Safety analysis and risk assessment of a Micro-GtL Plant

Laboratory hydrogen generators, medical oxygen, and micro-breweries are examples of modular and micro technologies that are commercial successes. Researchers, patients, and unskilled workers operate these facilities but more complex processes require highly qualified personnel to ensure they operate safely. Modular-micro processes in isolated locations meet economic objectives when operated remotely thereby minimizing labor costs. Mitigating the risk requires a comprehensive hazards analysis with advanced control systems particularly for explosive and toxic compounds. Here, we propose a method called Failure Mode Risk Decision (FMRD) to review the inherent hazards of a micro-refinery unit (MRU) that converts flared and wasted natural gas to long chain hydrocarbons. This approach combines the Process Flow Failure Mode (PFFM) methodology as a systematic and reliable technique with a novel numerical risk assessment to improve the analytical evaluation of hazardous conditions. The objective is to combine causes and consequences in a single metric, where scaled probability of evident causes and severity of consequences are used to derive a risk level measure. With the proposed metric, the magnitude of a potential hazard is directly correlated with the risk level. This mechanism identifies extra risk scenarios compared to the classical hazard analysis method and provides a straightforward comprehensive numerical assessment to represent the inherent and residual risks to facilitate justifying the hazardous scenarios. Accordingly, we design a safety loop and supply all the required facilities to remove the potential risks at the process plant. Not only the proposed methodology clarifies the risks of the MRU presented in this study, but can be extended to review the hazards of other chemical process plants.     

Risk assessment tools incorporating human error probabilities in the Japanese small-sized establishment

Although it has been estimated that as many as 80% of all occupational accidents have human errors as a cause, no risk assessment tools incorporating human-related elements have been developed for small companies. Human error probability (HEP) and human error analysis (HEA) have been used for large-scale, safety-critical industries for last three decades, but these tools are not suitable for smaller, more general industries that comprise the majority of accident settings.Here, we describe and verify a risk assessment tool that includes human-related elements for small companies. The tool expands on traditional risk assessment methods, such as matrix, risk graph and numerical scoring method, by adding human-related elements. The tool is easy-to-use in occupational environments, and includes assessments of human behavior and potentially outdated machinery at work place.     

Safety is the antonym of risk for some perspectives of risk

Safety and safe are terms closely related to risk, but do they extend beyond the realm of risk? Is safety/safe just the antonym of risk, or the same as acceptable risk? This issue has been given due attention in the literature and in this paper we explore how different perspectives of risk affect the relationship between safety/safe and risk. If risk is defined as an expected value or as a measure of the probability and severity of adverse effects, the conclusions would be different than if the essential component of risk is uncertainty. For risk understood as uncertainty about and severity of the consequences of an activity we argue that safe means acceptable risk. Three dimensions of safety are discussed; events and consequences (harm), probability and uncertainty.     

Integrating lean principles and fuzzy bow-tie analysis for risk assessment in chemical industry

In this research, a framework combining lean manufacturing principles and fuzzy bow-tie analyses is used to assess process risks in chemical industry. Lean manufacturing tools and techniques are widely used for eliminating wastes in manufacturing environments. The five principles of lean (identify value, map the value stream, create flow, establish pull, and seek perfection) are utilized in the risk assessment process. Lean tools such as Fishbone Diagram, and Failure Mode and Effect Analysis (FMEA) are used for risk analysis and mitigation. Lean principles and tools are combined with bow-tie analysis for effective risk assessment process. The uncertainty inherent with the risks is handled using fuzzy logic principles. A case study from a chemical process industry is provided. Main risks and risk factors are identified and analyzed by the risk management team. Fuzzy estimates are obtained for the risk factors and bow-tie analysis is used to calculate the aggregated risk probability and impact. The risks are prioritized using risk priority matrix and mitigation strategies are selected based on FMEA. Results showed that the proposed framework can effectively improve the risk management process in the chemical industry.     

