Continuous performance assessment and improvement of integrated HSE and maintenance systems by multivariate analysis in gas transmission units

In this study, an integrated “Health, Safety, and Environment (HSE)” and maintenance systems are presented. Multivariate analysis is used for continuous performance assessment and improvement of these systems. The two subjects of “Maintenance System” and “HSE” have been individually investigated several times in different studies. However, few studies have been done to integrate these two systems and provide an integrated system for their implementation. This study evaluates current maintenance and HSE systems of a Gas Transmission Unit by Data Envelopment Analysis (DEA) and Principal Component Analysis (PCA). Moreover, decision making units (DMUs) are examined and ranked. Employees are considered as DMUs. This is done through investigating and measuring their efficiencies and identifying the inefficient and less-efficient units. Since an increase in the number of inputs does not lead to an increase in the number of outputs with the same scale, an output-oriented DEA with a Variable Returns to Scale (VRS) is used. The Fuzzy DEA (FDEA) is also used in this research to decrease uncertainty existing in qualitative indicators and human error. Finally, suggestions are given to improve those DMUs. The managers and employees of the gas transmission unit constitute the statistical population of the study. To achieve the objectives of this study, standard questionnaires with respect to HSE and Maintenance system are completed by operators. The proposed approach would help policy makers and top managers of Gas Transmission Company to have a more comprehensive and thorough understanding the working conditions with respect to the maintenance and HSE features.     

An adaptive neural network algorithm for assessment and improvement of job satisfaction with respect to HSE and ergonomics program: The case of a gas refinery

Researchers have been continuously trying to improve human performance with respect to Health, Safety and Environment (HSE) and ergonomics (hence HSEE). This study proposes an adaptive neural network (ANN) algorithm for measuring and improving job satisfaction among operators with respect to HSEE in a gas refinery. To achieve the objectives of this study, standard questionnaires with respect to HSEE are completed by operators. The average results for each category of HSEE are used as inputs and job satisfaction is used as output for the ANN algorithm. Moreover, ANN is used to rank operators performance with respect to HSEE and job satisfaction. Finally, Normal probability technique is used to identify outlier operators. Moreover, operators with inadequate job satisfaction with respect to HSEE are identified. This would help managers to see if operators are satisfied with their jobs in the context of HSEE. This is the first study that introduces an integrated ANN algorithm for assessment and improvement of human job satisfaction with respect to HSEE program in complex systems.     

A neuro-fuzzy algorithm for assessment of health,safety, environment and ergonomics in a large petrochemical plant

Process plants such as petrochemical units have been continuously trying to improve Health, Safety, Environment and Ergonomics (HSEE) programs. This study proposes an adaptive network-based fuzzy inference system (ANFIS) for assessment of HSEE programs in a petrochemical plant. The proposed neuro-fuzzy approach is applied to a set of operators in the petrochemical unit to show its applicability and superiority. To achieve the objectives of this study, standard questionnaires with respect to HSEE are completed by operators. The average results for each category of HSEE are used as inputs and accomplishment of HSEE programs is used as output for the algorithm. Moreover, this algorithm is used to rank operators performance with respect to HSEE. Finally, the algorithm identifies efficient operators with respect to HSEE. This is the first study that introduces an intelligence algorithm for assessment and improvement of HSEE program in a petrochemical plant.     

Performance assessment system of health,safety and environment based on experts' weights and fuzzy comprehensive evaluation

Performance evaluation of Health, Safety and Environment (HSE) is the measurement of a company's achievement in HSE management. In order to receive a comprehensive and objective evaluation result, it is necessary to consider all evaluation factors and experts at different levels when HSE performance assessment is conducted. To improve conventional HSE performance evaluation, where weighted average method was used, a Fuzzy Comprehensive Evaluation (FCE) method is used in this study by taking experts' weights into account. Further, an HSE operating performance assessment system is designed to simplify manual and complex assessment process and generate charts and analysis reports automatically. Finally, a case of petrochemical enterprise is used to illustrate the effectiveness of the method and system.     

