Challenges in building resilience engineering (RE) and adaptive capacity: A field study in a chemical plant

Safety issue in a chemical plant is absolutely critical because loss of control can result in a catastrophic consequence which is not limited to the boundaries of the plant. Thus, a risk assessment system is required for (a) preventing accidents by anticipation, (b) surviving disturbances by recovery, and (c) handling disruptive events by adaptation. RE is a proactive approach claiming to achieve all these objectives. The present research tries to identify challenges in the procedure of building RE and its adaptive capacity in a chemical plant. Primary data were collected through on-site observations and interviewing personnel. The results indicated the main challenges could be classified into nine categories of: lack of explicit experience about RE, intangibility of RE level, choosing production over safety, lack of reporting systems, ‘religious beliefs’, out-of-date procedures and manuals, poor feedback loop, and economic problems. Finally, it is concluded that the management insight about safety in such systems should avoid hindsight bias and tend to create foresight. Changing this insight can lead to achieve high reliability and resilience in the plant.     

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.     

A new method for risk assessment of pillar recovery operation

Safe pillar recovery operations can result in better miner safety and more efficient recovery of ore reserves. Several parameters influence on safety of pillar recovery operation. Each of these parameters is able to reduce safety of operation and cause to detrimental effects during pillar recovery. In this paper, by emphasizing ground control aspects, the most important technical parameters influencing on safety of pillar recovery are introduced and the role of them is described. Then, a new method is presented by combining all of these parameters to assess overall risk of pillar recovery operation in pre-developed room and pillar mines. The proposed method involves calculating the PR-Risk (Pillar Recovery-Risk) indicator. PR-Risk value is between 0 and 100 that based on overall risk of pillar recovery operation divides into four categories: low, medium, high, and very high. PR-Risk is an important indicator for predicting the safety of pillar recovery operation and based on it decision can be made about the safe implementation of operation. Finally, the overall risk of pillar recovery operation in main panel of Tabas Central Mine, located in the mid eastern of Iran, is assessed by use of proposed method in this paper. PR-Risk value in this panel was obtained 51 that show overall risk of operation is medium. Moreover, based on individual assessment of parameters, for the safe implementation of operation and reduction of related risks, reinforcement of roof prior to beginning of operation and partial pillar extraction have been suggested as the most efficient controlling measures.     

Misoperation monitoring and early warning during startup and shutdown of petrochemical units

Most petrochemical units run under extreme conditions, such as high temperatures, pressures, and speeds. Consequently, the equipment operators may commit errors because the startup and shutdown processes usually involve complicated operation steps; moreover, the operators may lack experience in handling abnormal situations. Misoperation can lead to accidents, including fires and explosions. Thus, risk analysis for process operations and the development of preventive measures have become an effective means of avoiding misoperation-related accidents. However, it is challenging to ensure the comprehensiveness of risk-analysis results. In this paper, we present a method for misoperation monitoring and early warning in the startup and shutdown processes of petrochemical units. The mechanisms of misoperation occurrence are summarized based on investigations of serious accidents in the recent past. Knowledge regarding the mechanisms of misoperation is crucial for the risk analysis of petrochemical units. The potential risk information, such as causes, adverse consequences, key monitoring parameters, and prevention control solutions, should be acquired and be employed to construct an early-warning knowledge database. Furthermore, misoperation judgment rules need to be formulated to identify misoperations. The data obtained from the monitoring module, misoperation judgment rules, and analysis results can aid in developing schemes to avoid possible abnormal situations. This paper reports a misoperation monitoring and early-warning system for a hydrogenation unit. As demonstrated, conducting risk analysis to determine the potential operational risks and formulating misoperation judgment rules to analyze the process data are essential for enabling early warning. The application of this method will contribute to operational guidance, economic loss reduction, and accident avoidance.     

