Inherent risk assessment—A new concept to evaluate risk in preliminary design stage

Quantitative Risk Assessment (QRA) has been a very popular and useful methodology which is widely accepted by the industry over the past few decades. QRA is typically carried out at a stage where complete plant has been designed and sited. At that time, the opportunity to include inherent safety design features is limited and may incur higher cost. This paper proposes a new concept to evaluate risk inherent to a process owing to the chemical it uses and the process conditions. The risk assessment tool is integrated with process design simulator (HYSYS) to provide necessary process data as early as the initial design stages, where modifications based on inherent safety principles can still be incorporated to enhance the process safety of the plant. The risk assessment tool consists of two components which calculate the probability and the consequences relating to possible risk due to major accidents. A case study on the potential explosion due to the release of flammable material demonstrates that the tool is capable to identify potential high risk of process streams. Further improvement of the process design is possible by applying inherent safety principles to make the process under consideration inherently safer. Since this tool is fully integrated with HYSYS, re-evaluation of the inherent risk takes very little time and effort. The new tool addresses the lack of systematic methodology and technology, which is one of the barriers to designing inherently safer plants.     

基于模糊综合评价的化工工艺本质安全指数研究

建立化工工艺的本质安全评价指标体系,包括可燃性、爆炸性、毒性、反应性、温度、压力、储量等7个指标。为解决前人指数法中的边界波动效应,采用模糊综合评价建立化工工艺本质安全评价指数模型,确定各指标的权重、危险分级及对各分级的隶属函数。以甲基丙烯酸甲酯的5条工艺路线为例进行分析,结论与前人提出的指数方法的评价结果相吻合,表明该指数方法可以用来进行化工工艺的本质安全评价,以指导设计初期的本质安全型工艺路线选择。     

基于本质安全的化学工艺风险评价方法研究

基于本质安全原理对化学工艺进行风险评价，以易燃性、易爆性、毒性、腐蚀性、反应热、化学活性、工艺温度、工艺压力和存储量9个指标，建立化学工艺的本质安全评价指标体系。采用基于遗传算法的Shepard插值算法对本质安全进行评价，以甲基丙烯酸甲酯的合成工艺路线为例进行分析，结果表明该方法适用于化学工艺本质安全评价，相对传统方法更加科学，能够有效对危险工艺进行选择，为政府监管部门和化工企业提供工艺选择决策技术。     

Historical evolution of process safety and major-accident hazards prevention in Spain. Contribution of the pioneer Joaquim Casal

This paper aims at presenting the evolution of process safety in Spain from various points of view. In first place, a study of the accidents occurred in this country in the process industry and in the transportation of chemical substances is presented. After this, the starting point of the process safety research in Spain and its evolution during the years are explained. The importance of this topic has also been reflected in the chemical engineering studies in some Spanish universities. Therefore, the current status of the studies on process safety in Spain is analyzed in this paper. A section has also been devoted to the process safety in the Spanish industry. An analysis of the related legislation and its implementation in the Spanish process industry is also presented in this paper. Finally, the professional career of Prof. Joaquim Casal, the pioneer in Spain in process safety and risk assessment, is summarized.     

Application of domino effect quantitative risk assessment to an extended industrial area

Escalation of primary accidental scenarios triggering a “domino effect” have caused extremely severe accidental events in the chemical and process industry. The identification of possible escalation events is required in the safety assessment of sites where relevant quantities of hazardous substances are stored or handled. In the European Union, “Seveso-II” Directive requires the assessment of on-site and off-site possible escalation scenarios in sites falling under the obligations of the Directive. In the present study, a methodology developed for the quantitative assessment of risk due to domino effect was applied to the analysis of an extended industrial area. Recently developed equipment damage probability models were applied for the identification of the final scenarios and for escalation probability assessment. The domino package of the Aripar-GIS software was used for risk recomposition. The results evidence that quantitative risk assessment of escalation hazard is of fundamental importance in order to identify critical equipment and to address prevention and protection actions.     

道化学火灾、爆炸危险指数法在1,3丁二烯聚合安全性评价中的应用

道化学火灾、爆炸危险指数法是在化工领域中广泛应用的一种评价方法,根据该法制定的指数选取规则,可对工艺单元火灾爆炸危险性进行量化和分级.以某化工厂3000t/a三聚体生产项目为背景,从工艺过程、危险物质、安全设施设计等方面,对1,3丁二烯聚合过程火灾、爆炸危险性进行分析;定量评价工艺装置及所含物料潜在危险性,得出主装置区、储罐区固有危险等级,分析不同状态下安全补偿系数对降低危险等级的影响,提出相应安全对策措施.     

