HAZOP-FTA综合分析方法在煤化工装置中的应用

为提高煤化工生产工艺安全水平,降低事故发生的可能性和严重程度,有必要对其工艺过程中的危害因素进行全面系统的辨识分析。以某甲醇公司煤制甲醇气化装置为例,运用HAZOP方法准确识别工艺偏差危害因素,定性分析偏差产生的可能原因、后果及现有安全措施;在此基础上,运用FTA方法,获得顶上事件发生概率值和基本事件重要度结果,实现工艺设备设施危害因素的定性与定量分析,提出有针对性的建议安全措施。两种方法的综合应用,给予煤化工企业系统安全分析一种新的思路,使其得到更加科学准确的危险性分析结果,为企业开展危害因素的分级管理,有效预防和减少事故的发生提供了理论支撑。     

Methodology for computer aided fuzzy fault tree analysis

Probabilistic risk assessment (PRA) is a comprehensive, structured and logical analysis method aimed at identifying and assessing risks of complex process systems. PRA uses fault tree analysis (FTA) as a tool to identify basic causes leading to an undesired event, to represent logical dependency of these basic causes in leading to the event, and finally to calculate the probability of occurrence of this event.To conduct a quantitative fault tree analysis, one needs a fault tree along with failure data of the basic events (components). Sometimes it is difficult to have an exact estimation of the failure rate of individual components or the probability of occurrence of undesired events due to a lack of sufficient data. Further, due to imprecision in basic failure data, the overall result may be questionable. To avoid such conditions, a fuzzy approach may be used with the FTA technique. This reduces the ambiguity and imprecision arising out of subjectivity of the data.This paper presents a methodology for a fuzzy based computer-aided fault tree analysis tool. The methodology is developed using a systematic approach of fault tree development, minimal cut sets determination and probability analysis. Further, it uses static and dynamic structuring and modeling, fuzzy based probability analysis and sensitivity analysis.This paper also illustrates with a case study the use of a fuzzy weighted index and cutsets importance measure in sensitivity analysis (for system probabilistic risk analysis) and design modification.     

乙炔干燥变温吸附装置安全性分析与燃爆事故预防对策

针对乙炔变温吸附装置的燃爆事故问题,采用HAZOP方法对该装置进行安全性分析,找出存在的安全隐患,提出整改措施,指出装置发生燃爆事故的可能性;又将该装置可能发生的燃爆事故作为顶上事件,利用FTA方法进行分析,得到了装置发生燃爆事故的可能原因,制定了预防发生燃爆事故的对策。通过将HAZOP和FTA分析方法结合使用,有效地识别出乙炔装置存在的隐患,降低了装置操作的危险性,预防了燃爆事故的发生,值得推广应用。     

原油集输联合站故障树分析研究

采用故障树分析法对原油集输联合站生产工艺流程和危险危害因素进行分析,确定原油集输联合站的故障树因素表,以该站故障为顶上事件,以火灾爆炸、介质泄漏、其他危险作为故障树的中间事件,建立联合站故障树。通过定性定量分析,求取联合站故障树的最小割集为77组,进而确定故障树顶事件的事故发生概率为5.68×10-3和底事件结构重要度,得出影响集输联合站安全性的重要因素为通风不良、储罐密封不良、液体腐蚀、盘管穿孔和人员误操作等。因而提出加强原油集输联合站安全监察和监控措施,及时地发现和处理故障,以提高联合站运行安全可靠性和生产效率。     

饮食业油烟道火灾事故概率的模糊事故树分析

根据常规事故树定量计算中基本事件概率的不确定性问题,通过引入模糊集的概念,将常规事故树中基本事件的发生概率模糊化,用三角形模糊数代替确定性发生概率,应用模糊数截集方法,推导了模糊事故树的相关算法.采用模糊事故树方法得到饮食业油烟道火灾事故发生概率,并进行了敏感性分析,找出对顶事件发生概率影响较大的基本事件,确认减小油烟道火灾事故发生的相关措施.研究表明,饮食业油烟道火灾事故概率的模糊事故树分析是切实可行的,有助于对饮食业油烟道火灾的认识、预防和扑救工作.     