A structural approach to the HAZOP – Hazard and operability technique in the biopharmaceutical industry

Recently, the use of analytical techniques to identify, assess and address risks within the pharmaceutical industry is increasing from the initial and operating phases until the final use of products aiming to eliminate or reduce the severity of deviations. The hazard and operability studies – HAZOP establish that accidents are the result of failure modes in process variables out of operational parameters. In this paper, the HAZOP methodology was used to assess risks in the system for recombinant protein production where a multidisciplinary group used the brainstorming strategy to identify the risk level and deviations in nodes defined by functionality in the system. Nineteen critical nodes were identified, deviations were established in based on knowledge, and experience by the group, thus precluded the need of deviation's records to estimate frequency and impacts of events. It was also shown that in the pharmaceutical industry the most-critical risks are those that have adverse impacts on production like partial and total losses and when noncompliance of regulations are involved. The HAZOP risk assessment tool can be easily followed by people who are interested in starting to use this technique to improve the security environment within the institution and when required by regulatory agencies.     

基于模糊贝叶斯网络的煤气化职业健康风险分析

针对煤气化行业职业健康风险影响因素不确定及模糊的特点,建立了职业健康风险计算模型。该模型将模糊数学与贝叶斯网络相耦合,模拟事件概率,找出导致风险的主要因素。通过分析煤气化行业中存在的多种风险因素,应用问卷调查法和模糊集理论模拟了根节点的发生概率,得出职业健康风险概率的预测值;应用贝叶斯网络反向推理的功能计算根节点后验概率并排序,确定了薄弱环节。该模型不仅能解决概率缺失情况下的风险量化推算问题,定量进行职业健康风险评估,还可以实现关键因素的识别,并能有针对性地提出改进措施,为职业健康风险预防提供决策依据。     

Does your facility have a dust problem: Methods for evaluating dust explosion hazards

The hazards of dust explosions prevailing in plants are dependent on a large variety of factors that include process parameters, such as pressure, temperature and flow characteristics, as well as equipment properties, such as geometry layout, the presence of moving elements, dust explosion characteristics and mitigating measures. A good dust explosion risk assessment is a thorough method involving the identification of all hazards, their probability of occurrence and the severity of potential consequences. The consequences of dust explosions are described as consequences for personnel and equipment, taking into account consequences of both primary and secondary events.While certain standards cover all the basic elements of explosion prevention and protection, systematic risk assessments and area classifications are obligatory in Europe, as required by EU ATEX and Seveso II directives. In the United States, NFPA 654 requires that the design of the fire and explosion safety provisions shall be based on a process hazard analysis of the facility, process, and the associated fire or explosion hazards. In this paper, we will demonstrate how applying such techniques as SCRAM (short-cut risk analysis method) can help identify potentially hazardous conditions and provide valuable assistance in reducing high-risk areas. The likelihood of a dust explosion is based on the ignition probability and the probability of flammable dust clouds arising. While all possible ignition sources are reviewed, the most important ones include open flames, mechanical sparks, hot surfaces, electric equipment, smoldering combustion (self-ignition) and electrostatic sparks and discharges. The probability of dust clouds arising is closely related to both process and dust dispersion properties.Factors determining the consequences of dust explosions include how frequently personnel are present, the equipment strength, implemented consequence-reducing measures and housekeeping, as risk assessment techniques demonstrate the importance of good housekeeping especially due to the enormous consequences of secondary dust explosions (despite their relatively low probability). The ignitibility and explosibility of the potential dust clouds also play a crucial role in determining the overall risk.Classes describe both the likelihood of dust explosions and their consequences, ranging from low probabilities and limited local damage, to high probability of occurrence and catastrophic damage. Acceptance criteria are determined based on the likelihood and consequence of the events. The risk assessment techniques also allow for choosing adequate risk reducing measures: both preventive and protective. Techniques for mitigating identified explosions risks include the following: bursting disks and quenching tubes, explosion suppression systems, explosion isolating systems, inerting techniques and temperature control. Advanced CFD tools (DESC) can be used to not only assess dust explosion hazards, but also provide valuable insight into protective measures, including suppression and venting.     