Application of human factors evaluation in engineering design and safe operation of dense phase ethylene treaters

Ethylene treaters are widely used in the petrochemical industry to remove impurities from ethylene feedstock imported from pipeline networks or storage caverns. The safety concerns of dense phase ethylene treaters due to the reactive and highly flammable nature of ethylene are well known and studied. Under certain conditions, ethylene may self-polymerize and decompose violently with heat release. Under other conditions, ethylene will auto-refrigerate, generating cold liquids that may cause potential brittle fracture hazards. Therefore, dense phase ethylene treaters present design challenges with the unique combination of high temperature decomposition and cold temperature brittle fracture hazards.Due to these safety concerns, it is important to select the appropriate engineering design options for dense phase ethylene treaters and the associated regeneration facilities. Totally automated treater regeneration systems add complexity and instrument maintenance requirements while manually operated systems rely heavily on operator training and procedures. Unfortunately, little or no information or design guidance is available from published research findings in the literature on the evaluation and risk assessment of current industrial design options and practices for dense phase ethylene treaters.This paper presents a systematic risk assessment method to evaluate the engineering design and safe operation options for dense phase ethylene treaters. The proposed risk assessment method integrates human factors task analysis into the traditional HAZOP, LOPA and fault tree analysis to allow evaluation of automated, manual and hybrid approaches with a goal of selecting and optimizing design options to ensure plant safety. This approach provides a realistic assessment of the operational risk and allows identification of fit-for-purpose risk reduction. Applying this systematic risk assessment approach, a simpler and more cost effective design solution can be justified, thereby avoiding the need for a high integrity protective system.     

Risk assessment of a compound feed process based on HAZOP analysis and linguistic terms

The size and complexity of industrial plants, along with the characteristics of the products used, require a study, analysis and control of the existing risks in every industrial process.In this paper, a methodology for risk assessment in industrial plants, based on the combination of risks identification through the Hazard and Operability (HAZOP) analysis and the risks evaluation through linguistic variables and fuzzy numbers is applied to a case study consisting on a compound feed plant located in the town of Silla (Valencia, Spain).The results from this study show that the main risk in the compound feed production process is the formation of explosive atmospheres (ATEX). Therefore, the corrective measures will focus on reducing the concentration of dust in the atmosphere and eliminating the possible sources of ignition, such as electrostatic discharges or sparks during the different phases of the process (the grinding, the transport of the raw materials, etc.)     

基于改进JHA铜冶炼维修作业风险辨识与信息化应用

基于能量意外释放论,提出改进的JHA风险辨识方法。在按设备结构划分维修作业后,不划分作业步骤,而是根据风险来源进行辨识,实现了辨识的实用性和系统全面性。基于辨识结果,建立信息化维修作业风险信息数据库,并作为《检修项目指令书》安全措施的信息支撑。实践表明,改进的JHA辨识方法是有效的,信息化应用改变了经验式的《检修项目指令书》,提高了风险管控的有效性。     

Inherent safety concept based proactive risk reduction strategies: A review

The growing scale and complexity of process industries have brought safety, health, and environmental issues to the forefront. As a result, proactive risk reduction strategies (RRSs) are commonly employed to address these issues by reducing the frequency or mitigating the consequences of potential incidents. Among these strategies, inherent safety, which is a proactive measure of loss prevention and risk management, is considered to be the most effective method. This review aims to provide a comprehensive analysis of RRSs for achieving inherency, as well as techniques for evaluating the performance of inherent safety, health, and environmental aspects. Background information is presented, including the development and implementation of the inherently safer process design, as well as the approaches for achieving inherently healthier and environmentally friendlier processes. Subsequently, the execution approaches and practical applications of other RRSs are discussed to highlight the distinctiveness and benefits of inherent safety. Next, this study examined the characteristics of inherency assessment tools (IATs) based on available information at different process stages. Furthermore, the evaluation methods and historical development of IATs are investigated from the perspectives of safety, occupational health, and environmental considerations, followed by a statistical analysis of IATs. It is concluded that the no-chemical hazards-based IATs have not been extensively studied yet, which may improve the safety level of process plants from the perspective of comprehensive inherency risk reduction. As a way forward, future research opportunities are proposed to promote the implementation of greater optimized risk management.     

