Methodology for Natech coupling risk assessment using correlative multi-criteria decision-making method

When a natural disaster occurs, it may damage multiple industrial facilities in a certain area at the same time, and the resulting Natech events may have an impact on the surrounding industrial facilities, generating coupling risk. In this study, the assessment of Natech events coupling risk is conducted using the method of correlated multi-criteria decision-making, and the knowledge of fuzzy measures is introduced to solve the uncertainty problem in Natech coupling risk. Natech Coupling Risk Index is constructed to involve physical and functional facilities. The concept of equivalent population is proposed to compare the risks generated by physical facilities and functional facilities. And economic indicators are added to calculate the comprehensive risk value. The purpose of this contribution is to enable local government managers to use their expertise and resources and the existing risk assessment of the plants themselves and rely on the scoring of experts limitedly to quickly and easily identify potential high Natech risk areas. In the calculation process of coupling risk, the government can also take the lead to promote information communication between different plants and other industrial subjects. The proposed method was applied in a realistic chemical industry area in Guangzhou, China and in a hypothetical town. The result shows that the physical risk may be transferred to the population and economy through the coupling between industrial facilities and the functional link between functional facilities and population and economy.     

Contribution of a systemic modeling approach applied to support risk analysis of a storage unit of chemical products in Morocco

This paper proposes a new systemic modeling approach using the unified modeling language (UML) as an operational tool to model a complex industrial system and analyzes its risks. This approach is presented as a modeling process divided into three phases corresponding to functional analysis, structural analysis and risk analysis. This study aims to formalize the interactions within an industrial system and to identify the abnormal situations which could generate risks. The application of this approach is demonstrated with an example of a storage unit of chemical products located in Morocco. This approach provides a comprehensive view that facilitates the understanding of the organization of an industrial system and leads to more effective analysis of its safety.     

Occupational chemical exposure and risk estimation in process development and design

Each year more people die from diseases caused by work than are killed in industrial accidents. Therefore, methods are needed to evaluate occupational health hazards as early as possible when the process is still under development. A method for estimating inhalative exposures and risks in petrochemical and related plants is presented. The method is simple and suffices with the limited data availability during the early design stages.The steps of the method, which utilizes preliminary process flow diagrams are as follows: first the fugitive emissions and process plot areas are estimated based on precalculated process modules representing the typical process sections (such as a distillation unit). Chemical concentration in the air is then calculated based on the wind velocity probability and the estimated process cross-sectional area. For this purpose a typical wind velocity distribution in the area is used. The worker risk of exposure to chemicals is evaluated either based on the concentration in air by using the hazard quotient method or calculating the carcinogenic chemicals intake and the resulting risk of cancer. The values are compared to the benchmarks.As a result the process route health characteristics such as fugitive emissions rate, critical wind speed, chemical concentration in air and intake amount as well as the corresponding risk of exposure are produced. By using statistical meteorological data, health risks of occupational exposure can be estimated more realistically as probabilities. The approach is capable of comparing alternative processes to select the concept which is inherently occupationally healthier. Using this method, the exposure problems of a process can be identified earlier and proper decisions can be made early in process development or predesign stage.The concentration-based method is demonstrated by a case study of six competing manufacturing routes for methyl methacrylate (MMA). The C3 is found to be the most harmful alternative to health. Both concentration-based and intake-based methods are applied. The study indicates that the intake-based risk estimation benchmark is stricter than the exposure limit-based benchmark for carcinogens.     

Dynamic risk analysis of offloading process in floating liquefied natural gas (FLNG) platform using Bayesian Network