RAPID-N: Rapid natech risk assessment and mapping framework

Natech accidents at industrial plants are an emerging risk with possibly serious consequences. For the mitigation of natech risk, authorities need to identify natech prone areas in a systematic manner. In order to facilitate probabilistic natech risk mapping, a unified methodology was developed that is based on the estimation of on-site natural hazard parameters, determination of damage probabilities of plant units, and assessment of probability and severity of possibly triggered natech events. The methodology was implemented as an on-line, extensible risk assessment and mapping software framework called RAPID-N, which allows rapid local and regional natech risk assessment and mapping with minimal data input. RAPID-N features an innovative data estimation framework to complete missing input data, such as on-site natural hazard parameters and plant unit characteristics. The framework is also used for damage assessment and natech consequence analysis, and allows easy modification of input parameters, dynamic generation of consequence models according to data availability, and extension of models by adding new equations or substituting existing ones with alternatives. Results are presented as summary reports and interactive risk maps, which can be used for land-use and emergency planning purposes by using scenario hazards, or for rapid natech consequence assessment following actual disasters. As proof of concept, the framework provides a custom implementation of the U.S. EPA's RMP Guidance for Offsite Consequence Analysis methodology to perform natech consequence analysis and includes comprehensive data for earthquakes. It is readily extendible to other natural hazards and more comprehensive risk assessment methods.     

Shelter-in-place risk assessment for high-pressure natural gas wells with hydrogen sulphide and its application in emergency management

This paper provides a risk assessment method of sheltering in-place for high-pressure natural gas wells with hydrogen sulphide. In this paper, the shelter-in-place risk is estimated by integrating the health consequences of an individual taking one kind of emergency response to the emergency orders of sheltering in place from the emergency decision makers and the probability of the corresponding emergency response action. The probability of the corresponding emergency response action in the proposed method is estimated through the accident probability analysis and the probability analysis of taking a certain response action. The health consequence estimation is based on air exchange rate test of the shelter buildings as well as accident consequence calculation. The evaluation of shelter-in-place risks based on “as low as reasonably practicable (ALARP)” guidelines was employed to provide suggestions for emergency management under both normal conditions and off normal conditions. A case study of risk assessment of sheltering in the local residential houses in Xuanhan County of Sichuan Province, China was taken as an example to illustrate the proposed risk assessment process of shelter-in-place and its application in the decision-making process for emergency management.     

化工过程中毒事故风险的模糊综合评估

影响化工过程中毒事故风险性的不确定因素较多,其风险具有相对性且大部分因素具有模糊性的特点。为此,笔者建立了化工过程多级多指标中毒事故风险评估指标体系,根据模糊优选理论,提出了中毒事故风险的模糊综合评估模型,运用模糊层次分析法确定各指标权重,结合有关统计数据及工厂实际,对化工过程潜在的中毒事故风险性进行模糊综合评估,所获结果为化工过程中毒事故的综合防治提供了理论依据     

A new simple methodology for evaluation of explosion risk in underground coal mines

The key objective of this paper is the presentation of a new risk assessment tool for underground coal mines based on a simplified semi-quantitative estimation and assessment method.In order to determine the risk of explosion of any work process or activity in underground coal mines it is necessary to assess the risk. The proposed method is based on a Risk Index obtained as a product of three factors: frequency of each individual scenario P_ucm, associated severity consequences C_ucm and exposure time to explosive atmospheres E_ucm. The influence of exposure time is usually not taken into account up to now. Moreover, the exposure to explosive atmospheres may affect factors of hazardous event probability as much as its consequences. There are many definitions of exposure to explosive atmospheres but in the case of underground coal mines the exposure is defined as frequency risk of firedamp and coal dust. The risk estimation and risk assessment are based on the developed of a risk matrix.The proposed methodology allows not only the estimation of the explosion risk but also gives an approach to decide if the proposal investment is well-justified or not in order to improve safety.     

