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.     

Optimization of dilution ventilation layout design in confined environments using Computational Fluid Dynamics (CFD)

Dilution ventilation systems have been widely used to control the airborne toxic and explosive material in confined spaces. Layout design of dilution ventilation is critical to industrial hygiene control and ventilation efficiency. A properly designed dilution ventilation system can significantly improve the safety of confined workshops and maintain a comfortable work condition. In this work, Computational Fluid Dynamics (CFD) has been used to analyze the performance of dilution ventilation system in the confined workshop environment. Seven different ventilation layouts are proposed to evaluate ventilation performance of different installation layouts. Carbon monoxide (CO), which has the similar density as air, is selected as the sample contaminant to conduct steady-state CFD simulations. The simulation results of different layouts are examined and compared to get the optimal layout design for the best contaminant control. Results have shown that the layout with two opposite inlets has the highest ventilation efficiency among seven proposed layouts. This work can serve as a reference to increase dilution ventilation efficiency and minimize the energy cost in general confined areas.     

An approach for risk reduction (methodology) based on optimizing the facility layout and siting in toxic gas release scenarios

In this work, a new approach to optimize facility layout for toxic release is presented. By integrating a risk analysis in the optimization formulation, we propose a safer assignment for facility layout and siting. Accompanying with the economical concepts used in a plant layout, the new model considers the cost of willing to avoid a fatality, i.e. the potential injury cost due to accidents associated with toxic release near residential areas. The proposed formulation incorporates a real meteorological data to calculate the injury risk through the probit model and Monte Carlo simulation using dense gas dispersion modeling (DEGADIS). The overall problem was initially modeled as a disjunctive program where the coordinates of each facility and cost-related variables are the main unknowns. Then, the convex hull approach was used to reformulate the problem as a Mixed Integer Non-Linear Program (MINLP) that identifies potential layouts by minimizing overall costs. This approach gives the coordinates of each facility, and estimates for the total length of pipes, the land area, and the selection of safety devices. Finally, the 3D-computational fluid dynamics (CFD) was used to compare between the initial layout and the final layout. Moreover, analyses of separation distances fr2om hazard facilities and hindrance effects will be discussed based on the approach used in this work.     

复合物流模式下的机械加工车间安全布局设计

机械加工车间的物流形式不唯一,一般是小推车、天车等多种物流形式的复合,本文以河南省某机械加工车间为例,运用系统布局设置(SLP)方法,并综合考虑复合物流与危险源,进行车间安全布局。首先按照类型将车间分成13个区域,之后应用单纯型法核算车间内的复杂物流量,然后基于曼哈顿距离实现系统布局设置(SLP),最后综合考虑车间内的危险源以及小推车与天车的复合物流,得到作业位置相关图,并以此获得3个布局方案,再应用层次分析法从4个维度对方案择优,得出该车间的最优安全布局方案。     

通道中障碍物布局对行人运动影响的多格子模型研究

传统行人疏散运动模型对障碍物环境下的个体运动行为关注不足,而且未较好地讨论不同障碍物布局下的行人运动特性。通过改进多格子模型建立了考虑障碍物布局影响的行人运动模型,并与实验结果对比验证了该模型的有效性。利用该模型对不同障碍物布局下的单、双行人流进行模拟,探究不同障碍物布局对行人运动的影响。模拟结果表明,合理的障碍物布局有助于提高行人流的运动速度。丰富了传统多格子模型在障碍物环境下的运动规则,能够为行人交通设施设计及科学管理提供理论与技术支持。     

基于AHP-熵权法的输气站场区块风险因素权重确定方法研究

为合理地体现主、客观风险因素对输气站场安全状况的影响,综合运用AHP和熵权法在确定权重方面的优势,在充分尊重专家经验的基础上,最大限度地削弱了权重确定的主观性.针对输气站场设施种类繁多、数量巨大,且分布既相对独立,又相互联系的特点,以工艺流程单元为大致框架,并兼顾设施共性风险因素,将输气站场划分为了清管器收发区、计量区、压气区、阀组区、安全仪表系统区等10大风险区块,并重点关注各区块内关键设备在运行期间的风险因素,最终建立起了10大区块62小项的输气站场两级风险评价指标体系.权重确定过程利用yaahp层次分析法软件和Excel辅助计算,大大降低了数据处理的工作量,同时保证了计算结果的准确性.     

Fuzzy dynamic risk-based maintenance investment optimization for offshore process facilities

A methodology for maintenance planning is developed which helps in improving the reliability of the components and safety performance in process facilities. This methodology helps design an optimum safety maintenance investment plan by integrating the optimization techniques and a fuzzy dynamic risk-based method. Intuitionistic Fuzzy Analytic Hierarchy Process (IFAHP) is applied to deal with uncertain data. The proposed approach employs multi-experts’ knowledge which helps to optimize the maintenance investments. A separator system in an offshore process facility platform is selected as a case study to demonstrate the application of the proposed methodology. A practical example in the separator system is surveyed and potential failures and Basic Events (BEs) are identified. Finally, a risk-based maintenance plan is provided for future safety investment analysis. The results indicate that the developed methodology estimates the risk more accurately, which enhances the reliability of future process operations.     