Performance assessment and optimization of HSE management systems with human error and ambiguity by an integrated fuzzy multivariate approach in a large conventional power plant manufacturer

This study presents an integrated approach performance assessment and optimization of integrated health safety environment (HSE) management system-based on fuzzy data envelopment analysis (FDEA) considering the possible human error and data vagueness in a conventional power plant manufacturer. In doing so, it corresponds and integrates its registered HSE-MS with OHSAS 18001:2007 and ISO 14001:2004 to evaluate multiple inputs and outputs of over 35 subsidiary HSE divisions with parallel mission and objectives simultaneously. The HSE divisions of each subsidiary are considered as decision making units (DMUs). Not only doing this refutable method rank their relevant performance efficiencies in certain and uncertain conditions, but also it determines efficient target indices for each DMU, and could assure continuous improvement in the organization. This would help managers to identify the areas of strengths and weaknesses in their HSE management system and set improvement target plan for the related HSE management system. In this model based on Deming’s continuous improvement cycle, managers are also able to evaluate the prevailing strengths and weaknesses and target their improvement strategies at the relevant stages of the cycle.     

Assessment and improvement of integrated HSE and macro-ergonomics factors by fuzzy cognitive maps: The case of a large gas refinery

This study analyzes and assesses the integrated health, safety, environment (HSE) and ergonomics (HSEE) factors by fuzzy cognitive maps (FCM) approach. This is achieved through integrating ergonomic and macro-ergonomic as well as occupational health and safety arrangements in an integrated modeling for assessment of their multi-faceted impact on workers' productivity, injury rate and satisfaction. This paper uses FCM to assess the direct and indirect effects of HSEE factors on system performance indicators. The results of FCM are used to develop leading indicators useful for proactive management of productivity, injury rate, and job satisfaction. The result of a comprehensive survey of 37 experts in control rooms and maintenance activities in a large gas refinery is used to show the applicability and usefulness of FCM approach. Moreover, FCM results are used to determine the causal structure of HSEE factors and system performance indicators. It is concluded that macro-ergonomics factors such as instructions and education, familiarity with organization's rules, and proper communications most contribute to improve workers' safety, satisfaction, and productivity.     

Management of the UK HSE failure rate and event data

The UK Health and Safety Executive (HSE) requires failure rate data for the assessment of COMAH safety reports and in the implementation of its statutory functions relating to land use planning in the vicinity of major hazard sites. Many of the existing failure rates used by HSE were derived over 20 years ago, but have been subject to periodic review to ensure that they remain appropriate for modern planning enquiries or quantified risk assessments. HSE needs to be assured that its sources of data and their application continue to be fit to support its statutory duties.HSE has implemented a programme of work to be carried out by the Health and Safety Laboratory (HSL). This includes the development and maintenance of a single source of quality assured failure rate data, ideally accessible from the Internet, bringing together and updating existing failure rate data sources and reviewing new sources not previously available to HSE.A review of HSE’s current failure rate values is being carried out and this will be used to generate a single source of publically available failure rate data for use by both HSE and the public. This would help industry and HSE move toward a common position or understanding on failure rates. It would also help ensure that HSE professional advice is defensible and transparent.This paper will detail the progress made to date on the programme of work. It will also discuss the issues that arise as a consequence of changing failure rates and how HSE deals with these issues.     