The growing demand for natural gas has pushed oil and gas exploration to more isolated and previously untapped regions around the world where construction of LNG processing plants is not always a viable option. The development of FLNG will allow floating plants to be positioned in remote offshore areas and subsequently produce, liquefy, store and offload LNG in the one position. The offloading process from an FLNG platform to a gas tanker can be a high risk operation. It consists of LNG being transferred, in hostile environments, through loading arms or flexible cryogenic hoses into a carrier which then transports the LNG to onshore facilities. During the carrier's offloading process at onshore terminals, it again involves risk that may result in an accident such as collision, leakage and/or grounding. It is therefore critical to assess and monitor all risks associated with the offloading operation. This study is aimed at developing a novel methodology using Bayesian Network (BN) to conduct the dynamic safety analysis for the offloading process of an LNG carrier. It investigates different risk factors associated with LNG offloading procedures in order to predict the probability of undesirable accidents. Dynamic failure assessment using Bayesian theory can estimate the likelihood of the occurrence of an event. It can also estimate the failure probability of the safety system and thereby develop a dynamic failure assessment tool for the offloading process at a particular FLNG plant. The main objectives of this paper are: to understand the LNG offloading process, to identify hazardous events during offloading operation, and to perform failure analysis (modelling) of critical accidents and/or events. Most importantly, it is to evaluate and compare risks. A sensitivity analysis has been performed to validate the risk models and to study the behaviour of the most influential factors. The results have indicated that collision is the most probable accident to occur during the offloading process of an LNG carrier at berth, which may have catastrophic consequences.     

Integrating lean principles and fuzzy bow-tie analysis for risk assessment in chemical industry

In this research, a framework combining lean manufacturing principles and fuzzy bow-tie analyses is used to assess process risks in chemical industry. Lean manufacturing tools and techniques are widely used for eliminating wastes in manufacturing environments. The five principles of lean (identify value, map the value stream, create flow, establish pull, and seek perfection) are utilized in the risk assessment process. Lean tools such as Fishbone Diagram, and Failure Mode and Effect Analysis (FMEA) are used for risk analysis and mitigation. Lean principles and tools are combined with bow-tie analysis for effective risk assessment process. The uncertainty inherent with the risks is handled using fuzzy logic principles. A case study from a chemical process industry is provided. Main risks and risk factors are identified and analyzed by the risk management team. Fuzzy estimates are obtained for the risk factors and bow-tie analysis is used to calculate the aggregated risk probability and impact. The risks are prioritized using risk priority matrix and mitigation strategies are selected based on FMEA. Results showed that the proposed framework can effectively improve the risk management process in the chemical industry.     

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.     

Appraisal of a new risk assessment model for SME

The identification, assessment and reduction of the risks is among of the most important issues of the safety at work. This paper’s goal is to demonstrate the effectiveness of a new risk assessment method proposed by the authors and presented in the past (Fera and Macchiaroli, 2009). In general, one can deal with risk assessment using different methods: quantitative, qualitative or a mix; however, the typical models proposed in the literature are difficult to implement in SMEs. The method proposed in this paper is a mixed one whose effectiveness is demonstrated through an application study carried out in different industrial systems, like a steel industry or a logistic services provider.     

Carbon capture and storage-desirability from a risk management point of view

Environmental and safety risks related to carbon capture and storage concern leakages and accidental releases during transport and geological storage. Based on principles widely accepted in the EU and beyond in the discussion about the where’s and why’s of nuclear waste repositories, this paper discusses the desirability of carbon capture and storage from a risk management point of view, focusing on environmental risks on the global level (climate change). On this basis it is concluded that, if the key energy issue of coming generations, not just in Europe but all around the world, is not the abundance of fossil resources but rather an unacceptably high probability of global warming due to greenhouse gas emissions, then the solution should not include any massive hiding of the emissions but entirely focus on the avoidance based on improved technology in power plants and other industrial installations.     

基于免疫机理的氯化工艺事故风险模糊评价

为预防氯化工艺安全生产事故,基于生物免疫机理,先应用仿生学方法分析了氯化安全生产事故预警体系与生物免疫系统的相似性,结合氯化生产工艺的实际情况,构建了基于抗原-抗体模式的安全生产预警体系的层次模型,并确定了各评价指标的权重。结果表明,影响较大的抗原A指标有A12(个体的防护水平)、A24(氯的毒性)、A34(暴露于危险环境);影响较大的抗体B指标有B12(应急机制的完善)、B26(反应物料比例的控制和连锁)、B29(冷却系统中冷却介质的温度)、B30(冷却系统中冷却介质的压力)。基于所构建的氯化工艺安全生产预警指标体系,结合某厂氯苯生产工艺及操作控制指标,进一步运用模糊综合评价方法,对该工艺的事故风险进行了模糊评价。结果表明,以抗原-抗体模式建立的事故风险模糊综合评价方法可操作性强、效果较好,可以提高事故的预防和控制能力,可在工艺过程的安全综合评价中广泛应用。     

