Lessons learned from recent incidents: Facility siting, atmospheric venting, and operator information systems

Recent incidents have focused attention on a number of technical and management systems that need to be addressed by industry. A multiple layer of protection approach is essential for the prevention of incidents and/or reduction of consequences. Safety culture and operational discipline are the overall embracing factors that influence the safety performance of a facility. However, as recent events have indicated, there are a number of technical and engineering issues that must also be developed and implemented appropriately. Some of these issues that could lead to incidents with catastrophic consequences include facility siting and atmospheric relief venting. Impact of operator information systems on the prevention of releases of hazardous materials from their containment is also another significant factor that should be given appropriate attention.

This paper describes these three topics based on the findings from recent incidents and historical data. Engineering standards, regulatory requirements, and industry practices are discussed for facility siting, atmospheric relief venting, and operator information systems. Finally, a summary of gaps and needs in technology, standards, and practices is presented.     

Integrating human factors and systems engineering to reduce the risk of operator “error”

Introducing safety devices does not always reduce the frequency of accidents. Operators adjust their response to technological improvements. Protection mechanisms may be used to support “unsafe” working practices so that the net risk of failure remains unchanged or may even rise. Regulatory bodies have reacted against this risk compensation. Rules and procedures have been imposed upon the day-to-day operation of protection equipment. Unfortunately, these constraints often fail to preserve the safety of an application. Inattention, fatigue, poor training and willful neglect can lead to rules and guidelines being ignored. In this paper alternative means of reducing threats posed by risk compensation are explored. In particular, it is argued that designers must exploit an integrated approach to the development of high-risk applications. By this we mean that both human factors and systems engineering must be recruited to support the development of protection equipment.     

Some unusual case histories from personal experience

Is protection of equipment the only consideration when setting the relieving pressures of safety relief valves? I will show you a case where other factors should have been considered and suggest that you might give your safety valve set pressures a second thought.Do you have side-by-side pieces of identical equipment? If so, you must consider that operating or maintenance personnel may become confused, and the results maybe catastrophic. A PVC reactor incident will demonstrate this point.Does your process contain materials that could decompose? After thirty years of safe operation in butadiene units, there was a vinyl acetylene decomposition. Could it happen to you?It is my hope that these three unique and unusual cases will provide valuable information for operations and maintenance personnel, managers, safety professionals, and engineers.     

Fire and explosion assessment on oil and gas floating production storage offloading (FPSO): An effective screening and comparison tool

Fires and explosions have been identified as major potential hazards for Oil and Gas Floating Production Storage Offloading (FPSO) installations and pose risk to personnel, assets, and the environment. Current fire and explosion assessment (FEA) tools require physical effect modeling software and follows standards from API, ISO, and engineering practices. However, the tools are not specific to any particular system such as an FPSO, and do not provide comprehensive guidance for safety engineers to perform FEA.This paper discusses the development of a screening and comparison tool for FEA on FPSOs and the incorporation of an expert system into the tool. The results are computerized using MS Excel/VBA to provide a structured and comprehensive assessment on each equipment and module handling natural gas, crude oil, methanol and diesel on FPSO topsides.This tool features built-in calculations for jet and pool fire size estimation for gas/liquid releases, and the ability to perform Quantitative Risk Analysis (QRA) to specify the personnel and equipment risk for varying leak sizes and process conditions. Control and recovery measures are incorporated as an expert system based on report findings, engineering practices, and relevant standards. Bowtie analysis is applied in the tool to define detailed control and recovery measures for the FPSO based on the incident scenarios. An explosion assessment is performed by incorporating physical effect modeling software results.Unique features provided in the tool include fire and radiation contour mapping on an FPSO layout to help determine personnel and equipment risk more accurately and fire pump sizing that can be used to verify the amount of water deluge system required to mitigate fires and explosions. In addition, flexibility of data input (process data, failure rate data, etc.) and user interfaces assist safety engineers to screen and compare process alternatives, check design quality, and evaluate design options at any design stage.     

