Method for identifying errors in chemical process development and design base on accidents knowledge

It has been claimed that the high accident rate in the chemical process industry is due to poor dissemination of accident knowledge that affects directly the level of learning from accidents. In response to this situation, this paper utilized past accident knowledge as a basis to develop a safety oriented design tool whereby the accident information were directly disseminated into plant design. The method was developed based on our previous accident analysis of design error in which the common design errors were ranked in accordance to their frequency and its origins during normal plant design project. Based on the design error ranking and its origin at a specific design phases, a method for design error detection is proposed. The method is expected to be able to identify the possible design error and its causes throughout chemical process development and design. The main objective is to trigger safe design thinking at the specific design phases so that appropriate action for risk reduction could be timely implemented. The Bhopal and BP Texas tragedies are used as case studies to test and verify the method. The proposed method can detect up to 74% of design errors.     

Approach enhancing inherent safety application in onshore LNG plant design

This study aims to provide the approach for inherent safety design of onshore LNG plants to be applied at the very early stages (concept definition phase) of the project development. Onshore LNG plant development project starts from the “Concept Definition” phase, where financial feasibility is estimated and major conditions, such as site location and plant foot print, are set.The inherent safety design basic criteria and design measures should be identified and selected when setting the basic conditions during the Concept Definition phase of the project development, such as the site location (relative location from populated areas), site condition (prevailing wind direction) and plant production capacity (number of process train, number of product tanks). The safety measures, which are usually not fully developed at the project early stages in the current design execution practices, are the emergency systems, which mitigate an accident escalation, the modularized plant and layout, and the tank selection.The inherent safety design measures discusses in this paper were identified based on the categories of plot plan, emergency system, and module plant application.The proposed approach will contribute to improve inherent safety design of onshore LNG plants and it will also yield schedule and cost benefits.     

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.     

Design as a contributor to chemical process accidents

The paper discusses the design errors in chemical process industry (CPI) by analyzing major equipment related accident cases from Failure Knowledge Database (FKD). The aim is to recognize the contribution of design to chemical process accidents and to evaluate the time of occurrence of the errors in a plant design project. The analysis of accident cases found out that the contribution of design to accidents is very significant: 79% of accident cases analyzed were contributed by design errors. The most critical design errors were poor layout (17%), insufficient consideration of chemical reactivity and incompatibility (16%) and incorrectly chosen process conditions (16%). The design errors were initiated at basic (32%), detailed (32%) and preliminary (22%) design phases of the project. Errors in fundamental aspects of chemical processes e.g. route selections are more severe (as compared to others errors class) and might creates many similar errors in later phases of design project. Based on the accident information gathered, a straightforward point-to-look list for error detection and elimination was suggested for process lifecycle stages.     

Don't just pass the parcel: Accidents that would not have occurred if those involved had talked together

In many design organisations responsibility for a project is passed on from one group of people to another. The research chemists develop a process and then pass it on to the process design group who blame the chemists for their ignorance of what is practicable. The project is then passed to the mechanical engineering group who develop the detailed design while the electrical, instrument and other specialized groups add their contributions. The project then passes to the construction team and finally to the team who will start up and operate the plant. These different groups may be in different buildings or places and may rarely or never speak to each other.Many accidents and operating problems have arisen as a result of such “pass the parcel” organisation. Some are described. To avoid these problems representatives of all the various groups should meet regularly as the project progresses. Each group is then able to suggest changes that will make the design easier for them and can comment on features which will increase their costs. Everyone will gain some knowledge of other groups' problems.     