Implementing a safety culture in a major multi-national

This paper reports on the implementation of an advanced safety culture in a major oil and gas multi-national. The original proposal came from the company after it had become clear that expectations had been raised after the successful implementation of Health, Safety and Environment (HSE) Management Systems subsequent to the Piper Alpha disaster. The proposal made by the company, to develop a workforce intrinsically motivated for HSE, was operationalised as the development of an advanced safety culture after a review of the literature on motivation. The model used was the HSE Culture Ladder that had become the industry standard accepted by the OGP (International Association of Oil and Gas Producers). This model was intended to show that there were considerable opportunities for improvement even after HSE-MS had been implemented and that the more advanced cultures were ones people felt were desirable and achievable for themselves. Once top management had provided the initial support for the development of a more advanced safety culture, a number of supporting tools were developed, under the Hearts and Minds brand, and a strategy for implementation was developed that relied more on bottom-up ‘pull’ rather than top-down ‘push’ – the standard implementation model for new initiatives. The tools were designed to provide a clear direction, a road map to an advanced culture defined in terms provided by people within the industry, to support lasting changes in attitudes and beliefs, to promote an increased feeling of control when solving HSE-specific problems – all components of a more advanced culture. The tactics employed, using a pull rather than a push approach, had to allow for local variation within the general limits set by the strategy that eventually became a mixed top-down and bottom-up approach. Next there is a discussion of the current status and the lessons to be learnt from the implementation so far: moving away from command and control is hard for large organizations; such programs have to be driven by different performance indicators; managers have to learn to disperse their control; it is essential to communicate both successes and failures. Finally there is a discussion about the respective roles of academia and the industry in such endeavours, the requirement to concentrate on more than a single cultural characteristic such as reporting, and the difficulties of evaluating such programs in a worldwide environment that is continuously changing.     

石油企业HSE管理文化建设实践

HSE管理体系在石油企业得到广泛推广和应用，对企业加强安全和环保管理起到了很好的作用。但由于中国石油企业的HSE管理与国外石油企业的发展经历不同，文化建设上必然存在差异。如何实现与国际石油界HSE管理的接轨，建立企业HSE文化，是当前石油企业国际化发展的一个重要课题。本文从石油企业建立HSE管理体系的探索和实践出发，提出了对HSE管理文化建设的思考，对企业加强制度管理、抓住HSE管理体系重点和把握HSE文化建设方向，有很好的指导作用。     

中国石油集团公司HSE管理体系运行模式的研究

从1991年国际石油工程协会把健康安全与环境(简称HSE)作为一个完整概念提出以来,各国石油公司都进行了积极探索与实践,并逐步发展成国际石油届开展合作业务的基本运行规则.中国石油天然气集团公司结合企业生产实际和传统管理方法,在HSE管理体系探索、实践中,发展了一整套既符合中国石油企业管理实际的情况,又满足与国际接轨要求的HSE运行模式,对企业实施HSE管理体系有很好指导意义.     

关于石油管道企业HSE管理体系、环境管理体系和职业安全健康管理体系的整合探讨和建议

石油管道企业已经建立了HSE管理体系。为了提高企业的管理水平 ,适应企业的发展和参与国际石油管道建设市场的竞争 ,在近几年内 ,石油管道企业计划建立ISO140 0 0和职业安全健康管理体系。为了提高企业管理效率 ,便于 3个体系的运行和操作 ,笔者提出了企业在建立体系中将EMS、HSEMS、OSHMS整合的思路 ,并对整合的可能性作了探讨 ,提出了体系整合后的基本框架。     

Learning from the application of nuclear probabilistic safety assessment to the chemical industry

This paper introduces the new approach of risk analysis established by the French Ministry of the Environment and develops the benefits of applying nuclear probabilistic safety assessment approaches to the chemical industry.In the aftermath of the AZF disaster in Toulouse on 21 September 2001, a new law was proposed by the French government asking for the investigation of all representative scenarios and the assessment of the probability of the resulting dangerous phenomena to demonstrate an acceptable level of safety. Therefore, any accident is investigated from a global point of view, according to its gravity and its probability.In 2000, the French Ministry of the Environment asked the Institute for Radiological Protection and Nuclear Safety (IRSN), and in particular its Systems and Risk Protection Assessment (SESPRI) and its Industrial Risks, Fire and Containment Assessment and Study (SERIC) departments, to conduct a Probabilistic Safety Assessment (PSA) study of an LPG distribution facility, specially for the BLEVE scenario. This study has showed the power of PSA for defining and prioritizing actions to be carried out to improve safety of facilities; however, it requires credible data for reliability and failure of the equipment, not available in generic failure databases.Since 2007, IRSN has taken several initiatives in collaboration with operators in order to provide more precise and representative failure rates for main safety equipment, ready to use in future PSA relative to LPG plants.     

