Using a system theory based method (STAMP) for hazard analysis in process industry

Different hazard analysis techniques are used in the chemical process industry. Most of these techniques were developed long time ago. There is an argument that significant changes have occurred in the process industry but these techniques have not been modified accordingly. Therefore, there may be limitations in identifying hazards related to the modern process industry in complex sociotechnical environment using these techniques. Recently new hazard analysis techniques based on systems theory have been introduced. STPA (System-Theoretic Process Analysis) is one of these systemic techniques. It has been used in some fields with promising results but with limited application in the process industry. This paper applies STPA to a process plant as an industrial case study. Recommendations generated by STPA are compared with the HAZOP study of the process plant which is a traditional technique. Conclusions are presented on the application of systemic techniques to the process industry as a complementary study to analyze the safety of the system as a whole and also to capture interactions between component of the system. Further studies are required to study STPA in more details and evaluate if it can be used as an alternative to HAZOP.     

基于系统理论事故模型与过程的危险性分析方法

传统危险性分析方法将事故视为开始事件诱发的一连串事件所造成的不幸后果,适于处理相对简单或由物理组件构成的系统,但无法胜 任较为复杂的社会技术系统,有必要研究和探索推广性更好、更为有效的系统安全分析手段。系统理论事故模型与过程（STAMP）将安全视为系 统组件间交互的一种涌现特性,并认为事故起因除了组件失效,组件间交互失常而违背安全约束也是重要诱因。主张在系统开发、设计和运行 中通过加强控制和强化有关安全约束来预防事故。基于此,先引入了STAMP的基本概念,并介绍了其分析步骤,然后,以贴近真实的导弹拦截系 统危险性分析案例,阐述了基于STAMP的分析过程。该分析方法可为开发较高安全性水平的社会技术系统提供技术支持。     

On the need for system-theoretic hazard analysis in the process industries

Most process hazard analysis (PHA) studies today are conducted using traditional methods such as the hazard and operability study (HAZOP). Traditional methods are based on a chain-of-events model of accident causality. Current models of accident causality are based on systems theory and provide a more complete representation of the causal factors involved in accidents. Consequently, it is logical to expect that PHA methods should reflect these models, that is, system-theoretic hazard analysis (STHA) should be used. Indeed, system-theoretic process analysis (STPA) has been developed as such a method. STPA has been used in a variety of industries but, at this time, it has not gained acceptance by the process industries. This article explores the reasons for this situation. Expectations for PHA in the process industries are examined and issues for the application of STPA in the process industries are discussed. It is concluded that a variety of matters must be addressed before STPA can be considered as a viable PHA method for the process industries and the case for the use of STHA in the process industries is not yet proven.     

Reasonableness of a proposed System Theoretic Process Analysis (STPA) validation framework: An interview study

Since its inception, the STPA technique has gained increasing popularity among researchers and industry practitioners. Nevertheless, the validity of its application has not yet received much scientific attention. Although some informal validation approaches have been used by STPA users, no formalized validation framework has been elaborated for practical use. This paper investigates the reasonableness of the recently proposed STPA validation framework, which includes 15 validation tests, each focusing on a specific step of an STPA analysis. To do so, STPA experts in both academia and industry were interviewed. First, it is investigated what approaches they have been using for validating an STPA analysis, the findings of which were categorized and mapped with the proposed validation framework. This aims to investigate the similarities and dissimilarities between the theory-based validation framework and the informal methods applied by experts in current practice. Then, the proposed framework was presented to the interviewees to seek their judgments about its reasonableness. Feedback from practitioners indicated that the proposed STPA validation framework has certain strengths, while several opportunities exist for further improvement. In particular, the findings indicate that most of the proposed theory-based tests have been already used by STPA experts in an unstructured manner. The experts appreciated the framework in that it provides clear guidance on how to validate each step of an STPA analysis systematically, and found some additional theory-based tests interesting for consideration in practice. The results also suggest that further research is needed to develop systematic techniques for performing each test to facilitate its application by STPA experts.     