Review of 62 risk analysis methodologies of industrial plants

For about 10 years, many methodologies have been developed to undertake a risk analysis on an industrial plant. In this paper, 62 methodologies have been identified, these are separated into three different phases (identification, evaluation and hierarchisation). In order to understand their running, it seems necessary to examine the input data, methods used, obtained output data and to rank them in several classes. First, all the input data are grouped together into seven classes (plan or diagram, process and reaction, products, probability and frequency, policy, environment, text, and historical knowledge). Then, the methods are ranked in six classes based on the combination of four usual criteria (qualitative, quantitative, deterministic and probabilistic). And finally, the output data are classified into four classes (management, list, probabilistic and hierarchisation). This classification permits the appraisal of risk analysis methodologies. With the intention of understanding the running of these methodologies, the connections between the three defined previously criteria (determinist, probabilistic and determinist and probabilistic) are brought to the fore. Then the paper deals with the application fields and the main limitations of these methodologies. So the hierarchisation phase is discussed and the type of scale used. This paper highlights the difficulties in taking into account all risks for an industrial plant and suggests that there is not only one general method to deal with the problems of industrial risks.     

A thermal hazard risk evaluation of emulsion polymerisation and vinyl acetate monomers in the latex manufacturing process

Latex is extensively used in industrial products. However, completing some processes at scale leads to unacceptable levels of risk that need to be quantified and mitigated. Systemic risks must be eliminated wherever possible, and safety takes priority over efficiency and quality. To assess the process risks accurately, four raw materials were examined in this study: polyvinyl acetate (PVA), latex process-initiator-ammonium persulfate (APS) and hydrogen peroxide (H₂O₂), and vinyl acetate monomer (VAM). The physicochemical composition of the PVA latex process was determined via calorimeters, including differential scanning calorimetry (DSC) and vent sizing package 2 (VSP2). The calorimetry results showed that the protective colloid was a critical component in the polymerisation reaction. In addition, when adding initiators to the system, it is vital to observe the normal ratio of materials and keep the stirring system operating. The scenario system also simulated the effects of shutting down various inhibitory programs, including the build-up of free radicals that could result in a runaway reaction when the initiator was added in excess. On the other hand, the result of the risk matrix displayed as a medium level, indicating that although the probability of an accident is low, the resulting severity is at disaster level. As a result, this study provides process safety engineers with a reliable frame of reference for assessing the potential dangers in the PVA latex manufacturing process.     

Safety analysis and risk assessment of a Micro-GtL Plant

Laboratory hydrogen generators, medical oxygen, and micro-breweries are examples of modular and micro technologies that are commercial successes. Researchers, patients, and unskilled workers operate these facilities but more complex processes require highly qualified personnel to ensure they operate safely. Modular-micro processes in isolated locations meet economic objectives when operated remotely thereby minimizing labor costs. Mitigating the risk requires a comprehensive hazards analysis with advanced control systems particularly for explosive and toxic compounds. Here, we propose a method called Failure Mode Risk Decision (FMRD) to review the inherent hazards of a micro-refinery unit (MRU) that converts flared and wasted natural gas to long chain hydrocarbons. This approach combines the Process Flow Failure Mode (PFFM) methodology as a systematic and reliable technique with a novel numerical risk assessment to improve the analytical evaluation of hazardous conditions. The objective is to combine causes and consequences in a single metric, where scaled probability of evident causes and severity of consequences are used to derive a risk level measure. With the proposed metric, the magnitude of a potential hazard is directly correlated with the risk level. This mechanism identifies extra risk scenarios compared to the classical hazard analysis method and provides a straightforward comprehensive numerical assessment to represent the inherent and residual risks to facilitate justifying the hazardous scenarios. Accordingly, we design a safety loop and supply all the required facilities to remove the potential risks at the process plant. Not only the proposed methodology clarifies the risks of the MRU presented in this study, but can be extended to review the hazards of other chemical process plants.     

