Analysis of laboratory incident database

With the growth of academic institutions, the number of labs handling hazardous chemicals has increased. Although the chemicals used in academic institutions are well-known, the dosage, usage, and management of these chemicals pose significant threat to researchers at all levels. As a step towards incident prevention, a laboratory incident database was developed to record incidents at universities and secondary schools. The data consisted of 128 entries occurring during the years 2012–2015. Incidents were classified by institution type, hazard type, consequences, substance type, body parts injured and direct causes. Of 128 incidents, 65% of the incidents were taking place in universities. Chemical spills were observed to be the most recurrent hazard type contributing to 45% of the incidents following by explosions (23%) and fires (21%). The consequence which most frequently occurred in incidents was personal injury and hazmat response contributing to 22% each. It was observed that in 41% of the incidents, the body parts injured in the incident was not known or reported. Of the total 128 incidents, about 50 incidents occurred due to improper storage and handling.     

Severity of emergency natural gas distribution pipeline incidents: Application of an integrated spatio-temporal approach fused with text mining

The transportation of natural gas often relies on pipelines which require constant monitoring and regular maintenance to prevent spills or leaks. Pipeline incidents could pose a huge adverse impact on people, the environment, and society. Numerous efforts have been invested to identify contributing factors to pipeline incidents so that countermeasures could be developed to proactively prevent some incidents and reduce incident severities or impacts. However, the countermeasures may need to vary for different incidents due to the potential heterogeneity between incidents, and such heterogeneity is likely related to the geology, weather, and built environment which vary across space and time domain. The objective of this study is to revisit the correlates of pipeline incidents, focusing on the spatial and temporal patterns of the correlations between natural gas pipeline incident severity and contributing factors. This study leveraged an integrated spatio-temporal modeling approach, namely the Geographically and Temporally Weighted Ordered Logistic Regression (GTWOLR) to model the natural gas pipeline incident report data (2010–2019) from the U.S. Pipeline and Hazardous Material Safety Administration. Text mining was performed to extract additional information from the narratives in reports. Results show several factors have significant spatiotemporally varying correlations with the pipeline incident severity, and these factors include excavation damage, gas explosion, iron pipes, longer incident response time, and longer pipe lifetime. Findings from this study are valuable for pipeline operators, end-users, responders to jointly develop localized strategies to maintain the natural gas distribution system. More implications are discussed in the paper.     

Risk management of cost consequences in natural gas transmission and distribution infrastructures

A critical aspect of risk management in energy systems is minimizing pipeline incidents that can potentially affect life, property and economic well-being. Risk measures and scenarios are developed in this paper in order to better understand how consequences of pipeline failures are linked to causes and other incident characteristics. An important risk measure for decision-makers in this field is the association between incident cause and cost consequences. Data from the Office of Pipeline Safety (OPS) on natural gas transmission and distribution pipeline incidents are used to analyze the association between various characteristics of the incidents and product loss cost and property damage cost. The data for natural gas transmission incidents are for the period 2002 through May 2009 and include 959 incidents. In the case of natural gas distribution incidents the data include 823 incidents that took place during the period 2004 through May 2009. A two-step approach is used in the statistical analyses to model the consequences and the costs associated with pipeline incidents. In the first step the probability that there is a nonzero consequence associated with an incident is estimated as a function of the characteristics of the incident. In the second step the magnitudes of the consequence measures, given that there is a nonzero outcome, are evaluated as a function of the characteristics of the incidents. It is found that the important characteristics of an incident for risk management can be quite different depending on whether the incident involves a transmission or distribution pipeline, and the type of cost consequence being modeled. The application of this methodology could allow decision-makers in the energy industry to construct scenarios to gain a better understanding of how cost consequence measures vary depending on factors such as incident cause and incident type.     

