A comparative analysis of process safety management (PSM) systems in the process industry

The root cause of most accidents in the process industry has been attributed to process safety issues ranging from poor safety culture, lack of communication, asset integrity issues, lack of management leadership and human factors. These accidents could have been prevented with adequate implementation of a robust process safety management (PSM) system. Therefore, the aim of this research is to develop a comparative framework which could aid in selecting an appropriate and suitable PSM system for specific industry sectors within the process industry. A total of 21 PSM systems are selected for this study and their theoretical frameworks, industry of application and deficiencies are explored. Next, a comparative framework is developed using eleven key factors that are applicable to the process industry such as framework and room for continuous improvement, design specification, industry adaptability and applicability, human factors, scope of application, usability in complex systems, safety culture, primary or secondary mode of application, regulatory enforcement, competency level, as well as inductive or deductive approach. After conducting the comparative analysis using these factors, the Integrated Process Safety Management System (IPSMS) model seems to be the most robust PSM system as it addressed almost every key area regarding process safety. However, inferences drawn from study findings suggest that there is still no one-size-fits-all PSM system for all sectors of the process industry.     

Determining a realistic ranking of the most dangerous process equipment of the ammonia production process: A practical approach

OCI Nitrogen seeks to gain knowledge of (leading) indicators regarding the process safety performance of their ammonia production process. The current research determines the most dangerous process equipment by calculating their effects resulting from a loss of containment using DNV GL's Phast™ dispersion model. In this paper, flammable and toxic effects from a release from the main equipment of an ammonia plant have been calculated. Such an encompassing approach, which can be carried out for an entire plant, is innovative and has never been conducted before. By using this model, it has been demonstrated that the effects arising from an event of failure are the largest in process equipment containing pressurized synthesis gas and ‘warm’ liquid ammonia, meaning the ammonia buffer tanks, ammonia product pumps, and the ammonia separator. Most importantly, this document substantiates that it is possible to rank the most hazardous process equipment of the ammonia production process based on an adverse impact on humans using the calculated effect distance as a starting point for a chance of death of at least 95%. The results from the effect calculations can be used for risk mapping of an entire chemical plant or be employed and applied in a layer of protection analysis (LOPA) to establish risk mitigation measures.     

A role and expectancy model of participative decision-making: A replication and theoretical extension

Schuler's process model of employee participation in decision-making and job satisfaction (Schuler, 1980; Lee and Schuler, 1982) was tested using a path analytic approach. Reanalysis of Schuler's data and replication on a new sample indicated that (a) participation in decision-making has both direct and indirect effects on job satisfaction; and (b) performance–outcome expectancy, role conflict, and role ambiguity all appear to mediate the relationship between participation and satisfaction. In an extension of the model, organizational level and job involvement were hypothesized to moderate the participation–satisfaction relationship (i.e. function interactively). Although neither variable functions as a moderator, job involvement operates in a fashion similar to participation in the model. In general, consistent results across four independent samples strongly support Schuler's basic process model.     

Evaluation of design alternatives for sewing scissors with respect to hand performance,discomfort and usability

The effects of three re-designed models of sewing scissors on hand performance measures, discomfort and usability were investigated, and the results were compared with those of conventional scissors. Adjustments were made to the scissors handle with emphasis on more neutral wrist postures (bent handle - model A), correction of the thumb's position and movements (model B) and reducing hand/finger discomfort (model C) while working with the tool. The results showed some improvements in hand performance, muscular effort, usability and discomfort with model B compared to the conventional model. Better hand performance and usability and lower discomfort were recorded with model C compared to the conventional model. The results suggest that the correction of the thumb's position and movement (model B) or even reduced hand/finger discomfort (model C) are perhaps more important considerations in scissors design than improved wrist posture (model A) for improving users' performance and usability of the tool.     

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.     

