安全仪表系统等级划分与HAZOP分析的结合应用

介绍了安全仪表等级的划分和HAZOP分析，并用此方法分析了苯酐装置。大多数现役或在建苯酐装置的氧化反应器存在较大的火灾、爆炸危险性，一旦在操作、控制和管理上稍有疏忽，就可能发生火灾、爆炸事故。HAZOP方法针对指定系统进行结构化和系统化的审查，辨识系统中潜在的危害和潜在操作问题，基于HAZOP给出安全仪表等级是今后安全设计的一条新路。     

HAZOP结合What-if方法在某延迟焦化装置除焦中的应用

为克服传统危险与可操作性（HAZOP）定性分析方法在复杂操作、间歇作业等过程中使用的局限性,提出在传统HAZOP定性分析方法的基础上结合What-if（故障假设）方法,对人的不安全行为和操作规程不完备所导致的风险后果分析作出补充。详细说明其技术原理、工作流程等使用细节,系统阐述该方法与传统HAZOP定性分析方法的区别,并在某延迟焦化装置的除焦操作的风险分析中应用。经分析,识别出在“给水-泡焦”节点,有“操作规程错误”场景2项,“操作规程不具体”场景1项,不存在“操作人员未按操作规程执行”场景。研究结果表明:本文方法有效且具有较好效果,可以广泛应用于操作规程/作业指导书审查、作业过程隐患排查等方面,帮助企业开展操作层面的风险识别与管理,提升企业的生产安全水平。     

Inherent safety in offshore oil and gas activities: a review of the present status and future directions

Inherent safety is a proactive approach for hazard/risk management during process plant design and operation. It has been proven that, considering the lifetime costs of a process and its operation, an inherently safer approach is a cost-optimal option. Inherent safety can be incorporated at any stage of design and operation; however, its application at the earliest possible stages of process design (such as process selection and conceptual design) yields the best results.Although it is an attractive and cost-effective approach to hazard/risk management, inherent safety has not been used as widely as other techniques such as HAZOP and quantitative risk assessment. There are many reasons responsible for this; key among them are a lack of awareness and the non-availability of a systematic methodology and tools.The inherent safety approach is the best option for hazard/risk management in offshore oil and gas activities. In the past, it has been applied to several aspects of offshore process design and operation. However, its use is still limited. This article attempts to present a complete picture of inherent safety application in offshore oil and gas activities. It discuses the use of available technology for implementation of inherent safety principles in various offshore activities, both current and planned for the future.     

HAZOP在煤矿通风系统安全风险分析中的应用

HAZOP是一种基于“引导词”的、由各专业人员组成的分析小组通过一系列的分析会议来完成的,对系统工艺或操作过程中存在可能导致风险的各种偏差的一种系统化识别的定性分析方法。为提高煤矿通风系统安全风险分析效果,将HAZOP分析方法应用于煤矿通风系统中。通过对煤矿通风系统进行分析,证实了HAZOP分析方法在煤矿通风系统应用的可能性和充分性。分析结果不仅反映出了导致煤矿通风安全风险（或通风安全事故）的人的不安全行为和物的不安全状态等现场因素,而且还评审出煤矿通风系统的设计和管理缺陷,为煤矿如何更好的管理通风系统提供了有力依据。     

Dynamic model based safety analysis of a three-phase catalytic slurry intensified continuous reactor

Safety analysis like the HAZOP (HAZard OPerability) study can be much more efficient if a dynamic model of the system under consideration is available to evaluate the consequences of hazard deviations and the efficiency of the proposed safety barriers. In this paper, a dynamic model of a three-phase catalytic slurry intensified continuous chemical reactor is used within the context of its HAZOP (HAZard OPerability) study. This reactor, the RAPTOR®, is an intensified continuous mini-reactor designed by the French company AETGROUP SAS that can replace batch or fed-batch processes in the case of highly exothermic reactions involving hazardous substances. The highly hazardous hydrogenation of o-cresol under high pressure and temperature is taken as an example of application. Deviations as a temperature increase of the cooling medium or no cooling medium flow can produce an overheating of the reactor. Thus, three possible safety barriers are evaluated by simulation: shut off the gaseous reactant feed, shut off the liquid reactant feed or stop the agitation. The more efficient actions are the stopping of the agitation and/or of the gas reactant feed. The simulation results can efficiently help the reactor design and optimisation. Safety analysis can also be one of the criteria to compare batch and intensified continuous processes.     