HAZOP方法的定量改进措施研究

HAZOP方法通过结构化和系统化的方式识别潜在的危险与可操作性问题,在化工安全评价中得到了广泛应用.但其做为一种定性评价方法,定量化是其发展的趋势.探讨了定量化风险矩阵技术在HAZOP分析中应用的问题,研究提出了将火灾、爆炸危险指数方法应用于风险矩阵事故后果严重度的计算和将事故树评价方法应用于风险矩阵事故发生概率的计算,实现了风险矩阵的定量化并应用于不饱和聚酯树脂工艺HAZOP分析,为HAZOP分析的定量化提供了一种新的技术方法.     

Uncertainty reduction for improved mishap probability prediction: Application to level control of distillation unit

At all levels, the understanding of uncertainty associated with risk of major chemical industrial hazards should be enhanced. In this study, a quantitative risk assessment (QRA) was performed for a knockout drum in the distillation unit of a refinery process and then probabilistic uncertainty analysis was applied for this QRA. A fault tree was developed to analyze the probability distribution of flammable liquid released from the overfilling of a knockout drum. Bayesian theory was used to update failure rates of the equipment so that generic information from databases and plant equipment real life data are combined to gain all available knowledge on component reliability. Using Monte Carlo simulation, the distribution of top event probability was obtained to characterize the uncertainty of the result. It was found that the uncertainty of basic event probabilities has a significant impact on the top event probability distribution. The top event probability prediction uncertainty profile showed that the risk estimation is improved by reducing uncertainty through Bayesian updating on the basic event probability distributions. The whole distribution of top event probability replaces point value in a risk matrix to guide decisions employing all of the available information rather than only point mean values as in the conventional approach. The resulting uncertainty guides where more information or uncertainty reduction is needed to avoid overlap with intolerable risk levels.     

环氧乙烷生产装置的安全分析与评价

综合运用道化学公司火灾、爆炸危险指数评价法,事故树分析以及事件树分析对环氧乙烷生产装置进行安全评价,定量地得出装置的危险程度,定性地分析了各危险因素的大小以及系统中各元件的故障率对事故发生概率的影响程度,并提出了改进措施.结果表明,该装置的危险程度很大,必须加强安全生产管理,采取有效措施控制氧气的浓度,从而降低危险性等级,保证生产安全.     

Fuzzy fault tree analysis for fire and explosion of crude oil tanks

Crude oil tank fire and explosion (COTFE) is the most frequent type of accident in petroleum refineries, oil terminals or storage which often results in human fatality, environment pollution and economic loss. In this paper, with fault tree qualitative analysis technique, various potential causes of the COTFE are identified and a COTFE fault tree is constructed. Conventional fault tree quantitative analysis calculates the occurrence probability of the COTFE using exact probability data of the basic events. However, it is often very difficult to obtain corresponding precise data and information in advance due to insufficient data, changing environment or new components. Fuzzy set theory has been proven to be effective on such uncertain problems. Hence, this article investigates a hybrid approach of fuzzy set theory and fault tree analysis to quantify the COTFE fault tree in fuzzy environment and evaluate the COTFE occurrence probability. Further, importance analysis for the COTFE fault tree, including the Fussell–Vesely importance measure of basic events and the cut sets importance measure, is performed to help identifying the weak links of the crude oil tank system that will provide the most cost-effective mitigation. Also, a case study and analysis is provided to testify the proposed method.     

模糊故障树分析及其应用研究

基于某些实际情况下系统故障发生概率具有模糊性和不确定性的特点 ,笔者将模糊集理论引入故障树分析并针对自动化立体仓库的故障特征 ,对立体仓库各个环节发生故障时所遇到的各种模糊信息进行了科学的、定量的处理。实例证明 ,该方法是行之有效的 ;它能解决传统故障树分析不能处理同时存在随机不确定性和模糊不确定性的故障事件的问题     

Estimation of failure probability of oil and gas transmission pipelines by fuzzy fault tree analysis

Failure of oil and gas transmission pipelines was analyzed by fault tree analysis in this paper. According to failure modes of pipeline: leakage and rupture, a fault tree of the pipeline was constructed. Fifty-five minimal cut sets of the fault tree had been achieved by qualitative analysis, while the failure probability of top event and the important analyses of basic events were evaluated by quantitative analysis. In conventional fault tree analysis, probabilities of the basic events were treated as precise values, which could not reflect real situation of system because of ambiguity and imprecision of some basic events. In order to overcome this disadvantage, a new method was proposed which combined expert elicitation with fuzzy set theories to evaluate probability of the events. As an example, failure probability of pipeline installation was assessed by using the proposed method, achieving its fuzzy failure probability of 6.4603×10⁻³. The method given in this article is effective to treat fuzzy events of FTA.     