Nanotechnologies,engineered nanomaterials and occupational health and safety – A review

The significance of engineered nanomaterials (ENM) and nanotechnologies grows rapidly. Nanotechnology applications may have a positive marked impact on many aspects of on human every day life, for example by providing means for the production of clean energy and pure drinking water. Hundreds of consumer nano-based products are already on the market. However, very little is known of the risks of ENM to occupational safety and health (OSH), even though workers are likely to be at extra risk, as compared with other potentially exposed groups of people, because the levels of exposure are usually higher at workplaces than in other environments. However, knowledge of the exposure to, or effects of, ENM on human health and safety in occupational environments is limited and does not allow reliable assessment of risks of ENM on workers’ health. Several issues related to ENM in the workplaces require marked attention. The most topical issues include: (1) improved understanding of ENM metrics associated with ENM toxicity; (2) development of monitoring devices for ENM exposure assessment; (3) understanding the changes of ENM structure and state of agglomeration at different concentrations in aerosols; (4) understanding translocation of ENM in the human body; (5) identifying the key health effects of ENM including pulmonary toxicity, genotoxicity, carcinogenic effects, and effects on circulation; (6) development of tiered approaches for testing of safety of ENM; and (7) utilizing these data for health risk assessment, with a special emphasis on occupational environment. Available data on several ENM – ability to enter the body and reach almost any organ, to cause pulmonary inflammation and fibrosis, and even to cause increased risk of mesotheliomas in animal models, call for immediate action. It is crucial to identify those ENM that may cause occupational health and safety risks from those ENM which are innocent, hence allowing prioritization of regulatory and preventive actions at workplaces at national, regional and global levels.     

运用危险源控制方法改进职业健康安全管理的有效性

危险源辨识和风险评价是GB/T28001职业健康安全管理的基本方法,通过危险源辨识找出与职业健康安全有关的管理点（危险源）,评价出职业健康安全管理需要管理的重点（中度和高度风险）,制定适宜的方法,即制定目标指标方案、运行控制或应急预案加以控制和改善,体现职业健康安全管理的基本原则和思路。只有正确运用危险源辨识和风险评价的方法,才能做到合理策划危险源的控制方法,集中力量抓主要矛盾解决主要问题,兼顾次要矛盾和一般问题的管理;根据不同危险源的具体情况选择适宜合理的方法,既保证危险源的有效控制,又保证采用的任何危险源控制方法和措施与危险源产生后果的严重性和伴随的风险相适应,尽量避免危险源控制的盲目性和不经济,达到追求最佳职业健康安全绩效的目的,提高整体和系统管理的有效性。     

运用风险管理理念,提高灭火救援水平

根据消防部队灭火救援工作中的职业危险 ,引入了风险管理理念。笔者运用安全系统工程的理论和方法 ,建立了灭火救援工作的风险管理方法以及风险识别、风险评价的方法和步骤 ,并针对当前的情况 ,提出风险控制的具体措施。该方法简单 ,易于操作。在安全管理工作中应用风险管理方法 ,根据现有资料和知识经验 ,针对部门的具体情况 ,找出灭火救援工作中存在的风险 ,并对各种风险及其危险程度进行评价 ,在此基础上 ,采取相应的控制措施。分析和研究表明 ,运用风险管理有利于控制或减少消防人员在灭火救援中存在的风险 ,防范事故发生 ,提高灭火救援的水平。     