HAZOP 分析在酸性水汽提装置上的应用与研究

危险与可操作性分析对于石化装置的工艺安全管理具有重要意义,介绍了HAZOP分析方法在工艺装置上的应用流程,并讨论了HAZOP分析与风险矩阵的结合运用。以克拉玛依石化公司的80吨/小时酸性水汽提装置为例,详细阐述了HAZOP分析的流程及其与半定量分析相结合的方法在实践中的应用,并针对危险源给出了风险削减措施。基于HAZOP分析在实践中的应用情况,总结了一些客观存在的问题,并提出了意见和建议。     

Process hazards review applied to the use of anhydrous ammonia in agriculture: an example of chemical process safety for small business

Process hazards review (PHR) techniques have generally been applied by large, sophisticated companies in the nuclear, aerospace, and chemical process industries. There remains, however, a large population of smaller distributors and consumers of hazardous materials which could benefit equally from the application of PHR. These consumers unfortunately are generally less sophisticated and individually lack the necessary resources required to apply such state-of-the-art safety techniques.

Where common processes can be identified, it is possible to conduct a more generic PHR that will provide a sound technical basis for recognizing and preventing the development of hazards wherever these processes are used. Some facility-specific issues will always need to be considered, but the existence of the generic PHR should make the conduct of a PHR by each facility considerably easier and less costly.

Researchers from the National Institute for Occupational Safety and Health (NIOSH) contracted with DNV Technica Inc. to lead a hazard and operability study (HAZOP) of agricultural handling of anhydrous ammonia, from the receipt of ammonia at the retail distribution centre to the application of the ammonia by farmers to the fields. The multidisciplinary HAZOP team consisted of representatives from NIOSH, an agricultural chemical trade association, an ammonia producer, state ammonia facility inspectors, a retail distributor, and an equipment manufacturer. Several participants were part-time farmers with ammonia application experience.

Some specific aspects of applying the HAZOP technique in the context of this study, the findings obtained, and the plans to disseminate the important safety information developed during the course of the PHR are discussed. Finally, it is suggested that this approach could prove to be a useful addition to the product stewardship activities of chemical producers.     

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。     

HAZOP与风险矩阵组合技术应用研究

通过对国外风险矩阵和个体风险研究,同时结合国内相关法律法规和企业事故管理规定,首次提出风险矩阵制定的依据,为企业行业制定风险矩阵提供理论基础,并制定出适合自身企业的风险矩阵。将HAZOP分析方法与风险矩阵相结合,提出"HAZOP+风险矩阵"组合技术,并采用该组合技术对精对苯二甲酸(PTA)装置氧化反应器单元的危险与可操作性问题进行系统分析,识别出装置中存在的过程安全问题并提出建议,对整个装置重大工艺安全事故的预防和安全平稳运行起到重要作用。     

An extended HAZOP analysis approach with dynamic fault tree

An extended hazard and operability (HAZOP) analysis approach with dynamic fault tree is proposed to identify potential hazards in chemical plants. First, the conventional HAZOP analysis is used to identify the possible fault causes and consequences of abnormal conditions, which are called deviations. Based on HAZOP analysis results, hazard scenario models are built to explicitly represent the propagation pathway of faults. With the quantitative analysis requirements of HAZOP analysis and the time-dependent behavior of real failure events considered, the dynamic fault tree (DFT) analysis approach is then introduced to extend HAZOP analysis. To simplify the quantitative calculation, the DFT model is solved with modularization approach in which a binary decision diagram (BDD) and Markov chain approach are applied to solve static and dynamic subtrees, respectively. Subsequently, the occurrence probability of the top event and the probability importance of each basic event with respect to the top event are determined. Finally, a case study is performed to verify the effectiveness of the approach. Results indicate that compared with the conventional HAZOP approach, the proposed approach does not only identify effectively possible fault root causes but also quantitatively determines occurrence probability of the top event and the most likely fault causes. The approach can provide a reliable basis to improve process safety.     