Fire protection as the underpinning of good process safety programs

This paper will provide an overview of the role of fire protection engineers in the mitigation phase of a process safety program. Fire protection engineers are involved in the assessment of hazards and the selection of fire protection strategies which can reduce the risk to an acceptable level according to the stipulated goals and objectives. Fire protection strategies may include the installation of a variety of approaches, such as passive and active fire protection systems, manual intervention and siting. Passive systems include fire rated barriers and protection of openings in those barriers, while active systems include systems such as fire detectors and sprinklers. Manual intervention may include the manual activation of fixed fire protection systems or firefighting activities by facility fire brigades or municipal fire departments. The manual firefighting activities are typically considered to be in the ‘response’ phase.     

突发公共事件与个体防护装备

作者论述了个体防护装备的作用、种类和发展 ;从军事斗争、劳动防护和社会公众防护等方面论述了个体防护装备的重要性 ,指出突发公共事件正在呼唤个体防护装备 ;对我国个体防护装备的发展和应用提出了意见和建议     

突发公共事件与个体防护装备

本文论述了个体防护装备的作用、种类和发展;从军事斗争、劳动防护和社会公众防护等方面论述了个体防护装备的重要性,指出突发公共事件正在呼唤个体防护装备;对我国个体防护装备的发展和应用提出了意见和建议。     

Whole-body vibration and postural stress among operators of construction equipment: a literature review

INTRODUCTION: Operators of construction equipment perform various duties at work that expose them to a variety of risk factors that may lead to health problems. A few of the health hazards among operators of construction equipment are: (a) whole-body vibration, (b) awkward postural requirements (including static sitting), (c) dust, (d) noise, (e) temperature extremes, and (f) shift work. It has been suggested that operating engineers (OEs) are exposed to two important risk factors for the development of musculoskeletal disorders: whole-body vibration and non-neutral body postures. METHOD: This review evaluates selected papers that have studied exposure to whole-body vibration and awkward posture among operators of mobile equipment. There have been only few studies that have specifically examined exposure of these risk factors among operators of construction equipment. Thus other studies from related industry and equipment were reviewed as applicable. CONCLUSION: In order to better understand whole-body vibration and postural stress among OEs, it is recommended that future studies are needed in evaluating these risk factors among OEs.     

Using ergonomics in engineering design to improve health and safety

This paper outlines the importance of ergonomics in engineering design. It describes some of the cost benefits and principles underlying the application of ergonomics. The practical impact of the latter has become increasingly important in the light of European directives which are likely to have a substantial impact on the way engineers design. Three ergonomics case studies are described, the first two illustrate ways of identifying costs of poor ergonomics and the cost benefits of redesign using ergonomics principles. The third illustrates work which led to engineers redesigning assembly line workstations and ergonomics becoming an important part of manufacturing design. The background to this was concern about an increase in cases of Upper Limb Disorders (ULDs) and recognition that ergonomic advice was needed to find the source of problems and help in finding design options. Ergonomists were brought in and helped in identifying problems with workstations and tools. Final designs were developed by the company's own engineers based on the ergonomic study and reduced incidence of ULDs has been reported. Photographs showing examples before and after redesign can be found in the Health and Safety Executive's notes of guidance published in 1990, and some issues surrounding the nature of the detailed design solutions are discussed here. The impact of the ergonomics contribution resulted in engineers being trained in ergonomics so that it could be implemented on a routine basis throughout the site.     

Mechanical Equipment Injuries in Small Manufacturing Businesses. Knowledge,Behavioral, and Management Issues

This paper presents findings from an extensive study intofactors that impact upon the high rate of injuries due to mechanical equipment, especially in small manufacturing firms. Issues relating to knowledge of health and safety issues and to management practices have been shown to be extremely important with regards to safety in smaii businesses. Knowledge and awareness of hazards were found to be relatively low and few respondents, especially managers, had received adequate safety training. Managers did not regard the identification and control of risks as a priority. Workplaces generally lacked effective safety management procedures such as safety rules and regulations, procedures for recording and learning from accidents, and clearly defined responsibilities for safety. Some issues requiring further investigation, and some recommendations for improving safety in small businesses, are presented.     