天然气管道工程风险对策研究

风险管理对策包括风险规避、风险控制与消减、风险自留和风险转移四个方面,风险管理的目标即是通过科学的风险管理策略使风险降到可以接受的水平。企业对风险的容忍程度除与风险控制的期望成本相关外,还与企业的风险偏好,以及政治、经济等外部环境因素相关。管道建设工程面临的风险因素复杂,可以从人的因素、物的因素、环境的因素和管理的因素四个方面进行识别和归类。各风险事件发生的町能性以及后果严重性各不相同,在管道建设工程风险管理中过程中要综合采用各种风险对策,使每一风险因素降低到企业所能够承受的水平,甚至可以采用改线绕过特定风险地域或保险转移的策略,使项日业主不再承担特定的风险责任。     

矿井风险评价基本模型研究与探讨

提出风险的绝对值和相对值的概念,探讨了如何合成事故发生可能性和事故后果严重程度这两个指标,如何确定多个评价单元的评价对象的风险等级划分等问题。     

Safety evaluation of leak in a storage tank using fault tree analysis and risk matrix analysis

The work presented in this paper used a quantitative analysis of relevant risks through the development of fault tree analysis and risk analysis methods to aid real time risk prediction and safety evaluation of leak in a storage tank. Criticality of risk elements and their attributes can be used with real time data to predict potential failures likely to occur. As an example, a risk matrix was used to rank risk of events that could lead to a leak in a storage tank and to make decisions on risks to be allowed based on past statistical data. An intelligent system that recognizes increasing level(s) and draws awareness to the possibility of additional increase before unsafe levels are attained was used to analyse and make critical decisions. After a visual depiction of relationships between hazards and controls had been actualized, dynamic risk modelling was used to quantify the effect controls can potentially have on hazards by applying historical and real-time data into a probabilistic model. The output of a dynamic risk model is near real-time quantitative predictions of risk likelihood. Results from the risk matrix analysis method mixed with RTD and FTA were analyzed, evaluated, and compared.     

机械系统的风险概率与经济性安全评价方法研究与应用

针对机械事故频发,为预防和控制事故,依据安全评价发展方向,结合安全系统工程、模糊可靠性理论、人因可靠性技术和安全经济学,从人-机-环3方面分析风险评价因素,建立符合客观实际的风险评价模型,提出包括人为因素、机械设备和环境在内的基本事件失效概率估算方法;以安全经济学的角度将事故严重度量化为风险经济损失,根据每个风险因素的风险概率和风险经济损失来选择风险评价项目,通过检查评价项目状况,最终得出系统风险度,从而形成关于机械系统的定量风险概率与经济性安全评价方法。并给出起重机大车运行机构的工程示例,验证该方法的正确性和可行性。     

区域职业病危害风险综合评价及管理初探

区域职业病危害风险是一个地区特定时期内职业病与职业病危害事故发生的可能性与严重程度的综合反映,科学、客观地评价一个区域总体的职业病危害风险状况,对于科学制定有关政策、确定重点监管区域并合理分配职业病危害控制资源等都具有重要意义。在分析区域职业病危害风险影响有关因素并建立量化评定方法的基础上,研究遴选提出了用于区域职业病危害风险综合评价的指标,构建了区域综合职业病危害风险评价模型,确立了区域职业病危害风险分级标准,并给出了区域职业病危害风险管理的初步建议。     

Improving PHA/LOPA by consistent consequence severity estimation

Most risk analysis methods rely on a qualitative judgment of consequence severity, regardless of the analysis rigor applied to the estimation of hazardous event frequency. Since the risk analysis is dependent on the estimated frequency and consequence severity of the hazardous event, the error associated with the consequence severity estimate directly impacts the estimated risk and ultimately the risk reduction requirements. Overstatement of the consequence severity creates excessive risk reduction requirements. Understatement results in inadequate risk reduction.Consistency in the consequence severity estimate can be substantially improved by implementing consequence estimation tools that assist PHA/LOPA team members in understanding the flammability, explosivity, or toxicity of process chemical releases. This paper provides justification for developing semi-quantitative look-up tables to support the team assessment of consequence severity. Just as the frequency and risk reduction tables have greatly improved consistency in the estimate of the hazardous event frequency, consequence severity tables can significantly increase confidence in the severity estimate.