Safety compliance climate concerning risk assessment and preventive measures in EU legislation: A Finnish survey

The aim of the present study is to explore the process dynamics of the safety compliance climate and work relationships, including their antecedents and consequences. After investigating the many dimensions of safety compliance climate and of work relationships, the study concludes that a multi-component measure is needed to fully assess all of their dimensions. With respect to the impacting positively on safety compliance legislation, the present study found the following factors: “contribution measures”, “concrete preventive measures” and “risk assessment process”. For risk assessment factors on safety compliance the study identified “planning, guidelines, policy, management”, “prioritization of proactive measures”, “results in cooperation and information” and “active use of risks assessment document”. In a regression model for the workers, both risk assessment process and contribution measures had a statistically highly significant (p < 0.001) effect on concrete preventive measures. In the regression analysis of the employers risk assessment process had a statistically significant (p < 0.01) effect and contribution measures had a statistically highly significant (p < 0.001) effect on concrete preventive measures.     

An extension of the fuzzy improved risk graph and fuzzy analytical hierarchy process for determination of chemical complex safety integrity levels

The risk graph (RG) is widely used to evaluate the safety integrity level (SIL) of safety instrument systems (SIS). However, subjective opinion-based conventional RGs cannot provide successful results for the problems of risk parameters, such as shortages or lack of data; hence, the output of a conventional approach lacks sufficient reliability. We introduced the fuzzy improved risk graph (FIRG), an extension of fuzzy set theory, to deal with possible ambiguities during SIL study and increase the reliability of conventional RGs. In the present study, the levels of consequences defined as linguistic terms were converted into qualitative intervals; therefore, by correlating the proposed approach with experts’ opinions and attributing weight factors, a desired SIL value was obtained. The output of this new approach can be compared directly with quantitative risk assessment techniques to improve the safety performance of industrial systems.     

Organizational Climate Metrics as Safety,Health and Environment Performance Indicators and an Aid to Relative Risk Ranking within Industry

The chemical, pharmaceutical and other related process industries are characterized by inherently hazardous processes and activities. To ensure that considered risk management decisions are made it is essential that organizations have the ability to rank the risk profiles of their assets and operations. Current industry risk ranking techniques are biased toward the assessment of the risk potential of the asset or operation. Methodologies used to assess these risks tend to be engineering-based and include, for example, hazard identification and event rate estimation techniques. Recent research has associated lagging safety performance indicators with metrics of organizational safety climate. Despite the evidence suggesting their potential usefulness, organizational climate metrics have not yet been exploited as a proactive safety, health and environmental performance indicator or as an aid to relative risk ranking. This paper summarizes research that successfully produced a statistical model of organizational climate and its relationship to site significant injury frequency rates, allowing the relative risk ranking of sites based upon organizational climate metrics. The responses to an industrial organizational survey are examined for a pharmaceutical company's sites in the United Kingdom, Sweden and the United States. Projection to Latent Structures Analysis is performed on the survey responses. The resultant models are shown to be able to accurately model the site significant injury frequency rates. The organizational climate metrics that discriminate between the safety performance levels of different sites are identified.     

Quantitative assessment of domino scenarios by a GIS-based software tool

A software procedure was developed for the quantitative assessment of domino effect. The procedure was based on a systematic methodology for the identification of domino scenarios and for the assessment of consequences and expected frequencies of the escalation events. A geographical information system (GIS) platform was interfaced to the domino assessment software. The implementation of plant lay-out data to the GIS allowed the automatic identification of the possible targets of escalation effects by the software procedure, and a straightforward calculation of the contribution to individual and societal risk indexes caused by the possible domino scenarios. The procedure was applied to the analysis of several case-studies based on actual plant lay-outs. The results evidenced that the approach allows the quantitative assessment of risk caused by escalation events with a limited additional effort with respect to that required by a conventional QRA. The use of a GIS-based software was a key element in the limitation of the effort required for the quantitative assessment of domino scenarios. Moreover, the results of the case-studies pointed out that the estimation of risk increase due to domino events is an important tool for an effective assessment and control of industrial risk in chemical and process plants.     

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.     