工矿企业实施设备、设施本质安全化探讨

分析了企业生产过程中,设备、设施本质安全化的状况,认为企业安全工作的根本出路在于设备、设施本质安全化.提出了通过加强企业领导安全意识,提高生产系统的安全投入,在建设项目的设施过程中力争提高设备设施的本质安全化水平,抓好新建、改建、扩建工程项目的"三同时"管理和安全评价,生产单位通过认真做好生产过程中的维护管理等途径提高设备、设施本质安全化.     

基于改进层次分析法的火灾高危单位消防安全评估

开展消防安全评估对提升火灾高危单位消防安全管理水平和维护公共安全具有重要意义。根据火灾高危单位的特点,给出了消防安全评估指标体系,包括建筑防火、消防设备设施和消防安全管理3项一级指标,建筑整体布局、安全疏散系统、消防给水系统、自动灭火系统、防排烟系统、电气防火系统、其他设备及器材、日常管理、应急制度及培训教育、电器燃气消防器材管理10项二级指标,建筑类别、安全出口、室外消防水、自动喷水灭火系统、风机、消防电源及其配电、防火门窗、消防安全管理制度、应急制度、电器管理等54项三级指标。在现场调研和理论分析的基础上,利用改进的层次分析法计算得到某火灾高危单位消防安全评估指标体系各指标的权重,建立了火灾高危单位消防安全评估模型,对其火灾危险性进行了评估。     

JHA在橇式脱水装置检修过程中的应用

工作危害分析法（Job Hazard Analysis，简称JHA），是一种比较细致的分析作业过程中存在危害的方法，它将一项工作活动分解为相关联的若干个步骤，识别出每个步骤中的危害，并设法控制事故的发生。集气站橇式脱水装置检修工期紧、工作量大，文章在简要的介绍了橇式脱水装置工艺流程的同时，对橇式脱水装置检修过程进行描述，运用JHA分析了橇式脱水装置检修中的风险，制定了相应的安全对策，不仅保证了施工过程的安全，同时避免了检修过程中造成的环境污染。     

性能化设计思想在化工设施布局安全设计中的应用

指令性规范是目前化工设施平面布局安全设计的主要依据,但其在应用中存在着条款僵化、安全理论基础不全面、可拓展性不明确等问题。本文将性能化设计思想引入到化工企业平面布局安全设计中,初步提出了一种包含危险辨识、性能化目标确定、后果评估及安全设施效用评估等主要组成部分的基于性能化设计思想的平面布局安全设计体系。对体系中最重要的部分—性能化目标确定进行了重点分析,将化工设施布局安全设计分为装置内设备之间的位置设计、厂区内装置区之间的位置设计以及厂区与外部单位之间的位置设计三个级别,从工艺关联性等角度对各级别布局设计中事故场景选择及设施可接受受损水平进行分析,并提出了通过匹配事故场景和设施可接受受损水平来确定性能化目标的方法。     

Empirical research on diffusion behavior of leaked gas in the ground

Chemical plants and gas utilities own large underground pipelines to transport material such as combustible gas. For example, city gas utilities in Japan have about 230,000 km of pipelines, even if only the pipelines to deliver gas to their customers are considered. Any accidents involving such pipelines can lead to enormous human and physical damage, and their security is therefore a top-priority issue for utilities. For the safety management of underground pipelines, in addition to assessment of the long-term reliability of pipeline materials, it is extremely important to understand the diffusion behavior of gases in the ground, such as the diffusion range and time, in the case of leakage, and the impact on the surrounding area is a fundamental factor to be considered in the design and maintenance of safe facilities and for emergency response. Although many papers introduce the situations of gas diffusion in the atmosphere such as indoor and outdoor conditions, only fundamental surveys have been conducted on gas diffusion in the ground, and there have been few full-scale empirical studies. This study reports the results of the verification of the diffusion behavior with full-scale gas leakage experiments simulating real underground pipelines, as well as the outcomes of the applicability test of a numerical simulation model investigated and proposed based on the results. This technical knowledge regarding security will contribute to further improvement of safety in the industry.     

A flexible intelligent algorithm for identification of optimum mix of demographic variables for integrated HSEE-ISO systems: The case of a gas transmission refinery

This study proposes a flexible intelligent algorithm for assessment and optimization of demographic features on integrated health, safety, and environment and ergonomics (HSEE)-ISO systems among operators of a gas transmission refinery. To achieve the objectives of this study, standard questionnaires with respect to HSEE and ISO standards are completed by 80 operators. Demographic features include age, education, gender, weight, stature, marital status, and work type. The average results for each category of HSEE are used as inputs and effectiveness of ISO systems (ISO 18000, ISO 14000, and ISO 9000) are used as output for the intelligent algorithm. Artificial Neural Networks (ANN) and Adaptive Neuro Fuzzy Inference System (ANFIS) in addition to conventional regression are used in this paper. Result shows the applicability and superiority of the flexible intelligent algorithm over conventional methods through mean absolute percentage error (MAPE). Computational results show that the proposed ANN performs better than ANFIS and conventional regressions based on its relative error. Finally, the optimum mix of demographic variables from viewpoint of HSEE and ISO are identified. This is the first study that proposes a flexible intelligent algorithm for assessment of optimum mix of demographic features for HSEE and ISO systems in a complex system such as a gas transmission refinery.     