HAZID方法浅析

结合实际工程建设项目开展危险源辨识（HAZID）分析的情况,介绍了HAZID分析方法的广义和狭义概念内涵,主要分析步骤、每步主要工作内容、典型引导词、分析形式和特点,并将HA-ZID方法与常用的过程危险源方法、尤其是HAZOP分析方法进行了对比,以帮助读者更好地理解、运用此方法。本文拟推荐的HAZID分析方法将危险化学品行业的风险管理向前延伸到项目的早期阶段（如项目论证、可行性研究、基础工程设计或初步设计阶段）,可以帮助项目组在项目建设早期认识与项目有关的健康、安全、环境（HSE）各方面问题的重要性和相关性,所辨识出的关键危险源及其危险,为下一步有重点、有目的地开展项目HSE风险管理确定了关注重点。在早期阶段进行HAZID分析,还可以有机会以最小的代价实现对项目厂址和总图布置的调整、工艺方案和设计原则的优化,可以避免后期再发现HSE隐患、必须整改时可能存在的不可实施性,或对项目费用、进度等产生严重负面影响。     

武钢新一烧的环保设计及应用

根据武钢发展总体规划,武钢对一烧车间4台75 m2烧结机进行了易地改造,新建了1台450 m2烧结机.该改造工程淘汰老烧结机,推进设备大型化、自动化,采用先进的工艺技术和设备,从生产源头削减污染.对生产过程中产生的污染物积极治理,建立了相应的环保设施,最大限度地减少了污染物的外排及对环境的影响,实现了烧结的清洁生产.从清洁生产工艺和污染治理2个方面浅析了武钢新一烧环保设计的先进性、合理性.     

Model-based hazard identification in multiphase chemical reactors

Chemical productions operated in extreme conditions (high pressure, high temperature) require a detailed analysis of all potentially dangerous situations that can lead to a major industrial accident and thus cause a loss of life and property. Many accidents in the near or distant history underline the need of a detailed safety analysis in process industries, not only in the phase of plant design but also during the operation of the plant. It would be shown that simulation of a chemical unit using an appropriate mathematical model and the nonlinear analysis theory can be a suitable tool for safety analysis. This approach is based on mathematical modeling of a process unit where both the steady-state analysis, including the analysis of the steady states multiplicity and stability, and the dynamic simulation are used. Principal objective of this paper is to summarize problems regarding the model-based hazard identification in processes. A case study, focused on phenomena of multiple steady states in ammonia synthesis reactor will be presented. The influence of the model complexity and model parameters uncertainly on the quality of safety analysis would be underline.     

基于CW-MECN的冷却塔拆除爆破安全风险评价

为了对冷却塔拆除爆破过程进行安全风险评价,实现对各类影响因素的动态分析,融合信息熵理论、层次分析法和集对分析理论,提出了一种组合权重(CW)与多元联系数(MECN)的拆除爆破安全风险态势评价体系,从现场安全管理、拆除爆破方案设计、爆破施工过程管理和爆区作业环境4个方面,选取17个评价指标,建立了拆除爆破安全风险评价模型。以某电厂冷却塔拆除爆破工程为例,对建立的安全风险评价模型进行了应用。结果表明,该方法实现了冷却塔拆除爆破过程中的静态风险态势和动态风险趋势的综合评价,评价结果为此类拆除爆破施工提供了决策依据,有效弥补了现有评价方法的不足。     

Safety design approach for onshore modularized LNG liquefaction plant

A safety design approach for onshore modularized Liquefied Natural Gas (LNG) liquefaction plant is discussed in this paper. As onshore modularized LNG liquefaction plants have both onshore and offshore plants features, and the safety in design for the plant can only be achieved when the project environment and specific design features are properly understood, this paper identifies specific safety design features of each plant (onshore and offshore) and compares the typical “onshore” and “offshore” safety design approaches. Based on this comparison and consideration for modularization features, a safety design approach for onshore modularized LNG liquefaction plant is proposed.     

Assessing safety culture in the Spanish nuclear industry through the use of working groups

This paper presents the design and the implementation of a methodology for measuring and improving safety culture at a nuclear power plant (NPP). The study has involved the completion of a pilot project aimed at seeing how to make use of the RADAR logic (Results, Approach, Deployment, Assessment and Review) of the EFQM model as a tool for the self assessment of safety culture in a nuclear power plant. The work was aimed at finding evidence of the safety culture that was in place at the plant and at identifying both the strengths of that culture and any areas in which it could be improved. The score obtained from an analysis of those strengths and areas for improvement has made it possible to prioritise the actions to be taken. The identification of perceptions and evidence, the agreement on the strong points and areas for improvement and the quantification of the safety culture have been performed by groups comprising volunteers who work at the NPP. The advantages of this methodology are assessed in the paper.     