Delphi法职业危害风险评估模型及案例研究

为科学合理地进行建设项目职业病危害风险分类,基于系统工程及风险评估的基本原理,采用Delphi法分析和确定了影响职业病危害风险程度的因素,通过构建风险评估指标体系,建立了职业病危害影响因子赋值法(OHFA)定量化风险评估模型。根据对作业场所的危害源、本质及附加防护设施水平、人员接触机会、职业病防治管理等因子的综合分析,预测分析了研究对象的职业病危害的风险程度,为职业病危害风险辨识、风险评估、防治管理及防护设施设计等提供参考。并以某石化行业硫磺回收项目为实例进行应用与验证,得出了该项目的总体职业病危害风险度值为12,风险等级为Ⅰ级,各职业病危害因素的风险度由高到底排序为硫化氢、一氧化碳、二氧化硫、硫磺、高温,其风险分类的关键决定因素为硫化氢。实践表明该方法与专家评估结果及工程实际吻合较好,应用于职业病危害风险评估中可给出定量化的风险分类结果。     

Modeling and application of risk assessment considering veto factors using fuzzy Petri nets

Risk assessment is important for plant safety, and fuzzy set theory is useful for such assessment because many risk factors have fuzzy characteristics. In this study, veto factors for risk assessment are taken into account. Weighted fuzzy Petri nets (WFPN) with inhibitor arcs are proposed to model relationships between risk factors and establish the risk assessment structure considering veto factors. Definitions of WFPNs as well as the enabling rule and execution rule are provided. The modeling approach for the assessment combining normal factors with veto items is discussed. The proposed fuzzy risk assessment approach is illustrated by an example of the assessment of production installations and process technology of plants that deal with hazardous chemicals. Veto factors and non-veto factors are presented and the assessment structure based on WFPNs is established. Using the factor data of a plant, an assessment value is obtained through the operation of WFPNs and the verification of the approach is discussed.     

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.     

Planning protection measures against runaway reactions using criticality classes

A systematic approach to the assessment of thermal risks linked with the performance of exothermal reactions at industrial scale was proposed a long time ago. The approach consisted of a runaway scenario starting from a cooling failure and a classification of these scenarios into criticality classes. In the mean time these tools became quite popular and many chemical companies use them. Recently, the international standard IEC 61511 required the use of protection systems with reliability depending on the risk level. Since the criticality classes were developed as a tool for the choice of risk reducing measures as a function of the criticality, it seems obvious that the criticality classes may be used in the context of the standard IEC 61511, which provides a relation between the risk level and the reliability of protection systems.Firstly, the runaway scenario and the criticality classes will be shortly described. Secondly, the assessment criteria for severity and probability of occurrence of a runaway scenario will be described together with the required data and their interpretation in terms of risk. Thirdly, the assessment procedure is exemplified for the different criticality classes. Finally, the design of protection measures against runaway and the required IPL and SIL are based on the risk assessment obtained from the criticality classes. This approach allows minimising the required data set for the safety assessment and for the definition of the protection system designed in order to avoid the development of the runaway.     

职业健康安全管理体系运行中若干问题的探讨

通过解读OHSMS标准相关术语,分析OHSMS运行中对危险源的管控机制与常规安全管理强调的事故隐患排查治理机制的关系。基于企业现有风险评价方法的缺陷建议,宜采取定性和定量相结合的评价手段,提出针对不同风险性质的危险源策划控制措施应依据的原则和思路。从运行控制、绩效监控机制等方面分析职业健康安全管理体系与企业常规安全生产管理活动的对应关系。在OHSMS运行中应强调对危险源的管控,合理策划控制措施,通过实施管理方案和引入绩效监控机制实现持续改进。     

环境空气中挥发性有机物的健康风险评价研究进展

介绍了空气中挥发性有机物的研究进展,阐述了其污染对人体健康的致癌效应和非致癌效应。在此基础上对挥发性有机物的健康风险评价做了简要评述,并介绍了现在公认的健康风险评价方法,以及近年来室内外挥发性有机物污染健康风险评价的研究现状。最后,总结了健康风险评价的不足并进行了展望,提出利用不确定性方法解决健康风险评价问题将是未来研究的重点。