海洋钻井平台事故致因分析与评价指标研究

该文在广泛调研国内外已发生的海洋平台事故基础上,从人因失误、工艺设备、物料危险、管理缺陷和危险环境五个方面系统分析事故致因因素,提出海洋钻井平台事故致因评价框架,提出5个一级评价指标和24个二级评价指标,根据层次分析法,计算确定各指标的标准权重值.最后针对某在役海洋钻井平台,开展实例研究.为实际评价海洋钻井平台事故风险提供一种新方法,具有一定的实际应用价值.     

HAZOP分析方法在石油工业上游业务中的应用

基于国内石油工业上游业务风险分析和安全评价现状,针对油气勘探、油气田开发、油气集输和海洋石油各阶段工艺流程与作业环境特性,选择引导词、偏差进行安全评价,分析和探讨HAZOP分析方法在上游业务中应用的可行性和适用性。研究表明,对于油气田开发、油气集输阶段以及海上油气田生产方面,应用HAZOP分析,可从本质安全角度提出项目风险管理控制措施,提高装置安全性和可操作性,促进企业持续稳定发展。但对于油气勘探阶段,由于其风险呈层次型且评价方法依赖于数学建模和数值计算,不适宜采用HAZOP分析方法。     

Inherently safer design in offshore oil and gas projects

Like all hazardous installations, inherently safer design (ISD) is one of the key tools in offshore oil and gas projects to minimize risks in offshore facilities. As the life cycle of offshore facilities is relatively short compared with onshore counterparts and there are many projects running every year, the potential is high for raising inherent safety standards and lowering safety risks throughout the offshore industry as old facilities are phased out. This paper gives an overview of offshore facilities and examples of implementation of ISD. Good examples of ISD are numerous. Industry guidance on ISD implementation abound. Yet, the systematic implementation of it in the industry is patchy. There are many reasons for factors which impede the effective, efficient and consistent implementation of ISD in projects. This paper describes some of them and proposes solution to address them. They include (a) the effective integration of ISD into hazard management systems with appropriate language to engage all disciplines in projects, (b) the phasing of resources to enable the project to capture ISD measures which are only available during early phases, (c) application of appropriate ISD goals and ISD performance metrics at various stages and (d) the appropriate use of quantified risk assessment to support ISD.     

化工过程开发中本质安全化设计策略

本质安全化设计是预防人为失误及设备失效、降低化工过程风险应优先采用的技术。在比较传统设计方法与本质安全化设计方法的基础上,讨论了化工过程开发各阶段实现本质安全的机会,认为在开发初期,实施本质安全化的成本低,难度小;通过分析可行性研究、工艺研究、概念设计、基础设计、工程设计等阶段本质安全化设计的影响因素、设计目标和设计方法,探索化工过程开发中本质安全化设计策略,提出了化工过程本质安全化设计流程。通过工艺过程本质安全设计、工艺流程的简化和优化、不同设计方案的本质安全度评估等措施,可提高化工过程本质安全水平。     

基于全生命周期的海洋油气项目集风险管理

为了强化海洋油气项目集的风险管理,以海洋油气田固定区块开发为范围,基于甲方油气田单位和乙方服务单位立场,对项目集进行全生命周期的风险管理;将海洋油气项目集生命周期划分为6个阶段;提出了滚动风险管理模式,给出各阶段风险分解结构和风险应对策略;以时间、成本、质量为控制要素,建立项目整体风险动态评估方法。研究结果表明:通过生命周期6个阶段和整体2级动态迭代风险控制,能更早发现项目集各级过程风险,有助于避免或降低风险事故带来的损失,更有效地保障项目集收益和组织战略实现,可为我国海上油气田开发风险管理提供新参考。     

An integrated methodology to manage risk factors of aging urban oil and gas pipelines