What can the trove of CSB incident investigations teach us? A detailed analysis of information characteristics among chemical process incidents investigated by the CSB

Understanding the commonalities among previous chemical process incidents can help mitigate recurring incidents in the chemical process industry and will be useful background knowledge for designers intending to foster inherent safety. The U.S. Chemical Safety and Hazard Investigation Board (CSB) reports provide detailed and vital incident information that can be used to identify possible commonalities. This study aims to develop a systematic approach for extracting data from the CSB reports with the objective of establishing these commonalities. Data were extracted based on three categories: attributed incident causes, scenarios, and consequences. Seventeen causal factors were classified as chemical indicators or process indicators. Twelve chemical indicators are associated with the hazards of the chemicals involved in the incidents, whereas five process indicators account for the hazards presented by process conditions at the time of the incident. Seven scenario factors represent incident sequences, equipment types, operating modes, process units, domino effects, detonation likelihood for explosion incidents, and population densities. Finally, three consequence factors were selected based on types of chemical incidents, casualties, population densities, and economic losses. Data from 87 CSB reports covering 94 incidents were extracted and analyzed according to the proposed approach. Based on these findings, the study proposes guidelines for future collection of information to provide valuable resources for prediction and risk reduction of future incidents.     

Major hazard pipelines: a comparative study of onshore transmission accidents

Failures of pipelines conveying dangerous substances can pose major risks. Identification of pipeline hazards associated with the different pipeline system functions is essential for risk analysis and historical data are of great importance. Incident data are analysed, following a review of official sources, by failure mechanism, size and function of the systems in two types of transmission networks around the world, i.e. natural gas and hazardous liquids. The development of the networks and the reporting criteria used by the official sources for the collection of incidents in the last twenty five years have shown remarkable differences. The performance of both gas and liquid transmission lines in Europe, the US and the former Soviet Union in terms of failures has shown a progressive improvement but the extent of consequences following gas releases and oil spillages have not shown any change in the last fifteen years. External interference is not always the predominant cause of failures in all systems depending also on pipe size. Failures with casualties in gas transmission have not shown any decrease over the last decade and there is a clear indication that many are connected with the parts and functions other than the main body of the pipeline. A comparison between European and US gas frequency data, derived under common constraints, shows that valuable information can be lost when criteria for incidents collection are only limited to the body of the pipeline.     

Worker-fatigue contributing to workplace incidents in New Zealand Forestry

ProblemReports of incidents in dangerous work environments can be analysed to identify common hazards, in turn aiding in the prevention of future accidents. Whilst studies exist that do this, most focus on causes that involve physical risks. In this paper we propose an alternative approach, and illustrate causes of forestry incidents from the perspective of worker-failure and fatigue. Method This paper outlines the analysis of eight years’ worth of New Zealand forestry incident data, with a focus on the cause of, and time that, incidents occur. Results This has resulted in two main findings. First, 70% of incidents can be attributed, at least in part, to worker-failures. Second, 78% of worker-failure based causes show indications of fatigue. This indicates that a significant number of forestry incidents are caused by worker-fatigue. Finally, this dataset showed inconsistencies in data quality, similar to those that exist in other datasets. This did not affect our analysis. However, these types of errors have the potential to affect the data quality in the national reporting system. Impact on industry The results from this study will be used in a larger project on detecting fatigue in forestry workers for injury and incident prevention. It is also our hope that other researchers may find these results of interest for further fatigue prevention research in hazardous industries.     

Harnessing database resources for understanding the profile of chemical process industry incidents

Analyzing historical databases can provide valuable information on the incident occurrences and their consequences for assessing the safety of the chemical process industry. In this study, the RMP and HSEES databases were utilized to understand the patterns and the factors influencing chemical process industry incidents. Frequency exceedance curves were generated by utilizing the different incident consequences from the databases to understand the profile of societal loss from reported incidents. Understanding the statistics and trends of the historical incidents could serve as important lagging indicators in order to assess the probable proximity to major consequences from the low-probability/high-consequence incidents. To this regard, the safety pyramids were also generated to better understand the relationship between the different consequences of the reported incidents. Furthermore, the safety pyramids were analyzed in comparison with the traditional safety pyramid proposed by Heinrich to understand the US process industry incident occurrence trends.     

石油钻井工业事故统计分析

石油钻井工业每年发生大量的事故,造成人员伤亡,环境污染和经济损失。本文通过对中东某采油区13年间3008起各类事故进行统计分析,找出不同因素影响下钻井事故发生的分布规律,为安全管理提供依据。统计结果表明,在炎热的季节,事故发生较为集中,在气候宜人的季节,事故相对较少;斋月所在的月份,事故数量明显增多,与斋月相邻的两个月事故数量明显减少;各类事故按其严重程度呈现金字塔形分布;手脚受伤在LTI中占据相当高的比例;HSE管理质量和承包商的变更对事故的分布有显著的影响。     