A mathematical model for predicting thermal hazard data

A systematic procedure and mathematical model for predicting thermal behavior is proposed. This model has been verified by experimental data. The results show that the model will predict thermal hazard behavior precisely. A procedure for predicting thermal hazard data is also developed. Some examples of predicting real behavior are simulated.     

基于基准系统比较法的雷达间隔评估

为缓解我国目前飞行流量日渐增加、空域紧张等情况,提出了一种系统评估航空器雷达间隔的新方法。首先,介绍了雷达间隔研究所使用的基准系统比较法,给出了分析方法和评估流程;其次,在综合考虑影响飞行安全各种因素的基础上,利用近距离危险接近概率(CAP)模型和基准系统比较法,建立了航空器间的雷达间隔评估模型,可对航空器飞行安全进行量化分析评估;最后,利用统计学知识和实测数据对该方法进行对比验证。结果表明:1)不同精度的雷达与雷达安全间隔密切相关,直接影响空中交通流量和航空器的运行效率;2)对于普通二次雷达,N-N模型更能反映雷达角度误差的分布情况;3)当雷达间隔为5 n mile时,危险进近概率为1.382 1×10-11,用精度更低(雷达角度误差为0.138 13)的雷达替换时,为保证航空器飞行安全,雷达间隔应增大到5.3 n mile;4)使用高精度雷达进行管制指挥和监控,可提高飞行流量,缓解航班延误,提升管制效率。     

Numerical study of choked two-phase flow of hydrocarbons fluids through orifices

Valves and orifices are the most widely devices of flow control used in oil and gas industry. In particular, they are installed in relief piping system in order to control the discharge flow during potential plant overpressuring scenarios, thus ensuring plant safety. It is a common practice to flow liquid and gas mixtures through such restriction devices.Rigorous models are available to precisely size pressure relief devices operating in single phase flow; however for two-phase flow, no models are considered sufficiently reliable for predicting the relevant flow conditions.In the present paper, two-phase flow of hydrocarbons fluids through an orifice under critical conditions has been numerically investigated.The existing literature has been analyzed and data on two-phase flow of highly volatile mixtures of hydrocarbons through openings have been collected. A comparison has been carried out with numerical simulations carried out by the multiphase flow simulation tool OLGA by SPT.The Henry–Fauske model has been used as orifice choke model and the orifice discharge flow coefficient, required as input by OLGA, has been calculated by Chisholm's model.Comparison between OLGA's results and experimental data shows that Henry–Fauske model markedly underestimates the mass flow rate through the orifice, if Chisholm's model is used to calculate discharge coefficient. It was found that the error of the model could be minimized using different values of orifice discharge coefficient (C_d).A new discharge flow coefficient model, suitable for choked two-phase flow across orifices, is proposed in this study and it has been determined to match the above mentioned experimental measurements.     

自适应神经网络在确定落煤残存瓦斯量中的应用

落煤残存瓦斯量的确定是采掘工作面瓦斯涌出量预测的重要环节，它直接影响着采掘工作面瓦斯涌出量预测的精度，并与煤的变质程度、落煤粒度，原始瓦斯含量、暴露时间等影响因素呈非线性关系，人工神经网络具有表示任意非线性关系和学习的能力，是解决复杂非线性，不确定性和时变性问题的新思想和新方法，基于此，作提出自适应神经网络的落煤残丰瓦斯量预测模型，并结合不同矿井落煤残存瓦斯量的实际测定结果进行验证研究，结果表明，自适应调整权值的变步长BP神经网络模型预测精度高，收敛速度快，该预测模型的应用可为采掘工作面瓦斯涌出量的动态预测提供可靠的基础数据，为采掘工作面落煤残存瓦斯量的确定提出了一种全新的方法和思路。     