Aging urban oil and gas pipelines have a high failure probability due to their structural degradation and external interference. The operational safety of the aging urban oil and gas pipeline is challenged by different hazards. This paper proposes a novel methodology by integrating an index-based risk evaluation system and fuzzy TOPSIS model for risk management of aging urban oil and gas pipelines, and it is carried out by evaluating the priority of hazards affecting pipeline safety. Firstly, the hazard factors of aging urban oil and gas pipelines are identified to establish an index-based risk evaluation system. Subsequently, the fuzzy TOPSIS model is employed to evaluate the importance of these hazard factors and to decide which factors should be managed with priority. This work measures the importance of a hazard factor from three aspects, i.e. occurrence (O), severity (S) and detectability (D), and the weights of these three parameters are determined by a combination weight method. Eventually, the proposed methodology is tested by an industrial case to illustrate its effectiveness, and some safety strategies to reduce the operational risk of the pipeline are presented. The proposed methodology is a useful tool to implement more efficient risk management of aging urban oil and gas pipelines.     

Actual safety performance of the Malaysian offshore oil platforms: Correlations between the leading and lagging indicators

IntroductionThis study establishes the correlations between performance of a set of key safety factors and the actual lagging performance of oil platforms in Malaysia, hence the relevance of the key safety factors in evaluating and predicting the safety performance of oil and gas platforms. The key factors are crucial components of a safety performance evaluation framework and each key safety factor corresponds to a list of underlying safety indicators.MethodIn this study, participating industrial practitioners rated the compliance status of each indicator using a numbering system adapted from the traffic light system, based on the actual performance of 10 oil platforms in Malaysia. Safety scores of the platforms were calculated based on the ratings and compared with the actual lagging performance of the platforms. Safety scores of two platforms were compared with the facility status reports' findings of the respective platforms.ResultsThe platforms studied generally had good performance. Total recordable incident rates of the platforms were found to show significant negative correlations with management and work engagement on safety, compliance score for number of incident and near misses, personal safety, and management of change. Lost time injury rates, however, correlated negatively with hazard identification and risk assessment. The safety scores generally agreed with findings of the facility status reports with substandard process containment found as a contributor of hydrocarbon leaks.ConclusionsThis study proves the criterion validity of the safety performance evaluation framework and demonstrates its usability for benchmarking and continuous improvement of safety practices on the Malaysian offshore oil and gas platforms.Practical applicationsThis study reveals the applicability of the framework and the potential of extending safety reporting beyond the few conventional lagging safety performance indicators used. The study also highlights the synergy between correlating safety factors to streamline safety management on offshore platforms.     

Solvent design and inherent safety assessment of solvent alternatives for palm oil recovery

The concept of inherent safety is important in developing an inherently safer and user-friendly process. This paper discusses a new integrated approach of computer-aided product design and inherent safety assessment. Computer-aided Molecular Design (CAMD) approach was utilized in this work to identify potential alternative to n-hexane, the widely used industrial solvent in extracting residual palm oil from pressed palm fibre. The formulation of solvent mixtures was optimized to meet the targeted physical properties before being tested using the Soxhlet Extraction method. Inherent safety assessment to assess the solvent's flammability, toxicity, reactivity, and explosiveness was conducted on the new solvent mix, Mixture 1 (n-hexane + ethanol), Mixture 2 (n-hexane + acetone) and Mixture 3 (n-hexane + n-butanol). It was found that Mixture 1 and 3 are safer than n-hexane and able to extract more oil than n-hexane and Mixture 2. However, the utilization of the solvent is dependent on the end product from the residual palm oil.     

Barrier management in the offshore oil and gas industry

Accident investigations indicate that inadequate barrier management has been a main cause of many accidents in the process industry. In 2013, the Norwegian Petroleum Safety Authority issued a barrier management framework for the offshore oil and gas industry. The framework describes principles related to barrier management and may be a valuable guide for the entire process industry. However, the offshore industry faces several challenges when implementing the framework. This paper discusses these challenges and clarifies the central concepts and steps of barrier management. A key message is the need for clarity and integration in a systematic approach to risk and barrier management.     

Implementing inherent safety throughout process lifecycle

Inherent safety should be implemented as early as possible in the design life cycle, since the changes in process design are easier and cheaper the earlier they are done. The problem is, how to evaluate process alternatives in the terms of inherent safety in the early design phases, when much of the information is missing. In this paper the process life cycle phases and the possibilities of implementing and evaluating inherent safety are discussed. The applicability and accuracy of an inherent safety index method is presented by a case study.     

