concerns and is often measured in terms of risk. Dynamic risk assessment method is meant to reassess risk in terms of updating initial failure probabilities of events and safety barriers, as new information are made available during a specific operation. In this study, a Bayesian network model is developed to represent a well kick scenario. The concept of dynamic environment is incorporated by feeding the real-time failure probability values (observed at different time intervals) of safety barriers to the Bayesian network in order to obtain the corresponding time-dependent variations in kick consequences. This study reveals the importance of real-time monitoring of safety barrier performances and quantitatively shows the effect of deterioration of barrier performance on kick consequence probabilities. The Macondo blowout incident is used to demonstrate how early warnings in barrier probability variations could have been observed and adequately managed to prevent escalation to severe consequences.     

Pilot sample risk analysis for underground coal mine fires and explosions using MSHA citation data

After three decades of sustained continuous improvement of mine safety performances in the US, mine disasters in 2006 and 2007 compromised an excellent record and presented new challenges and vulnerabilities for the underground coal mining industry. In the aftermath of the incidents, formal investigations and new scrutiny of mine safety by the US Congress and expert study groups followed. The US Congress passed the Mine Improvement and New Emergency Response Act of 2006 (MINER Act), which mandated new laws to address the issues, including those related to mine fires and explosions from which miners must be protected. The National Mining Association-sponsored Mine Safety Technology and Training Commission report highlighted the role of risk analysis and management in identifying and controlling major hazards, such as fires and explosions. In this paper an approach is given for analyzing the risks for fires and explosions based on the Mine Safety and Health Administration citation database. Using 2006 citation data and focusing on subsystem failures, the methodology is applied to a database for a pilot sample of underground coal mines stratified by mine size and state.     

重大危险源普查与建立重大事故预防控制体系

本简要介绍了重大危险源普查技术方法和北京、上海等6城市重大危险源普查结果。论述了重大事故预防控制体系要素，包括重大危险源普查(辨识)、评价、安全管理、应急计划、安全规划、安全监察，GIS网络监控系统等。     

Does your facility have a dust problem: Methods for evaluating dust explosion hazards

The hazards of dust explosions prevailing in plants are dependent on a large variety of factors that include process parameters, such as pressure, temperature and flow characteristics, as well as equipment properties, such as geometry layout, the presence of moving elements, dust explosion characteristics and mitigating measures. A good dust explosion risk assessment is a thorough method involving the identification of all hazards, their probability of occurrence and the severity of potential consequences. The consequences of dust explosions are described as consequences for personnel and equipment, taking into account consequences of both primary and secondary events.While certain standards cover all the basic elements of explosion prevention and protection, systematic risk assessments and area classifications are obligatory in Europe, as required by EU ATEX and Seveso II directives. In the United States, NFPA 654 requires that the design of the fire and explosion safety provisions shall be based on a process hazard analysis of the facility, process, and the associated fire or explosion hazards. In this paper, we will demonstrate how applying such techniques as SCRAM (short-cut risk analysis method) can help identify potentially hazardous conditions and provide valuable assistance in reducing high-risk areas. The likelihood of a dust explosion is based on the ignition probability and the probability of flammable dust clouds arising. While all possible ignition sources are reviewed, the most important ones include open flames, mechanical sparks, hot surfaces, electric equipment, smoldering combustion (self-ignition) and electrostatic sparks and discharges. The probability of dust clouds arising is closely related to both process and dust dispersion properties.Factors determining the consequences of dust explosions include how frequently personnel are present, the equipment strength, implemented consequence-reducing measures and housekeeping, as risk assessment techniques demonstrate the importance of good housekeeping especially due to the enormous consequences of secondary dust explosions (despite their relatively low probability). The ignitibility and explosibility of the potential dust clouds also play a crucial role in determining the overall risk.Classes describe both the likelihood of dust explosions and their consequences, ranging from low probabilities and limited local damage, to high probability of occurrence and catastrophic damage. Acceptance criteria are determined based on the likelihood and consequence of the events. The risk assessment techniques also allow for choosing adequate risk reducing measures: both preventive and protective. Techniques for mitigating identified explosions risks include the following: bursting disks and quenching tubes, explosion suppression systems, explosion isolating systems, inerting techniques and temperature control. Advanced CFD tools (DESC) can be used to not only assess dust explosion hazards, but also provide valuable insight into protective measures, including suppression and venting.