石化企业危险化工工艺风险等级评估指标分解

伴随石化企业的迅猛发展,危险品越来越多,生产条件越来越苛刻,同时带来的是更为重大的风险隐患以及安全事故,因此对危险工艺的风险评估就显得尤为重要.考虑到目前还没有什么好的方法来判别某种工艺就一定是危险化工工艺,因此本文在国家安监总局划分的15种危险化工工艺的基础上,根据危险化工工艺表征涉及的影响因素,结合化工工艺的实际情况,选择具有典型代表意义的重要性评价指标作为研究对象,建立了由67个具体指标形成的动态指标体系,并运用指标分类分解方法对各个指标进行量化,最后采用模糊数学综合评价对危险化工工艺进行了软件化评估,从而为政府和企业加强安全管理提供了便利,进一步实现石化企业的本质安全化.     

A semi-quantitative methodology for risk assessment of university chemical laboratory

University chemical laboratory is a high-risk place for teaching and scientific research due to the presence of various physical and chemical hazards. In recent years, university chemical laboratory accidents occur frequently. This urges the need to enhance university chemical lab safety. A semi-quantitative methodology comprising Matter-Element Extension Theory (MEET) implemented with Combination Ordered Weighted Averaging (C-OWA) operator is proposed to assess the risk of a university chemical laboratory. First, an index-based risk assessment system of university chemical laboratory is built by identifying various risk factors from a system perspective. Then, C-OWA operator is used to calculate the weight of assessment indices, whereas MEET is employed to determine the correlation degree of assessment indices. Finally, the comprehensive risk of university chemical laboratories is assessed, and some safety measures are proposed to reduce the risk of university chemical laboratories. The applicability of the proposed methodology is tested using a practical case. It is observed that the methodology can be a useful tool for risk assessment and management of university chemical laboratories.     

重大危险设备的确定及其失效后果严重度分析

采用火灾、爆炸危险指数(F&EI)方法对石化设备的危险性进行评价,根据计算设备的危险指数值来确定其是否为重大危险设备;应用模糊综合评价方法对石化装置失效后果严重程度进行综合评价研究,建立了石化装置失效后果严重程度的综合评价指标体系;采用定性与定量相结合的层次分析法计算评价因素的权重,运用模糊综合评判理论,提出失效后果严重度的二级模糊综合评价方法,实现对其失效后果严重度的综合评判。实例表明:模糊综合评价方法可操作性强、效果较好,可在石化装置失效后果严重度评价中广泛应用。     

Thermochemical stability: A comparison between experimental and predicted data

The first step to be performed during the development of a new industrial process should be the assessment of all hazards associated to the involved compounds. Particularly, the knowledge of all substances thermochemical parameters is a primary feature for such a hazard evaluation. CHETAH (CHEmical Thermodynamic And Hazard evaluation) is a prediction software suitable for calculating potential hazards of chemicals, mixtures or a single reaction that, using only the structure of the involved molecules and Benson's group contribution method, is able to calculate heats of formation, entropies, Gibbs free energies and reaction enthalpies. Because of its ability to predict the potential hazards of a material or mixture, CHETAH is part of the so-called “desktop methods” for early stage chemical safety analysis.In this work, CHETAH software has been used to compile a complete risk database reporting heats of decomposition and Energy Release Potential (ERP) for 342 common use chemicals. These compounds have been gathered into classes depending on their functional groups and similarities in their thermal behavior. Calculated decomposition enthalpies for each of the compounds have also been compared with experimental data obtained with either thermoanalytic or calorimetric techniques (Differential Scanning Calorimeter – DSC – and Accelerating Rate Calorimeter – ARC).     

Dynamic failure assessment of an ammonia storage unit: A case study

Chemical Process Industries usually contain a diverse inventory of hazardous chemicals and complex systems required to perform process operations such as storage, separation, reaction, compression etc. The complex interactions between the equipment make them vulnerable to catastrophic accidents. Risk and failure assessment provide engineers with an intuitive tool for decision making in the operation of such plants. Abnormal events and near-miss situations occur regularly during the operation of a system. Accident Sequence Precursors (ASP) can be used to demonstrate the real-time operating condition of a plant. Dynamic Failure Assessment (DFA) methodology is based on Bayesian statistical methods incorporates ASP data to revise the generic failure probabilities of the systems during its operational lifetime.In this paper, DFA methodology is applied on an ammonia storage unit in a specialized chemical industry. Ammonia is stored in cold storage tanks as liquefied gas at atmospheric pressure. These tanks are susceptible to failures due to various abnormal conditions arising due process failures.Tank failures due to three such abnormal conditions are considered. Variation of the failure probability of the safety systems is demonstrated. The authors use ASP data collected from plant specific sources and safety expert judgement. The failure probabilities of some safety systems concerned show considerable deviation from the generic values. The method helps to locate the components which have undergone more degradation over the period and hence must be paid attention to. In addition, a Bayesian predictive model has been used to predict the number of abnormal events in the next time interval. The user-friendly and intuitive nature of the tool makes it appropriate for application in safety assessment reports in process industries.     