Supporting the selection of process and plant design options by Inherent Safety KPIs

Effective support of inherent safety implementation in process design requires a quantitative metric for monitoring and communicating the expected safety performance of alternative design options. The Inherent Safety Key Performance Indicators (IS-KPIs) methodology was developed to provide both a flexible procedure for the identification of the hazards, and a sound consequence-based quantification of the safety performance. The integration of different hazard identification techniques yields the relevant accident scenarios for each unit in the plant. The calculation of credible damage distances by consolidate consequence simulation models provides a sound basis for the definition of the KPIs based on worst case effects. Specific indicators were devoted to hazards from external actions, as natural events and intentional malicious acts. The methodology was demonstrated by the comparison of alternative technological options for LNG regasification. The application evidenced the potential of the IS-KPI method in pinpointing the critical issues related to each alternative configuration.     

An index to account for safety and controllability during the design of a chemical process

Inherent safety is well known as the best technique of risk management, but its implementation is a challenge when there is a conflict with other factors, in particular with the process dynamic performance when the application of the minimization principle is considered. In this work, a combined safety-controllability index applicable during the design stage of a process is presented. The index accounts for the process controllability and the risk of the chemical inventory inside the process. The condition number is used to assess controllability, and the quantitative risk analysis technique is carried out to obtain a distance of affectation as a metric for individual risk. The index, based on a combination of normalized values of metrics for controllability and risk, was applied to three case studies dealing with distillation processes that separate flammable and toxic chemicals. The effect of relevant design variables such as column diameter and residence time was analyzed. It is shown how conflicts between safety and controllability exist for different values of those design variables and how a proper controllability-risk compromise can be identified with the use of the proposed index.     

Promoting inherent safety

By inherent safety is meant that a hazard is eliminated rather than being managed by various add-on equipment and procedures. Practices of inherent safety have been developed in the chemical industry, and include for instance the substitution of hazardous substances by less hazardous ones. Inherently safer design strives to eliminate the possibility of major adverse events even when the probabilities of these events are small or cannot be meaningfully estimated. Considerations of security can be more easily incorporated into this approach than into most other branches of risk and safety analysis. Therefore, inherent safety has a great potential as a meeting-ground for the much-needed coordination of safety and security work. Its philosophical underpinnings are outlined, and proposals are made for more efficient promotion of its principles.     

海洋石油轮班作业风险定量分析方法研究

长期以来,海洋石油领域风险研究主要集中在对设施的潜在失效概率和后果研究方面,而对于人员可靠性及风险管理方面的研究较弱。然而,据统计资料显示,海上设施在其生命周期内的设计、建造和生产作业等各个阶段中发生的事故大多与人为错误和组织错误（HOE）有关联。在海洋工程领域,开展人员可靠性分析（HRA）的研究工作具有重要意义。根据海上作业的特殊性及轮班制度的特点,推导出轮班风险的定量分析公式,据此计算出每个工作日轮班风险的相对大小,然后结合我国海上作业的实际情况,对影响轮班风险的可变因素进行了敏感性分析,为风险控制与管理提供参考。     

Quantitative risk analysis of fire and explosion on the top-side LNG-liquefaction process of LNG-FPSO

Since the massive use and production of fuel oil and natural gas, the excavating locations of buried energy-carrying material are moving further away from onshore, eventually requiring floating production systems like floating production, storage and offloading (FPSO). Among those platforms, LNG-FPSO will play a leading role to satisfy the global demands for the natural gas in near future; the LNG-FPSO system is designed to deal with all the LNG processing activities, near the gas field. However, even a single disaster on an offshore plant would put the whole business into danger. In this research, the risk of fire and explosion in the LNG-FPSO is assessed by quantitative risk analysis, including frequency and consequence analyses, focusing on the LNG liquefaction process (DMR cycle). The consequence analysis is modeled by using a popular analysis tool PHAST. To assess the risk of this system, 5 release model scenarios are set for the LNG and refrigerant leakages from valves, selected as the most probable scenarios causing fire and explosion. From the results, it is found that the introduction of additional protection methods to reduce the effect of fire and explosion under ALARP criteria is not required, and two cases of the selection of independent protection layers are recommended to meet the SIL level of failure rate for safer design and operation in the offshore environment.     