Overview of GHS (Globally Harmonized System) in Korea and the direction of further development

Many chemicals are being developed with the growth of science technology. Such chemicals bring many advantages to humans but also cause many social problems because of the hazards of the materials. Therefore, it is necessary to have a system which identifies the hazards of chemicals. Some acts or regulations about information on warning labels or MSDS (Material Safety Data Sheet) information for chemicals are similar in each country but there are differences in definitions of degree of hazard, standard classification of harmful level, and indication methods. GHS is the indication method of worldwide integrated classification standard in order to prevent damage caused by disease or risks of accidents resulting from confusion by the users. In keeping pace with the world trend, Korea has conducted translation of the GHS manual from UN and selected it as the official GHS manual of the Korean government. The official Korean GHS translated version was published in July 2005. After that, the Korea Ministry of Employment and Korea Labor and the Ministry of Environment have implemented GHS MSDS for chemical substances since July 1, 2010 so that manufacturers and importers are required to apply it. The full implementation for compound materials will start on July 1, 2013. In Korea, database information for chemicals is provided by four organizations including The Korea Occupational Safety and Health Agency. However, domestic information on chemicals provided by domestic information providers has problems including differences in basic content and incorrect recording because of trade secrets. Efforts for improvement including reinforcing training for manufacturers and importers on recording consistent information for different organizations are urgently needed.     

基于层次分析法的企业HSE管理绩效评估

大部分石油化工企业通过HSE关键KPI来判断企业HSE管理绩效,这并不能真实反映企业HSE管理水平。本文通过分析企业建立的HSE管理体系和HSE业务管理重点,给出了建立企业HSE管理绩效评估指标体系的原则和步骤,指出了根据绩效评估指标体系编制审核检查表应当注意的事项,提出了HSE管理绩效评估结果的分级标准,指导企业建立科学合理的HSE管理绩效评估体系。本文还以炼化企业HSE管理为例,给出其三级评估指标体系及权重系数,并论述了企业如何利用该权重系数和审核检查表开展对下属二级单位的评估工作。应用结果表明,利用该方法便于企业量化与对比各二级单位的HSE绩效,通过各级指标分值的图形对比分析,有利于企业和二级单位查找HSE管理上的优点和缺陷,促进企业HSE管理的提升和持续改进。     

A medium scale test method for assessing the fire hazard of flammable solid materials

The medium scale test method currently operated by the Health and Safety Executive (HSE) as a means of assessing the fire hazard of flammable solids is described. The technique has been applied to a range of materials and the results, although specific to the apparatus, have proved useful in ranking relative fire performance     

Bund overtopping — the consequence of catastrophic tank failure

The Health and Safety Executive (HSE) has considerable interest in predicting the consequence of releases of hazardous liquids from storage tanks (HSE, 1998), because of its responsibilities as a statutory adviser to local planning authorities on the siting of hazardous installations and on the control of development in their vicinity, and because of its responsibilities alongside the Environment Agencies as the Competent Authority in the assessment of COMAH safety reports. As a result, HSE has commissioned a number of studies, including: experimental studies of the behavior of liquid spills (Lee and Kountouris, 1992, Skitt and Wheeler, 1989, Bentinck and Crow, 1991, Clark and Savery, 1993, Law and Johnskareng, 1994, Ruddle and Widowson, 1985, Ruddle and Elms, 1985, Cleaver, Cronin, Evans and Hirst, 2001), a review of overtopping data and theoretical models used to study liquid flow (Thyer & Jagger, 1997), the characterization of the profile of the leading edge of the spreading liquid (Thyer, MacMillan, & Jagger, 1999), and the development and use of complex mathematical models to predict overtopping fractions and liquid spill behavior (Daish et al., 1998, Ivings and Webber, 2001).This paper summarizes the consequences of catastrophic tank failure, the current position on the availability of liquid spill data for model validation, and indicates how such data may be used to predict the often considerable fraction of liquid that could overtop retaining bunds around real tanks.     