物理化学方法在安全评价中的应用研究

提出以本质安全与系统安全为目的,在安全评价领域中使用物理化学方法,对化工装置中化学反应过程及其他物理化学过程进行安全分析与评价,从而深入了解变化过程,提出安全对策与措施。对安全评价模式、方法进行了探索并应用到实际工作中,同时阐述了该模式中HAZOP方法、物理化学方法各自的特点。列举了物理化学方法在几个方面的应用并以一实例:催化剂制备装置的安全评价。     

一种新型危险化工工艺安全评估方法的设计

在安全生产过程中,建设项目风险评价在我国经过几十年的发展,无论在模型亦是方法上均有所进步,但对化工项目进行危险化工工艺风险等级评价的研究并不多见。本文按照危险化工工艺表征涉及的影响因素,在参考了日本劳动省"六阶段"的定量评价表以及危险度评价法并对15种危险化工工艺定性分析的基础上,提出了一种基于危险度评价法的更为全面的危险化工工艺辨识方法。该评价方法可用于确定危险化工工艺的风险等级。为化工企业工艺危险的实时评估和安全管理提供技术支撑和科学途径。     

化工过程本质安全性之模糊评价系统

在综合分析化工过程构成的基础上,建立的化工过程本质安全性评价指标,借鉴国内外本质安全评价的研究,应用Matlab模糊推理系统,以评价指标的等级划分、隶属度函数设计及推理规则设定等为主线,建立化工过程本质安全性模糊评价系统,实现评价指标和评价推理结果的可视化。通过甲苯高温加氢脱烷烃制取苯的工艺过程,实施不同工艺路线及其操作条件改变的本质安全性评价,验证了所建立模糊评价系统的可行性。研究结果对指导化工安全设计和安全评价、减少和消除重大危险源,进一步提升我国化工行业的整体安全水平具有重要的理论和现实意义。     

城市公共安全风险评估——以高层建筑火灾为例

为了提高城市公共安全管理水平,必须首先对城市涉及公共安全的风险进行客观和科学评估。简要介绍一种城市公共安全风险评估的方法,并以高层建筑火灾为例,详细地对风险事件进行风险识别、分析和评价,以及提出应对措施的过程。该方法可以作为我国城市公共安全风险管理的有效工具加以推广和使用。     

基于层次分析-模糊综合评判的化工园区安全评价研究

应用模糊数学理论,把模糊综合评价方法具体应用到化学工业园区安全综合评价研究中,结合化工园区的实际情况,建立了化工园区的安全现状综合评价指标体系,采用定性与定量相结合的层次分析法计算评价因素的权重,运用模糊综合评判理论,提出安全现状二级模糊综合评价方法,实现对化工园区安全等级的综合评判。应用该方法对某化工园区的安全现状进行了综合评价,得出其安全等级为"一般"。实例表明:模糊综合评价方法可操作性强、效果较好,可在化工园区的安全综合评价中广泛应用。     

有机酸性腐蚀品生产危险性分析

目前我国化工生产中涉及大量有机酸性腐蚀品,通过对某市化工行业调查及分析,发现有机酸性腐蚀品生产普遍,而且生产原料易燃易爆,生产过程存在火灾爆炸危险,结合具体生产工艺,采用预先危险性分析法和作业条件的危险性评价法分析生产过程危险性,从而揭示并概括有机酸性腐蚀品生产危险性.为更好地促进我国安全生产,在此基础上探讨了一些针对性的安全措施.     

基于本质安全的化工工艺物质危险指数研究

建立了基于本质安全的化工工艺物质危险性的评价体系,包括火灾危险性、爆炸危险性以及毒性等3个评价指数.基于风险的思想,各个评价指数均包括概率指标与后果指标.为了全面反映化工工艺的实际情况,在各个评价指数中均对所有物质的相应指数值加和.参数的取值以以往的指数法为基础,为了消除边界波动效应,取值采用内插法.由于各个指数的量纲...     

A survey-based system for safety measurement and improvement

PROBLEM:A task force sought to develop a method for safety measurement that is reliable and valid and provides a framework for improvement efforts. METHOD: Over a 10-year period, through working in a chemical company with about 6,000 employees and over 50 plants, the authors researched the use of employee surveys to measure safety and as a diagnostic tool for improvement efforts. RESULTS: The statistical studies indicate that this survey, which evolved from the Minnesota Safety Perception Survey, is both reliable and valid as a measurement tool. The survey measures important components of the management system including (a) management's demonstration of commitment to safety, (b) education and knowledge of the workforce, (c) effectiveness of the supervisory process, and (d) employee involvement and commitment. This study also describes anecdotal evidence that the diagnostic element of the survey enables the development of effective action plans to improve safety performance. This evidence includes ratings of the process by plant managers who have used it. IMPACT ON INDUSTRY: The survey and related methods have helped to improve safety performance in several companies.