基于三角模糊数的HAZOP分析在石油化工装置中的应用

工艺危害分析强调运用系统的方法对危害进行辨识、分析,并采取必要的措施消除和减少危害。HAZOP分析能对工艺过程非常系统、全面的进行分析,但传统的HAZOP分析在量化风险时,对于偏差原因发生的可能性评价存在较大的主观性。本文对于没有统计资料的HAZOP分析偏差原因发生可能性,采用专家打分法,利用三角模糊数来表示其模糊发生概率。对于有统计资料的偏差原因,直接表示成三角模糊数。这种方法能够很好的表示HAZOP分析偏差发生概率。介绍了基于三角模糊数的HAZOP分析步骤,并在石油化工装置中进行了应用。这对HAZOP分析技术在石油化工装置中的推广具有重要意义。     

Methodology for Computer-Aided Fault Tree Analysis

Fault tree analysis is a systematic, deductive and probabilistic risk assessment tool which elucidates the causal relations leading to a given undesired event. Quantitative fault tree (failure) analysis requires a fault tree and failure data of basic events. Development of a fault tree and subsequent analysis require a great deal of expertise, which may not be available all the time. Computer-aided fault tree analysis is an easy-to-use approach, which not only provides reliable results but also facilitates the validation and repeatability of the analysis. This enhances the overall results of the fault tree analysis and quantitative risk analysis.This paper presents a revised methodology for computer-aided fault tree analysis. The methodology includes fault tree development, minimal cutsets determination, cutsets optimization and probability analysis. The methodology uses advanced concepts of fault tree development and static and dynamic modularizing for complex and large fault trees. Furthermore, it enables sensitivity analysis of the system for design modification and risk-based decision making. Application of the proposed methodology to a process system is also discussed in the paper.     

石油化工储存装置定量风险评价方法研究

提出通过基础失效概率数据库、事故树分析、事件树分析3种方式来确定重大事故的发生概率.阐述了外界气象条件和人员分布情况对风险的影响和确定方法,给出了利用区域网格方式计算装置在平面某点的个人风险叠加模型和社会风险计算方法.最后,研制开发了石油化工储存装置定量风险评价软件,利用该软件计算了某化工厂4个储存装置所产生的个人风险...     

Dynamic risk assessment using failure assessment and Bayesian theory

To ensure the safety of a process system, engineers use different methods to identify the potential hazards that may cause severe consequences. One of the most popular methods used is quantitative risk assessment (QRA) which quantifies the risk associated with a particular process activity. One of QRA's major disadvantages is its inability to update risk during the life of a process. As the process operates, abnormal events will result in incidents and near misses. These events are often called accident precursors. A conventional QRA process is unable to use the accident precursor information to revise the risk profile. To overcome this, a methodology has been proposed based on the work of Meel and Seider (2006). Similar to Meel and Seider (2006) work, this methodology uses Bayesian theory to update the likelihood of the event occurrence and also failure probability of the safety system. In this paper the proposed methodology is outlined and its application is demonstrated using a simple case study. First, potential accident scenarios are identified and represented in terms of an event tree, next, using the event tree and available failure data end-state probabilities are estimated. Subsequently, using the available accident precursor data, safety system failure likelihood and event tree end-state probabilities are revised. The methodology has been simulated using deterministic (point value) as well as probabilistic approach. This Methodology is applied to a case study demonstrating a storage tank containing highly hazardous chemicals. The comparison between conventional QRA and the results from dynamic failure assessment approach shows the significant deviation in system failure frequency throughout the life time of the process unit.     