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.     

基于脆弱性分析的隧道施工安全管理问题研究

隧道施工安全管理不仅要关注常规体系下的技术细节,更要注重安全管理系统本身脆弱性所带来的突变。从脆弱性的角度进行隧道施工安全管理系统自身薄弱环节的辨识和分析。首先基于系统脆弱性的内涵分析了隧道施工安全管理系统的组成要素及内外部扰动源,形成了隧道施工安全管理脆弱性的分析模式。随后,基于ISM方法剖析脆弱性因素间的耦合关系,将其划分为11个层级,从而构建了脆弱性评价的层级体系。最后,以山西吕梁某隧道施工项目为例,分析安全管理资料和两起安全事故,提出了该项目安全管理系统的脆弱性因素及有针对性的改进措施。ISM及案例分析结果表明,ISM方法有效实现了脆弱性因素的层级划分,脆弱性指标直接反映安全管理系统的薄弱点。通过脆弱性分析能够发掘隧道施工安全管理系统的薄弱环节,并为系统的动态持续优化提供决策依据。     

A novel chemical product design framework with the integration of safety and health aspects

Computer-aided molecular design (CAMD) technique is a powerful tool for the design of molecules that meet a set of desirable properties. In most of the CAMD problems, the molecular physical and thermodynamic properties are often selected as the target properties, while safety and health aspects were not taken into consideration. However, certain chemical substances may cause adverse effects to human's health after prolonged and repeated exposure. Therefore, in order to ensure that the generated molecule does not bring harm and health-related risks to the consumers, it is crucial to incorporate both inherent safety and health into the existing CAMD techniques. In this work, a novel chemical product design methodology has been developed to integrate both safety and health aspects into the CAMD framework presented by a single optimisation model. The measurement of safety and health indicators are based on the molecular properties that have impact on both of these aspects. Each property is assigned with an index or penalty value based on the degree of potential hazards. A molecule with a higher index value has a higher hazard level and vice versa. Hence, a molecule that satisfies the target properties and has a low penalty value will be selected as the most reasonable choice. This new approach ensures that a product that possesses the desirable properties, and at the same time meets the safety and health criteria, is produced. A case study on the solvent design for gas sweetening process has been carried out to determine the optimal molecule.     

刚性桩复合地基的理论、实测与安全性研究

科学合理的设计理论是工程安全性和经济性的保障，现场监测是确保工程安全和质量最有效的手段。本文以提高刚性桩复合地基工程的安全性为目的，围绕关乎建筑物安全的“沉降量”等参数指标，从设计理论与试验监测两个方面开展研究。本文完善了刚性桩复合地基的设计理论，通过现场监测试验取得了第一手的数据资料，可作为今后类似工程的设计和施工参考。本研究为进一步提高刚性桩复合地基的安全性提供了理论和实践保障。     

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.     

Inherent safety tool for explosion consequences study

The lack of formal integration between process design stages with risk and consequence estimation is a hurdle to designing inherently safe process plants. Conventional risk assessment methodologies are often not carried out concurrently with process design. Therefore, process designers lack the information about risk levels and consequence that may result from the process conditions being considered in a particular process route until the design is completed. Hence, effects of changes in process conditions on risk levels and consequence cannot be studied in a time effective manner during the design stages. Few studies have been identified on the possibility and viability of integrating risk estimation with process design. But viable framework and methodology for doing so has not yet been reported. This paper presents a feasible framework in which risk and consequences estimation can be part of design stages. A demonstrative tool named as integrated risk estimation tool (iRET) was developed by using process simulation software, HYSYS and spreadsheet, MS Excel as the platforms. iRET estimates risk due to explosions by using TNT equivalence method and the TNO correlation method. iRET has a potential to be extended to include all forms of risk such as fire, explosion, toxic gas releases and boiling liquid expanding vapour explosion (BLEVE). The paper also presents case studies to demonstrate the functionality and viability of using iRET in conjunction with process design. The results of these case studies have successfully shown that the risk due to explosion can be assessed during the initial design stage ensuring a safer plant. The framework and iRET there by presented here provide systematic methodology and technology to design inherently safer plants.     