A proactive process risk assessment approach based on job hazard analysis and resilient engineering

Complex systems often experience a long period of incubation before accidents occur. Therefore, a proactive risk assessment is essential for process safety. The conventional job hazard analysis (JHA) method has been an effective tool to conduct a process risk assessment in the high-risk industrial field. However, the conventional JHA is inadequate for the proactive risk assessment since it is usually conducted during and before one specific operation process. Operations such as startup and maintenance are performed repeatedly on the lifecycle of a plant. Therefore, the risk reduction measures for the industrial process should include not only preventive actions obtained from the conventional JHA but also recovery ones. Resilience engineering (RE) has proven to be helpful for the recovery analysis of a complex system. The objective of this paper is to propose a proactive and comprehensive process risk assessment approach based on JHA and RE. The mechanism of applying RE to address operation process risk is illustrated. The integrated approach can provide guidelines to establish proactive risk reduction measures as well as maintain a low-risk level. Finally, a gas transmission startup process risk assessment case is presented to demonstrate its applicability.     

重大危险源安全与自动化监控系统

对重大危险源实施系统、有效的安全监控是重大工业事故预防控制体系中的关键环节。文中给出了针对重大危险源监控全安全生命周期过程的整体实施流程,提出了重大危险源危险与风险评估的重点,探讨了重大危险安全与自动化监控的三层构建框架和工作过程,研究了安全系统与基本过程控制系统相独立的监控方式,给出了安全仪表系统的设计要求。     

设计初期化工过程本质安全化设计策略

该文提出了一种在设计初期进行化工过程本质安全化设计的策略。首先进行危险物质与危险能量两类共计11种危险类型的危险辨识。针对辨识出的危险类型,通过与相应的临界条件比较进行快速的危险评价,对于不可接受的危险必须采取本质安全化措施,可接受的危险可有选择性地进行本质安全化设计。在设计初期可以使用的本质安全化原则主要是消除、最小化、替代和缓和,针对11种危险类型可以应用不同的本质安全化设计模型,以使实际进行本质安全化设计时更加简单与快捷。该文把提出的本质安全化设计策略应用到一个甲苯硝化制硝基甲苯的工艺,形成了多种本质安全化措施,可以用来在设计初期消除或减少危险。     

Qualitative Assessment for Inherently Safer Design (QAISD) at preliminary design stage

Conventional hazard evaluation techniques such as what-if checklist and hazard and operability (HAZOP) studies are often used to recognise potential hazards and recommend possible solutions. They are used to reduce any potential incidents in the process plant to as low as reasonably practicable (ALARP) level. Nevertheless, the suggested risk reduction alternatives merely focus on added passive and active safety systems rather than preventing or minimising the inherent hazards at source through application of inherently safer design (ISD) concept. One of the attributed reasons could be the shortage of techniques or tools to support implementation of the concept. Thus, this paper proposes a qualitative methodology that integrates ISD concept with hazard review technique to identify inherent hazards and generate ISD options at early stage of design as proactive measures to produce inherently safer plant. A modified theory of inventive problem solving (TRIZ) hazard review method is used in this work to identify inherent hazards, whereby an extended inherent safety heuristics tool is developed based on established ISD principles to create potential ISD options. The developed method namely Qualitative Assessment for Inherently Safer Design (QAISD) could be applied during preliminary design stage and the information required to apply the method would be based on common process and safety database of the studied process. However, user experiences and understanding of inherent safety concept are crucial for effective utilisation of the QAISD. This qualitative methodology is applied to a typical batch reactor of toluene nitration as a case study. The results show several ISD strategies that could be considered at early stage of design in order to prevent and minimise the potential of thermal runaway in the nitration process.