Compression system check-valve failure hazards

Processes that utilize multistage compression systems (olefins plant compression systems, gas processing, integrated refrigeration systems, etc.) have the potential for overpressure due to single or multiple check-valve failure. Catastrophic equipment failure resulting from overpressure can potentially occur due to compression system discharge, interstage, and/or suction check-valve failure, coincident with compressor shutdown. Depending on system design and application, overpressure values approaching or exceeding 300% of equipment design are possible, while for some equipment, even limited overpressure can result in catastrophic vessel failure due to brittle fracture. Additional hazards associated with compression system fail-to-check scenarios include risks associated with excessive flare loading and compressor rotor reverse rotation. In the case of an ethylene refrigeration compressor at a typical ethylene plant, rotor reverse rotation can potentially exceed overspeed limits.This paper provides risk assessment results based on analyses performed on the three primary compression systems in six ethylene plants. The methodologies used for risk identification screening, detailed risk assessment and evaluation of system dynamics are all presented. Alternative methods for mitigating risks are also discussed, along with check-valve reliability data. An overview of applicable overpressure protection requirements defined in the ASME Boiler and Pressure Vessel Code is provided. This paper will be of interest to anyone who designs or operates multistage compression systems in the chemical, petrochemical or refining industries.     

Organisational learning and continuous improvement of health and safety in certified manufacturers

Certified management systems have increasingly been applied by firms in recent decades and now cover the management of health and safety, principally through the OHSAS 18001 standard. In order to become certified, firms must not only observe the relevant legislation, but also improve performance and raise goals within health and safety on a continuous basis. The article examines how certified occupational and health management systems influence this process to evaluate how far they hinder or support learning. It presents a model with which it is possible to identify and analyse improvement processes. The model is applied to five cases from a qualitative study of Danish manufacturers with certified health and safety management systems. The cases illustrate the wide variation in health and safety management among certified firms.Certification is found to support lower levels of continuous improvement performance in handling health and safety issues. However, more advanced improvement practices are shown to be connected to the integration of health and safety in other managerial areas, as well as to the employment of similar advanced improvement processes within firms. The article argues that certified health and safety management does not obstruct learning, and can support advanced learning. Improvement practices with regard to health and safety are mainly dependent upon the firm’s overall organisational processes and do not automatically arise from the standard alone.     

The role of design issues in work-related fatal injury in Australia

PROBLEM: This study aimed to provide an assessment of the contribution of design to the occurrence of fatal work-related injuries in Australia. METHODS: The Australian National Coroners' Information System was the data source for fatal injuries. Deaths resulting from workplace injuries on or between 1 July 2000 and 30 June 2002 were included. RESULTS: Seventy seven (37%) of the 210 identified workplace fatalities definitely or probably had design-related issues involved. In another 29 (14%), the circumstances were suggestive that design issues were involved. The most common scenarios involved problems with rollover protective structures and/or associated seat belts; inadequate guarding; lack of residual current devices; inadequate fall protection; failed hydraulic lifting systems in vehicles and mobile equipment; and inadequate protection mechanisms on mobile plant and vehicles. SUMMARY: Design is a significant contributor to work-related fatal injury in Australia. There is considerable scope for preventing serious work-related injury through improving design of plant, equipment, and vehicles used for work-related purposes.     

Utilizing Integrity Operating Windows (IOWs) for enhanced plant reliability & safety

Several industry codes, standards and recommended practices have been developed and utilized to maintain pressure equipment integrity and improve reliability. These industry standards focus heavily on inspections (time or risk based) and guidelines for operating equipment at conditions that enable a tolerable deterioration rate. RBI (risk based inspection), in effect, utilizes process conditions at a snapshot in time to recommend inspection strategies which can cover the span of the equipment's remaining life. On a day to day level, changes that occur in process conditions (excursions and upsets) are not fed back into the risk and criticality calculation. When such changes to operating conditions affect key process variables, new damage mechanisms could be introduced that affect the remaining life of an asset or accelerate existing damage mechanisms. The increase in risk resulting from these process changes goes unaccounted for until the effect of the deterioration is captured at the next inspection.Integrity Operating Windows (IOWs) are established limits for key process variables that can affect the integrity of the equipment if the process operation deviates from the established limits. The development of these IOWs requires fundamental understanding of the process and resulting damage mechanisms and is best facilitated by a team of corrosion and process engineers along with feedback from plant operators. A well-established IOW program is designed to provide real time notification of an increased risk to the integrity of an asset so that identified actions can be taken by the operators and/or plant managers proactively in a timely manner. Combining an RBI program with an IOW program can greatly increase its effectiveness and provide early recognition of equipment risks due to process changes. This paper will focus on the development of an IOW program and the benefits of combining it with a viable RBI program.     