Assessing the hazards from a BLEVE and minimizing its impacts using the inherent safety concept

Many worlds' major process industry accidents are due to BLEVE such as at Feyzin, France, 1966 and San Juan Ixhuatepec, Mexico City, 1984. One of the approaches to eliminate or minimize such accidents is by the implementation of inherently safer design concept. This concept is best implemented where the consequence of BLEVE can be evaluated at the preliminary design stage, and necessary design improvements can be done as early as possible. Thus, the accident could be avoided or minimized to as low as reasonably practicable (ALARP) without resorting to a costly protective system. However, the inherent safety concept is not easy to implement at the preliminary design stage due to lack of systematic technique for practical application. To overcome these hurdles, this paper presents a new approach to assess process plant for the potential BLEVE at the preliminary design stage and to allow modifications using inherent safety principles in order to avoid or minimize major accidents. A model known as Inherent Fire Consequence Estimation Tool (IFCET) is developed in MS Excel spreadsheet to evaluate BLEVE impacts based on overpressure, radiation heat flux and missile effects. In this study, BLEVE impacts are the criteria used as the decision-making for the acceptability of the design. IFCET is integrated with iCON process design simulator for ease of data transfer and quick assessment of potential BLEVE during the design simulation stage. A case study was conducted to assess of potential BLEVE from a propane storage vessel at the design simulation stage using this new approach. The finding shows promising results that this approach has a potential to be developed as a practical tool.     

Inherent risk assessment methodology in preliminary design stage: A case study for toxic release

At preliminary design stage, process designers normally lack of information on the risk level from process plant. An inherently safer process plant could be designed if the information of risk levels could be known earlier at the preliminary design stage. If the risk level could be determined, there is a possibility to eliminate or reduce the risk by applying the well-known concept: inherent safety principle. This paper presents a technique to determine the risk levels at preliminary process design stage using a 2-region risk matrix concept. A model to calculate the severity and likelihood of a toxic release accident was developed in Microsoft Excel spreadsheet. This model is integrated with process design simulator, iCON to allow for data transfer during preliminary design stage. 2-region risk matrix is proposed and used to evaluate the acceptability of the inherent risk based on the severity and likelihood rating. If the inherent risk level is unacceptable, modification for improvement can be done using the inherent safety principles. A case study has been carried out to illustrate the benefit of applying this newly developed technique. It was successfully shown that an inherently safer plant could easily be designed by applying this technique.     

Assessment of the effect of technical and management characteristics on the frequency of release from piping: An application to a gas storage facility

The assessment of the frequencies of release from piping due to losses of containment is an essential step in the preparing Safety Reports, drawn up as required by the so-called “Seveso” Directive. These are usually calculated starting from the frequencies of random rupture included in international databases and are not plant-specific, furthermore, the quantification of the effect of the safety management system of the facility is not easy. A simple and flexible approach quantifying technical and management characteristics of the plant has been proposed by Milazzo and co-workers in 2010; it is based on the modification of the frequency taken from literature, through the use of the percentages of failure causes actually possible in that plant, and the judgment about their management. The data about the failure causes are taken from the literature and modified by using corrective factors to adapt them to the industrial context. To make possible the application of the method to a large number of major-hazard industry types, some aspects of the approach needed to be improved; these have been identified during a development project coordinated by RINA Consulting, on behalf of Saipem, with the collaboration of the University of Messina. The improvement of the approach focused on two main points, the development of a method to calculate the corrective factors for the failure causes associated with corrosion and erosion phenomena and the strengthening of the methodology for the formulation of the judgment about the safety management. This paper illustrates the fully improved method, as well as an application to a typical gas storage plant.