Process safety data management program based on HAZOP analysis and its application to an ethylene oxide/ethylene glycol plant

HAZOP analysis is a process hazard analysis method that has been widely applied both within and outside the chemical processing industries. This paper presents a design method for a process safety data management program for petrochemical plants based on HAZOP analysis and demonstrates the steps of application involved in building a process safety data management system for an ethylene oxide/ethylene glycol production plant. Firstly, the production data files and relevant documents of the plants should be classified and stored in the program database as reference documents and treatment schemes for coping with abnormal situations should be collected and summarized as guidance documents. Secondly, the HAZOP analysis method is employed to identify all the dangerous deviations possibly existing in the production process of the ethylene oxide/ethylene glycol plant. Then, the relationships among the deviations, the reference documents and the guidance documents should be considered and evaluated. Finally, each dangerous deviation will be given a corresponding reference document and guidance document. The reference documents and guidance documents stored in the expert system can be utilized to help operators solve the corresponding technical problems and cope with abnormal situations. The process safety data management program will contribute to the identification, analysis and resolution of operation problems. When an abnormal situation occurs, according to the deviations exhibited in the system, the necessary reference documents and guidance documents will be quickly consulted by the operators, and an appropriate decision will be made to address the abnormal situation. Therefore, by using the process safety data management program, plant security and human safety in the petrochemical industries will be improved.     

Integration of safety instrumented system with automated HAZOP analysis: An application for continuous biodiesel production

Integration of a human-machine interface (HMI) with hazard and operability (HAZOP) analysis is proposed in this work. This concept can potentially lead to the identification of some unexpected deviations, and radically decreases the time necessary for hazard identification. A continuous biodiesel production was simulated. This can be divided into two cases, covering both conventional and reactive distillation. Soybean oil (trioleic, trilinoleic and tripalmitic) at 1000 kg/h as raw material is converted to 99 wt% pure biodiesel. The HMI was designed to improve these processes by combining automatic HAZOP analysis. With this approach, users can receive sufficient information from the simulation to analyze the optimum operation and safety. Severity levels are also provided to classify the actions in the process. Severity levels 1 and 2 are concerned with operating conditions, which are 58-64 °C, and 50-150 kPa. If the analysis shows severity level 3, the safety instrumented system (SIS) will automatically manage the operation in order to reduce/restrain the amount of damage at this level. This proposed system could minimize the damage and also improve the overall quality of the process.     

TOPHAZOP: a knowledge-based software tool for conducting HAZOP in a rapid, efficient yet inexpensive manner

Hazard and operability (HAZOP) studies constitute an essential step in the risk analysis of any chemical process industry and involve systematic identification of every conceivable abnormal process deviation, its causes and abnormal consequences. These authors have recently proposed optHAZOP as an alternative procedure for conducting HAZOP studies in a shorter span of time than taken by conventional HAZOP procedure, with greater accuracy and effectiveness [Khan, F. I. and Abassi, S. A., optHAZOP. An effective and efficient technique for hazard identification and assessment Journal of Loss Prevention in the Process Industries, 1997, 10, 191–204]. optHAZOP consists of several steps, the most crucial one requires use of a knowledge-based software tool which would significantly reduce the requirement of expert man-hours and speed up the work of the study team. TOPHAZOP (Tool for OPTmizing HAZOP) has been developed to fulfil this need.

The TOPHAZOP knowledge-base consists of two main branches: process-specific and general. The TOPHAZOP framework allows these two branches to interact during the analysis to address the process-specific aspects of HAZOP analysis while maintaining the generality of the system. The system is open-ended and modular in structure to make easy implementation and/or expansion of knowledge. The important features of TOPHAZOP and its performance on an industrial case study are described.     