高速公路机电系统过电压保护与防雷接地设计

高速公路机电系统的特点是既有强电设备,又有大量的监控、通讯、收费等弱电设备,这些都是容易受到雷击或雷电感应的薄弱点.通过理论分析并结合工程实际,给出了高速公路机电系统过电压保护和防雷接地的体系和实现,分析了雷电对机电系统的危害途径,提出了雷电的接闪分流接地、等电位屏蔽布线以及过电压保护等设计内容,阐述了应从各个方面完善...     

生物质液化燃油的工业适用性及安全性探讨

简要介绍了中国石油安全面临的问题及其对国家经济可持续发展的可能影响;一般生物燃油的用途、物理性能指标、主要元素含量及其与石化轻油、重油同类指标的对比;论述了生物燃油的工业适用性、安全性和环保性;探讨了生物燃油的生产成本、市场销售预测、生产设备造价、产业化开发的经济收益以及农林剩余物资源潜力和产业化开发可能创造的就业机会等问题。     

安全带整体静负荷试验机的研制及应用

安全带是有效地预防高处作业人员因意外坠落而受到身体伤害的必要防护装备。本文根据GB6095—2009《安全带》、GB／T6096—2009《安全带测试方法》标准中安全带整体静态负荷试验的要求,对安全带整体静负荷试验机的研制与应用开展一些调研和探讨,希望对从事安全带检验的机构和安全带生产的企业中的科研、检验人员提供一些感性的认知和帮助。     

Comparing the work values of engineers with managers,production, and clerical workers: A multivariate analysis

Engineers and scientists have been compared in previous research on their work attitudes. Conceivably the interest in comparing these two groups of professionals was a result of the joint work they often do in research and development departments. The present framework suggests that engineers who work in production departments would have work values and attitudes which would be more similar to those of managers. Survey data was collected from 432 employees in two industrial corporations in Israel. Profile analysis showed that the work values of engineers were similar to those of managers and different from those of production and clerical workers. Furthermore, work values were also related to behavioral outcomes such as performance and tardiness. Implications regarding the study of engineering as a profession and the use of work values in organizational research are discussed.     

浅谈脱硫系统的防火设计

火灾报警及消防系统是人身、设备安全的重要保证.针对脱硫系统的具体实际,对火灾报警及消防系统设计进行了探讨,并给出一定的设计参考意见.     

A shell-based magnetic field model for magnetic proximity detection systems

Several magnetic proximity detection systems have been developed for mining vehicles and mobile machinery to protect nearby workers. Magnetic field generators are often used in these systems to establish magnetic fields around the equipment. A sensor worn by a worker provides a measurement of the magnetic flux density that is used to estimate the proximity to the machine. The proximity detection systems currently available for underground mining equipment are capable of identifying whether a worker is near the machine. However, it is a challenge for these systems to accurately locate the worker. Mining machines, which have fast-moving, articulated parts, present hazards that change depending on the situation at hand as well as the specific location of the worker. In addition, the dynamic nature and confined spaces of the mining environment often demand that the workers be close to the machinery. Therefore, in many cases, simply knowing the proximity of a worker may be inadequate. To provide the most effective protection, it would be advantageous to know the worker’s exact location relative to specific parts of the machine. To lay the foundation for measuring such a location, we have developed a shell-based model of the magnetic flux density distribution for a ferrite-cored generator. This paper will present an analysis of the model along with a model construction process. Also presented are the laboratory test results of a prototype system that implements this model to determine the exact location of a magnetic sensor using the fields from two generators.