Quantitative risk assessment integrated with dynamic process simulation for reactor section in heavy oil desulfurization process

A new methodology for quantitative risk assessment (QRA) integrated with dynamic simulation and accident simulation is proposed. The objective of this study is to discover inherent risks that are undetectable by conventional risk analysis methods based on steady-state conditions. The target process is the reactor section in the heavy oil desulfurization (HOD) process, which is likely to pose vast potential risks due to the high operating conditions of pressure and temperature. First, a dynamic simulation of a shut-down procedure was performed to observe the behavior of process variables using Aspen HYSYS V10, which is a commercially available process software. Based on the results of the dynamic simulation, several blind spots indicating a higher operating pressure than that in the steady-state simulation were identified. To assess the risks of the detected blind spots, a QRA was performed using the commercial software of SAFETI V8.22, which performs risk calculation based on consequence and frequency data. As a result of applying the proposed method to the HOD process, the risk assessment outcome was identified as intolerably risky unlike that of steady-state conditions, thereby indicating that dynamic simulations can serve as a method to spot inherent risks that are undetectable in steady-state conditions. In addition, mitigation procedures that reduce the risk of the process to a tolerable level are performed, thereby enabling a safer and more reliable process.     

An optimal level of dust explosion risk management: Framework and application

The current research provides guidance on the prevention and mitigation of dust explosion using a Quantitative Risk Management Framework (QRMF). Using concepts drawn from previous studies, the framework consists of three main steps: (i) a new combined safety management protocol, (ii) the use of DESC (Dust Explosion Simulation Code) and FTA (Fault Tree Analysis) to assess explosion consequences and likelihood, respectively, and (iii) application of the hierarchy of controls (inherent, engineered and procedural safety). QRMF assessment of an industrial case study showed that the original process was at high risk. DESC simulations and Probit equations determined the destructive percentages. FTAs revealed high probabilities of explosion occurrence; in addition, detailed individual and societal risks calculations were made, before and after the framework was applied. Based on the hierarchy of controls technique, the framework showed significant risk reduction to the point where the residual risk was acceptable for the process.     

危险点分析预控理论在锅炉设备中的应用

危险点分析预控理论,是电力职工从反事故的实践中摸索出来的新方法.将其应用于火力发电厂的安全工作中,使电厂工作人员通过分析危险而认识危险.分别对锅炉运行中的锅炉制粉系统和锅炉检修中的焊接作业进行危险点分析,提出了控制措施.     

An evaluation of risk assessment framework for industrial accidents in India

Due to rapid industrialization, with high population density and constraints of land, it is expected that level of risks arising from the hazardous industries will increase in India in the coming decades. However, 30 years after the Bhopal accident (1984), except a few discrete regulations, there is as yet no integrated system for assessing and managing risks arising out of these hazardous industries in India. The gravity of aspects related to the management of industrial risk still remains crucially important. In particular, there is no standard guideline on risk analysis methodology, acceptability or tolerability criteria, nor is there an accident database or a risk reduction strategy for the areas where risk levels are already high. On top of this, there are technical and legislative gaps in the institutional framework to implement any of the above mentioned issues. With the backdrop of the Bhopal gas tragedy, the objective of this paper is therefore to evaluate the effectiveness of a comprehensive risk assessment framework for the emerging economy of India, in order to control and/or to reduce the risk level that exists. In this context, regulations and policies pertaining to industrial risk assessment were reviewed.     

Shelter-in-place risk assessment for high-pressure natural gas wells with hydrogen sulphide and its application in emergency management

This paper provides a risk assessment method of sheltering in-place for high-pressure natural gas wells with hydrogen sulphide. In this paper, the shelter-in-place risk is estimated by integrating the health consequences of an individual taking one kind of emergency response to the emergency orders of sheltering in place from the emergency decision makers and the probability of the corresponding emergency response action. The probability of the corresponding emergency response action in the proposed method is estimated through the accident probability analysis and the probability analysis of taking a certain response action. The health consequence estimation is based on air exchange rate test of the shelter buildings as well as accident consequence calculation. The evaluation of shelter-in-place risks based on “as low as reasonably practicable (ALARP)” guidelines was employed to provide suggestions for emergency management under both normal conditions and off normal conditions. A case study of risk assessment of sheltering in the local residential houses in Xuanhan County of Sichuan Province, China was taken as an example to illustrate the proposed risk assessment process of shelter-in-place and its application in the decision-making process for emergency management.