高层建筑火灾风险分析及对策研究

统计归类高层建筑火灾事故原因,得出引发火灾的主要原因和起火的重点部位;采用事故树分析方法,应用安全系统工程理论,判断特定事故,对顶上事件进行演绎分析,层层剖析其发生的基本原因和典型故障,预测引发高层建筑重大或特大火灾事故的可能事件。采用定性和定量分析相结合的方法,对高层建筑火灾风险进行评估分析,并对易失控的初始事件进行量化,得出预防高层建筑火灾基本事件结构的重要度顺序。从安全技术和安全管理两个方面绘制高层建筑火灾防控措施框图,提出有针对性的应对措施和建议,为提高高层建筑预防和控制火灾的能力提供依据。     

HAZOP研究与故障树分析在合成氨装置危险辨识中的应用

合成氨装置的原料、产品危险性高,并且生产过程复杂,因此在运行过程中可能导致火灾、爆炸、中毒等事故,有些事故甚至给社会和环境造成严重破坏.对HAZOP研究与故障树分析进行组合,应用在合成氨装置的危险辨识中.通过HAZOP研究,合成氨主体装置共发现风险因素23项,其中合成氨装置的合成气压缩单元安全隐患较多,因此对其进行故障树分析,合成气压缩机单元火灾、爆炸故障树的最小割集为72个,最小径集为6个.从基本事件结构重要度结果来看,压缩机三级出口压力探测器( PIA3-2)故障,对压缩机发生火灾、爆炸的影响程度最大,应重点防范.     

核电站搬运核废料起重机的故障树分析

目的 :对某核电站用于搬运核废料的桥式起重机进行了故障树分析 ;方法 :以吊物坠落为顶事件而建立了故障树 ,通过故障树特征参数的计算对该事件进行了定性分析和定量分析。根据分析结果 ,确定了该起重机的关键元 (部 )件和薄弱环节 ,提出了降低吊物坠落概率的简便有效措施。     

Integration of process control protection layer into a simulation-based HAZOP tool

This paper discusses the framework methodology behind the proposed simulation-based HAZOP tool. Simulation-based approach is one of the many ways to support conventional HAZOP by its automation. Compared to knowledge-based and other approaches, a HAZOP software tool based on deviations simulation is able to examine the investigated process more into detail and so find root causes of hazardous consequences. Another advantage is the ability to identify also potential hazards which did not occur in the past and might be overlooked. The presented framework methodology uses a layer of protection analysis (LOPA) concept of independent protection layers (IPLs) testing. Control system integrated into the raw process design represents the first of various protection layers of the LOPA concept. As a case study, a CSTR chemical production with nonlinear behavior under Proportional-Integral-Derivative (PID) actions as the predominant type of classical feedback control strategy is used. The presented tool identifies hazardous regimes under conditions when control loop introduces hazardous consequences or even acts synergically with existing hazardous events. Risk derived from different consequences is ranked by the risk assessment matrix (RAM) as a part of the conventional quantitative HAZOP study.     

Risk assessment of an oxygen-enhanced combustor using a structural model based on the FMEA and fuzzy fault tree

The oxygen-enhanced combustor has the advantages of high burning efficiency and low emissions. However, it should not be promoted for industrial use until its reliability and safety have been fully recognized. A new methodology is proposed to assess the risk of an oxygen-enhanced combustor using a structural model based on the FMEA and fuzzy fault tree. In addition, it is applied to a selected pilot semi-industrial combustor. To identify the hazard source comprehensively, the pilot is divided into four subsystems: the combustor subsystem, feed subsystem, ignition subsystem and exhaust subsystem. According to the operational parameters of flow (flow rate, temperature and pressure) and the component functions in different subsystems, the cause and effect matrix can be built using the structural model, and the relationship between the operational parameters and the effects of the change for the operational parameters on the system can be presented. Based on the results of cause and effect matrix, the FMEA can be built to describe the failed models and accident scenarios of the pilot. The main accident forms include leakage, injury, fire and explosion. Accordingly, with the severity and probability analysis of different accident forms, the fire and explosion accidents should be further accessed quantitatively using the fuzzy fault tree analysis. The fault trees can be obtained in accordance with the FMEA, and the qualitative assessments of the basic events can be collected by using expert scoring. A hybrid approach for the fuzzy set theory and weight analysis is investigated to quantify the occurrence probability of basic events. Then, the importance analysis of the fault trees, including the hazard importance of basic events and the cut set importance, is performed to help determine the weak links of the fire and explosion trees. Finally, some of the most effective measures are presented to improve the reliability and safety of the combustion system.