Quantitative assessment of environmental risk due to accidental spills from onshore pipelines

The transport of hazardous materials by pipeline is widely used for the transfer of significant quantities of oil and chemicals. Due to the extremely low frequency of spills, pipelines are considered the safest mode for the land transportation of hazardous substances. Accident records, while confirming that Loss of Containment (LOC) events are rare, also point out the major-accident hazard of pipelines, due to the extremely severe potential consequences of spills. Quantitative Risk Analysis (QRA) techniques have been applied to pipelines since many years with the aim of evaluating risk for workers or exposed population. However, releases of liquids, as oil and oil products, also create an hazard to the environment, due to the potential of extensive soil and groundwater contamination. An integrated model was developed for the environmental Risk Analysis of spills from pipelines. Specific environmental risk indexes were defined, expressing the risk of soil and groundwater contamination, both in physical and economic terms. A case-study is presented and discussed to illustrate the features of the methodology. The results confirmed that the proposed model may be considered an important tool within a comprehensive approach to the management of risk related to onshore pipelines.     

A new approach for facility siting using mapping risks on a plant grid area and optimization

The present work is focused on developing a methodology to find the optimal placement of a hazardous process unit and other facilities using optimization theory while considering a risk map in the plant area. Incidents can have possible consequences resulting from flammable gas releases, which can be evaluated by using consequence modeling programs. The probability of each incident can be derived from initial leak hole size estimation through event tree analysis. In this methodology the plant area was divided into square grids and risk scores were estimated for each grid. The overall cost is a function of the probable cost of property damage due to fires or explosions and the interconnection cost including piping, cable, and management. The proposed approach uses a mixed integer linear optimization programming (MILP) that identifies attractive locations by minimizing the overall cost. A case study is presented for a hexane–heptane separation facility that considers the meteorological data for the given area in order to show the applicability of the proposed methodology. Results from this study will be useful in assisting the selection of locations for facilities and for risk management.     

Global process safety incidents in the pharmaceutical industry

The objective of this research is to analyse global process safety incidents within the pharmaceutical industry in terms of their consequences and factors contributing to the incidents. There were 73 process safety incidents leading to 108 fatalities found between 1985 and 2019. Trends between the number of incidents, number of fatalities, location, and contributing factors were identified and summarized. The most reported fatalities occurred in 2018 & 2019. 83% of fatalities occurred in China and India. Explosions were associated with 71% of incidents, which resulted in 89% of fatalities. For most of the international incidents, incident investigations were not available and thus insufficient details were available to determine the causes. Contributing factors were available or estimated from available data for about half of the incidents, with the following most common: hazard awareness & identification; operating procedures; design; safeguards, controls & layers of protection; safety culture; and preventive maintenance. These findings can be used as a basis to improve process safety performance in the pharmaceutical industry.     

Fire incident at a refinery in West Malaysia: the causes and lessons learned

Refineries are major hazard installations (MHI) which possess large quantities of hazardous substances. Refineries are characterized by high complexity and tight-coupled organization. Due to the high complexity and level of interaction among subsystems, designers and operators are unable to predict failures at the refinery units. The world has seen many incidents in refineries through leakage, fire and explosions. The consequences of the accidents sometimes extend beyond the boundary of the property and reach the neighboring residents. This paper reviews refinery incidents worldwide and also outlines the causes of a fire incident at a refinery in West Malaysia and the lessons learned.     

A review of quantitative risk assessment of onshore pipelines

This paper reviews and analyses frequency and consequences of failure of onshore pipelines transporting oil, refined products and natural gas. Generally accepted risk levels are indicated and a desirable risk range is proposed.Pipeline failure statistics from the United States (US), Canada, Europe and Brazil are compared. Failure rates for internal and external corrosion, human action and natural forces are analyzed and the expected failure rate for each failure mechanism is indicated. The effects of relevant construction and environmental factors on the failure frequency are studied and mean trends are obtained. Furthermore, the sizes of the holes indicated at different databases are compared and a typical distribution of failure sizes is proposed for each mode of failure. Finally, the frequency of ignition after a loss of containment is studied for gas and liquid pipelines.Historical data on consequences of the accidental loss of containment of onshore pipelines is reviewed. Property damage and environmental reparation costs are evaluated directly from pipeline failure data. Straightforward regression models are proposed to quantify these types of consequence taking into account the released fluid and the characteristics of the environment. Societal impact is evaluated by combining simple fire models, heat versus mortality correlations and population density.Finally, values for the desired risk level are evaluated by three methods: i) a risk value representing the good engineering practice; ii) the risk associated to the most relevant codes and regulations concerning pipeline risk assessment and/or construction and operation; iii) an analytically derived optimal risk level. The risk values obtained by the three methodologies are similar and a desirable risk range is proposed.     