化学絮凝法处理温室龟鳖养殖废水工艺参数优化

选择聚合氯化铝(PAC)、聚合硫酸铁(PFS)、聚合氯化铁(PFC)为絮凝剂,对比研究3种絮凝剂去除温室龟鳖养殖(greenhouse turtle aquaculture)废水悬浮物效果。结果表明,絮凝剂PAC的絮凝效果最佳。选择PAC为絮凝剂,阳离子聚丙烯酰胺(PAM)为助凝剂,通过响应面法以浊度去除率为响应值,PAC和PAM的投加量和搅拌时间为影响因素,对工艺关键参数进行优化,最终确定最佳工艺参数。根据响应面分析结果,确定龟鳖养殖废水的最佳絮凝条件为PAC质量浓度85.3 mg/L、PAM质量浓度19.8 mg/L、搅拌时间2 min。在此条件下浊度去除率为97.1%,为温室龟鳖养殖废水的优化絮凝处理提供了参考依据。     

The role of hindrance stressors in the job demand–control–support model of occupational stress: A proposed theory revision

Previous research on the job demand–control–support (JDCS) model of occupational stress has generally been inconsistent at best regarding a key issue: the interaction of demands, control, and support in predicting employee health and well‐being. However, the model continues to be tested in a variety of studies and academic journals owing to its intuitive appeal. By incorporating conservation of resources theory with knowledge from the challenge–hindrance stressor framework, we proposed that hindrance stressors, not the challenge stressors commonly assessed when testing JDCS theory, will provide validation for the model. A two‐wave panel study of 228 employees in a variety of occupations provided support for three‐way interactions between hindrance demands, control, and support predicting job‐related anxiety and physical symptoms. Three‐way interactions using a challenge demand (forms of workload) were not significant, consistent with our propositions. In summary, this study supports the buffering effect of control and support on the relationship between job demands and strain only when job demands reflect hindrance stressors, thereby proposing to alter the JDCS model by specifying that it applies primarily to hindrance stressors in a job hindrance–control–support model. Copyright © 2015 John Wiley & Sons, Ltd.     

A mathematical model for predicting the flash point of binary solutions

A mathematical model which may be used for predicting the flash point of binary solutions has been proposed and subsequently verified by experimentally-derived data, such data pertaining to an almost-ideal solution as also to highly non-ideal solutions. The results reveal that the model is able to precisely predict the flash point over the entire composition range of binary solutions for both ideal solutions and non-ideal solutions by way of utilizing the flash point of the individual components. The highly non-ideal solution like octane+ethanol exhibits the minimum flash-point behavior, which leads to the minimum on the flash point vs composition curve.     

A posteriori hazard analysis and feedback information of an accidental event in the grains storage of an agrochemical product

The present study concerns a hazardous event which occurred in an industrial storage tank of a ground insecticide. A preliminary post-accident approach of the hazard evaluation is performed. The rapid report of the presence of an unstable functional group in the active product and of its potential thermal instability (CHETAH indices) has led to complete this examination by an experimental study of thermal analysis using isotherm exposition measurement (DTA) or with temperature programming by differential scanning calorimetry (DSC) and oxidability tests (BAM). The apparent kinetics of decomposition of the active matter of the ground insecticide has been represented by a global Arrhenius law.

A model designed for the simulation of heterogeneous thermal runaways based on the numerical solution of the transient mass and energy balances has been further applied to define the critical conditions of the storage and simulate its behavior.

The results obtained during this analysis with the experienced feedback allowed us on one side to explain the hazardous event and especially on the other side to modify the operating protocol of the conditions of formulation of the active matter on the inert mineral support.     

A Multilevel Approach to Manual Lifting in Manufacturing Industries

Musculoskeletal injuries are often the consequences of wrong postural configurations used during Manual Materials Handling (MMH). This eventually leads to a large payout of worker’s compensation and loss of production time. A simulated study of back injury risks has been carried out on seven selected manufacturing industries to identify and evaluate harmful working postures. For each MMH task, Ovako Working Posture Analyzing System (OWAS) codes have been identified with the help of motion study pictures. Also, Chaffin's biomechanical model was used to calculate L5/S1 load compression values on the spine during MMH activities. The multilevel approach adopted was a combination of OWAS and Chaffin’s biomechanical model. The application of a digitizer enabled us to identify the coordinates and it made a subsequent evaluation of the angles of each body link possible.     