“四沿”化工企业污水处理系统安全事故状态下负荷缓冲及安全环境(SE)联锁探讨

在对"四沿"(沿江、沿河、沿湖、沿海)化工行业污水处理方法及流程特点总结的基础上,归纳出应对水力和污染物冲击负荷的缓冲方法。为克服缓冲控制能力有限的缺点,提出一种新方法——SE(安全和环境)联锁,以期达到完善管理、提高控制效果的目的,并详细阐述了该方法在管理及技术层面的实施途径。     

HAZID方法浅析

结合实际工程建设项目开展危险源辨识（HAZID）分析的情况,介绍了HAZID分析方法的广义和狭义概念内涵,主要分析步骤、每步主要工作内容、典型引导词、分析形式和特点,并将HA-ZID方法与常用的过程危险源方法、尤其是HAZOP分析方法进行了对比,以帮助读者更好地理解、运用此方法。本文拟推荐的HAZID分析方法将危险化学品行业的风险管理向前延伸到项目的早期阶段（如项目论证、可行性研究、基础工程设计或初步设计阶段）,可以帮助项目组在项目建设早期认识与项目有关的健康、安全、环境（HSE）各方面问题的重要性和相关性,所辨识出的关键危险源及其危险,为下一步有重点、有目的地开展项目HSE风险管理确定了关注重点。在早期阶段进行HAZID分析,还可以有机会以最小的代价实现对项目厂址和总图布置的调整、工艺方案和设计原则的优化,可以避免后期再发现HSE隐患、必须整改时可能存在的不可实施性,或对项目费用、进度等产生严重负面影响。     

Study of chemical supply system of high-tech process using inherently safer design strategies in Taiwan

The photoelectric, semiconductor and other high-tech industries are Taiwan's most important economic activities. High-tech plant incidents are caused by hazardous energy, even when that energy is confined to the inside of the process machine. During daily maintenance procedures, overhauling or troubleshooting, engineers entering the interior of the machines are in direct contact with the source of the energy or hazardous substances, which can cause serious injury. The best method for preventing such incidents is to use inherently safer design strategies (ISDs); this approach can fully eliminate the dangers from the sources of hazardous energy at a facility.This study first conducts a lithography process hazard analysis and compiles a statistical analysis of the causes of the fires and losses at high-tech plants in Taiwan since 1996, the aim being to establish the necessary improvement measures by using the Fire Dynamics Simulation (FDS) to solve relevant problems. The researchers also investigate the lithography process machine in order to explore carriage improvement measures, and analyse the fires' causes and reactive materials hazardous properties, from 1996 to 2012. The effective improvement measures are established based on the accident statistics. The study site is a 300 mm wafer fabrication plant located in Hsinchu Science Park, Taiwan.After the completion of the annual maintenance jobs improvement from September 2011 to December 2012, the number of lithography process accidents was reduced from 6 to 1. The accident rate was significantly reduced and there were no staff time losses for a continuous 6882 h. It is confirmed that the plant safety level has been effectively enhanced. The researchers offer safety design recommendations regarding transport process appliances, chemical storage tanks, fume cupboard devices, chemical rooms, pumping equipment, transportation pipelines, valve manual box (VMB) process machines and liquid waste discharge lines. These recommendations can be applied in these industries to enhance the safety level of high-tech plants, facilities or process systems.