基于HAZOP分析的加氢装置工程设计方法

加氢装置属甲类火灾、爆炸危险生产装置。为了在设计阶段尽可能消除或控制潜在风险,本文总结了多套加氢装置HAZOP分析报告中的设备类别及其分析内容,提出了基于危险与可操作性(HAZOP)分析的加氢装置工程设计方法。在传统工程设计方法的基础上增加了参数敏感性工程设计方法,依据分析报告中的设计建议,利用ASPEN软件计算过程参数变化对目标参数的影响程度,确定参数稳定操作区域;建立了数据库管理界面实现了加氢装置工程安全设计经验知识的有序管理。应用基于HAZOP分析的加氢装置工程设计方法,有助于将安全隐患问题在设计阶段消除或加以控制,可为降低石化装置改造成本和提高装置的安全水平提供方法依据。     

HAZOP技术在炼油火炬系统工艺危害分析中的应用

为系统辨识火炬系统存在的危险有害因素,提高火炬系统的安全设计及运行水平,采用危险与可操作性（HAZOP）分析对火炬系统开展了工艺危害分析。以火炬筒体为例,分析了火炬筒体的控制参数,给出了筒体火焰小、高空点火器点火不成功、地面爆燃点火系统点火失败等偏差的HAZOP分析结果,并针对高风险的偏差提出了相应的建议措施。从分析效果来看,HAZOP技术可用于炼油火炬系统的工艺危害分析,能系统地辨识炼油火炬系统存在的隐患,有助于提高装置工艺安全水平。     

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.     

基于模糊数学的石油化工装置HAZOP风险分析技术研究

对传统的HAZOP分析中偏差原因发生可能性进行量化。对于有统计数据的,根据行业数据、公司经验及企业事故建立HAZOP风险分析统计数据库;对于没有统计数据的HAZOP分析偏差原因发生概率,通过专家主观评判,用模糊数理论将专家自然语言转换为模糊数,采用左右模糊排序法将模糊数转换为模糊失效概率值。研究了偏差后果严重程度的划分标准,并根据偏差原因概率和偏差后果严重程度确定风险等级,利用风险矩阵得出偏差风险的大小。从而把HAZOP分析方法从定性改进为半定量的分析方法。据此对石油化工装置进行了HAZOP风险分析。     

在役柴油加氢装置HAZOP分析技术

柴油加氢装置属甲类火灾危险生产装置,为了保障其安全生产,实现事故早期预防,对其进行风险分析和安全评价势在必行.HAZOP分析方法是流程工业广泛使用的一种危险辨识和分析方法,具有较好的系统性和完备性.首先介绍了HAZOP分析方法的由来及应用情况,其次分析了在役装置HAZOP分析的难点,并提出了相应的建议,然后详述了在役装置HAZOP方法的分析流程.最后以中石油某石化公司在役柴油加氢装置为例进行了HAZOP分析,辨识出可能存在的安全隐患和潜在危险,对较高风险提出了必要的安全保护措施和合理的改进建议.结果表明,HAZOP分析是提高在役装置安全性的一种有效手段,其结果为装置安全管理提供了可靠的依据.     

计算机辅助HAZOP技术的研究

在HAZOP原理的基础上,讨论了计算机辅助HAZOP技术的优势,并针对传统的HAZOP、基于深层知识模型SDG的计算机辅助HAZOP和应用PHA-Pro软件3种方法进行了分析和比较;介绍了研发成功的针对开、停车过程和应急阶段顺序颠倒、操作步骤遗漏的人工误操作危险与可操作性分析系统MO-HAZOP;该系统具有定量计算出所有的人工误操作顺序组合的发生概率值,结合现有知识和专家经验,判定事件发生的风险等级,从而有重点地给出预防危险、保障生产安全的建议的功能;MO-HAZOP分析系统对于石化企业的安全生产具有重要意义。