Blast phenomena in urban tunnel systems

Traffic infrastructure in urbanised areas is increasingly projected in tunnels underground or covered over, these days. A consequence is that in case of an incident with hazardous materials the safety level for fellow road users in tunnels is considerably less than it is in surface infrastructure. To reduce the consequences of incidents for fellow tunnel users, urban tunnels are sometimes interrupted by open spaces of limited length. Open spaces allow, for instance, the release of smoke in case of a fire. In this way, possible lethal effects are limited to the tunnel section in which the incident occurred. To what extent an open space may also be effective in the mitigation of blast effects from an explosion in a tunnel system is subject of this paper.

To this end, the blast effects originating from the rupture of a 50 m³ LPG pressure vessel in an urban tunnel system have been computed by numerical simulation. The results show that an open space in a tunnel system has a significant mitigating effect on the blast effects indeed. However, as a consequence of the ingress of a high-velocity jet flow that follows on a primary blast wave, a second blast wave develops in the tunnel section following on an open space. The strength of this second blast wave is not very dependent on the length of the open space. It shows that an open space in a tunnel system may not always limit the lethal effects of explosion incidents in tunnels to the tube in which the incident occurred. The second blast wave in the tunnel section following on an open space may have lethal consequences for fellow tunnel users by car window failure.     

A framework for learning from incidents in the workplace

Learning from Incidents (LFI) in the workplace has been gaining increasing importance in the Health, Safety and Environment context. Although organisations adopt a variety of LFI initiatives, it is often unclear what learning approaches are the most appropriate and the most effective for different types of incidents across a range of contexts. The aim of the paper is to surface factors that are important for effective Learning from Incidents (LFI). The paper builds on a conceptual framework for learning from incidents, developed through an earlier study. This conceptual framework was validated through empirical data collected at two multinational corporations in the energy sector. From this data a refined framework for learning from incidents was devised with five factors important for LFI: participants of learning, type of incidents, learning process, type of knowledge and learning context. This framework can be used as an evaluation tool and as a guidance tool to develop holistic, organisational learning approaches.     

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.     

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.     

Large scale experiments to study fires following the rupture of high pressure pipelines conveying natural gas and natural gas/hydrogen mixtures

As part of the EC funded Naturalhy project, two large scale experiments were conducted to study the hazard presented by the rupture of high pressure transmission pipelines conveying natural gas or a natural gas/hydrogen mixture containing approximately 22% hydrogen by volume. The experiments involved complete rupture of a 150 mm diameter pipeline pressurised to nominally 70 bar. The released gas was ignited and formed a fireball which rose upwards and then burned out. It was followed by a jet fire which continued to increase in length, reaching a maximum of about 100 m before steadily declining as the pipeline depressurised. During the experiments, the flame length and the incident radiation field produced around the fire were measured. Measurements of the overpressure due to pipeline rupture and gas ignition were also recorded. The results showed that the addition of the hydrogen to the natural gas made little difference to radiative characteristics of the fires. However, the fraction of heat radiated by these pipeline fires was significantly higher than that observed for above ground high pressure jet fires (also conducted as part of the Naturalhy project) which achieved flame lengths up to 50 m. Due to the lower density, the natural gas/hydrogen mixture depressurised more quickly and also had a slightly reduced power. Hence, the pipeline conveying the natural gas/hydrogen mixture resulted in a slightly lower hazard in terms of thermal dose compared to the natural gas pipeline, when operating at the same pressure.     

天然气管道完整性管理探析

通过对国内外天然气管道事故的统计和分析,指出了对天然气管道进行完整性管理的重要性;在此基础上,简要介绍了管道完整性管理方法,着重探讨了天然气管道完整性管理的流程和环节,包括管道潜在危害辨识、管道数据信息搜集与分析、管道风险评价、管道完整性评价、完整性评价响应和减缓措施,并进一步说明了天然气管道完整性管理的实施方法;最后,给出了在我国开展天然气管道完整性管理的必要性和建议.