Near-miss management systems: A methodological comparison

A close relationship between near-miss events and major accidents has been demonstrated in major hazard facilities: a near-miss and an accident have often common causes. A near-miss could be defined as a hazardous condition where the event sequence could lead to an accident if it had not been interrupted. An effective Near-miss Management System (NMS) aims to quickly recognize signals from the operational fields in order to apply prevention strategies. As a standard reference model has not yet been developed, the NMS design represents a complex issue. The present paper proposes a critical comparison between two methodologies which could be applied for a near-miss event assessment: a matrix and an index based method. The purpose is to evaluate potentiality and pitfalls of their application as their global efficiency could influence the whole performance of the whole NMS design. An application in a test case of a chemical plant is proposed: results obtained have proved useful in supporting safety management in an effective design of a NMS.     

混合液体火灾爆炸危险性——闪点预测与实验研究

支持向量机应用核函数技术,已经成为当前国际上一个研究的热点,由于支持向量机具有良好的理论基础和泛化性能,可将其引入到混合液体闪点预测的研究之中,以期建立准确、高效的预测模型。本文建立了一个基于支持向量机的理论模型,用于预测二元互溶混合液体的闪点。根据所研究混合液体的物理性质,选择了纯物质的粘度、表面张力、配比、燃烧下限等物理参数来表征闪点,以这些参数作为输入参数,二元混合液体的闪点作为输出值,应用支持向量机方法对两者之间的内在定量关系进行模拟。结果表明,闪点预测值与实验值符合良好。本方法的提出为工程上提出了一种预测二元互溶液体闪点的有效方法,可应用于评估混合溶液的火灾爆炸危害性及本质较安全设计。     

Method to assess and optimise dependability of complex macro-systems: Application to a railway signalling system

Achieving a high degree of dependability in complex macro-systems is challenging. Because of the large number of components and numerous independent teams involved, an overview of the global system performance is usually lacking to support both design and operation adequately.A functional failure mode, effects and criticality analysis (FMECA) approach is proposed to address the dependability optimisation of large and complex systems. The basic inductive model FMECA has been enriched to include considerations such as operational procedures, alarm systems, environmental and human factors, as well as operation in degraded mode. Its implementation on a commercial software tool allows an active linking between the functional layers of the system and facilitates data processing and retrieval, which enables to contribute actively to the system optimisation.The proposed methodology has been applied to optimise dependability in a railway signalling system. Signalling systems are typical example of large complex systems made of multiple hierarchical layers. The proposed approach appears appropriate to assess the global risk- and availability-level of the system as well as to identify its vulnerabilities. This enriched-FMECA approach enables to overcome some of the limitations and pitfalls previously reported with classical FMECA approaches.     

A preliminary ergonomic assessment of piloting a lifeboat in ice

This paper examines human factors associated with piloting a totally enclosed motor propelled survival craft (TEMPSC or lifeboat) in ice. The first section of the paper describes the use of a usability assessment scale to evaluate the coxswain’s (TEMPSC captain) control panel. The second portion examines environmental conditions (habitability) inside the lifeboat during evacuation. All testing was completed in conditions that were consistent with those that might be experienced by ship or offshore oil and gas crewmembers in the event of abandonment due to an onboard emergency. Results indicated that the lifeboat test configuration presented considerable challenges to usability/functionality as well as habitability. These findings suggest that further research should be conducted to evaluate the safety of all existing lifeboat designs. Finally, it is recommended that the international maritime organization (IMO) and safety of life at sea (SOLAS) Convention should mandate user-centered design evaluations for future lifeboat manufacturing.