基于有界数据包络分析(DEA)模型的应急避难场所效率评价

应用数据包络分析(DEA)方法,针对应急避难场所规划建设和运营维护两种情况,分别建立以建设成本和运营成本为输入指标,以服务性、可达性、安全性为输出指标的效率评价指标体系,并选择有界DEA模型,分层次对应急避难场所的投入产出效率进行评价。实证案例表明,临时和中长期避难场所比短期避难场所更容易获得较高的DEA效率;位于区域内部、交通便利的应急避难场所DEA效率较高;提高应急避难场所的综合利用水平,更有利于提高其DEA效率。     

液态 CO2 相变致裂煤层增透技术布孔方式研究

液态CO2相变致裂技术是一种新颖的低透煤层增透技术。为了更好地将液态CO2相变致裂技术运用到低透气煤层增透领域中,在平煤十三矿进行了液态CO2相变致裂的穿层强化预抽煤层瓦斯现场试验,通过煤层致裂后的瓦斯抽采效果反映出的不同布孔方式下的致裂差异,确定液态CO2的爆破孔的合理布孔方式。现场试验表明液态CO2相变致裂在交错的梅花孔布置方式下由于能量分布均匀,致裂效果优于矩形孔布置方式,研究结果为该技术在煤层增透强化预抽领域的推广应用奠定了基础。     

毒气泄漏场景下基于蒙特卡罗的工厂布局研究

由于在工业生产中使用危险化学品会引起各种工业事故的发生,为了减小事故风险,降低由此产生的经济损失,必须将安全问题考虑在内,对工厂进行合理布局。采用蒙特卡罗模拟技术,研究某生产设施发生有毒气体泄漏的场景下,气象条件的不确定性对工厂布局的影响。以风向、风速及大气稳定性作为随机变量,通过扩散模型、概率函数和蒙特卡罗模拟得到中毒死亡概率。将上述随机方法应用在天津某个处于规划布局阶段的工厂内,以氨气泄漏为例,根据该地区常年风向分布及所得风险等值线图对工厂设施布局提出建议。案例分析表明:该工厂需要进行重新布局,应将受体设施布置在风险较小、风频较小的方位上;同时该随机方法能够为工厂布局提供决策支持。     

Estimation of safety distances in the vicinity of fuel gas pipelines

In this paper, safety distances around pipelines transmitting liquefied petroleum gas and pressurized natural gas are determined considering the possible outcomes of an accidental event associated with fuel gas release from pressurized transmission systems. Possible outcomes of an accidental fuel gas release were determined by performing the Event Tree Analysis approach. Safety distances were computed for two pipeline transmission systems of pressurized natural gas and liquefied petroleum gas existing in Greece using real data given by Greek Refineries and the Greek Public Gas Enterprise. The software packages chetah and breeze were used for thermochemical mixture properties estimation and quantitative consequence assessment, respectively. Safety distance determination was performed considering jet fire and gas dispersion to the lower flammable limit as the worst-case scenarios corresponding to immediate and delayed cloud ignition. The results showed that the jet fire scenario should be considered as the limiter for safety distances determination in the vicinity of natural and petroleum gas pipelines. Based on this conclusion, the obtained results were further treated to yield functional diagrams for prompt safety distance estimation. In addition, qualitative conclusions were made regarding the effect of atmospheric conditions on possible events. Thus, wind velocity was found to dominate during a jet fire event suppressing the thermal radiation effect, whereas gas dispersion was found to be affected mainly by solar radiation that favors the faster dissolution of fuel gas below the lower flammable limit.     

Development of a risk-based maintenance strategy using FMEA for a continuous catalytic reforming plant

Petrochemical facilities and plants require essential ongoing maintenance to ensure high levels of reliability and safety. A risk-based maintenance (RBM) strategy is a useful tool to design a cost-effective maintenance schedule; its objective is to reduce overall risk in the operating facility. In risk assessment of a failure scenario, consequences often have three key features: personnel safety effect, environmental threat and economic loss. In this paper, to quantify the severity of personnel injury and environmental pollution, a failure modes and effects analysis (FMEA) method is developed using subjective information derived from domain experts. On the basis of failure probability and consequence analysis, the risk is calculated and compared against the known acceptable risk criteria. To facilitate the comparison, a risk index is introduced, and weight factors are determined by an analytic hierarchy process. Finally, the appropriate maintenance tasks are scheduled under the risk constraints. A case study of a continuous catalytic reforming plant is used to illustrate the proposed approach. The results indicate that FMEA is helpful to identify critical facilities; the RBM strategy can increase the reliability of high-risk facilities, and corrective maintenance is the preferred approach for low-risk facilities to reduce maintenance expenditure.