基于STPA和模糊BN的装配式建筑吊装施工安全风险分析

为有效评估装配式建筑吊装施工中的安全风险状态,识别关键风险因素,运用系统理论过程分析方法(STPA)构建吊装施工过程中的控制反馈结构,识别导致危险的不安全控制行为,确定不安全控制行为的致因因素;基于风险因素间的关联关系构建贝叶斯网络(BN)模型,推理计算装配式建筑吊装施工安全风险状态概率,并结合反向诊断推理分析影响安全事故的风险因素;通过敏感性分析,识别装配式建筑吊装施工安全中的关键风险因素。结果表明：装配式建筑吊装施工安全风险处于低风险状态;起重机械超负荷运行、现场安全管理不到位和吊索吊具存在缺陷等因素是影响装配式建筑吊装施工安全风险的关键风险因素。     

Life cycle optimisation (LCO) of product systems with consideration of occupational fatalities

With the increasing pressures imposed upon industries on the environmental impacts of the manufacturing industry and chemical processes, numerous methodologies have been developed for the quantification, assessment and minimisation of waste and emissions. Meanwhile, methods for the simultaneous maximisation of economic performance within a product life cycle have also been developed. Similarly, various methodologies for screening of process alternatives based on the above factors have also been developed. However, the human lives put at risk in a supply chain constituting a life cycle tend to be overlooked as a factor of assessment, selection and optimisation of the process. Despite having life cycle assessment (LCA) methodologies for environmental assessment, no methodology has been developed for the minimisation of work-related casualties due to the unpredictable nature of workplace accidents. To address this problem, this paper develops a multi-objective optimisation model that utilises realistic statistical data for estimating the best possible pathway. The model results in the least potential fatality directly involved within the product life cycle while simultaneously minimising operating costs throughout the entire life cycle. A case study involving the utilisation of palm-based biomass formed for the production of value-added green products in Malaysia is used to demonstrate the model.     

Process safety aspects in water-gas-shift (WGS) membrane reactors used for pure hydrogen production

The syngas produced by coal gasification processes can be utilized in Pd-based water-gas-shift membrane reactors for the production of pure H₂. Pd/alloy composite membrane reactors exhibit comparative advantages over traditional packed bed reactors such as simultaneous reaction/separation in one compact unit and increased reaction yields. Furthermore, the development of comprehensive process intensification strategies could further enhance membrane reactor performance resulting in a substantially smaller and functional, inherently safer, environmentally friendlier and more energy efficient process.A systematic non-isothermal modeling framework under both steady state and dynamic/transient conditions for a catalytic high temperature water-gas shift reaction in a Pd-based membrane reactor has been developed to characterize the dynamic behavior of the process system at various operating conditions from a process safety standpoint. In particular, various reaction conditions as well as key process variables such as feed temperature and flow rate, catalyst loading, driving force for H₂ permeation are considered as they are critically related to various safety aspects in the operation of a Pd-based membrane reactor. Within the proposed framework, process parameters and operating conditions which may induce hazards and compromise process safety are identified, analyzed and characterized. Finally, the proposed approach is evaluated through detailed simulation studies in an illustrative case study involving a real Pd-based membrane reactor used for pure hydrogen production and separation that exhibits complex behavior over a wide operating regime.     

基于STAMP模型的建筑事故致因因素定量分析方法研究

为揭示建筑安全事故致因因素间的相互关系从而对其进行有效预防和控制,探讨1种STAMP模型的定量分析方法,用于深入剖析事故致因因素间的逻辑关系和属性特征。基于STAMP系统事故理论模型,从建筑工程安全控制结构入手逐层定性分析事故的致因因素;引入灰色DEMATEL与ISM相结合的方法对系统事故间的复杂逻辑关系进行层级划分;运用MICMAC分析计算各致因因素的驱动力和依赖度数值并判断其属性类别。结果表明:提出的定量分析方法运用到江西丰城冷却塔坍塌事故中的分析结果与事故调查报告相契合,能较全面地说明各层次结构间的相互作用。     

基于无线射频识别(RFID)技术的肉制品安全监控系统模糊综合评价

在无线射频识别(RFID)技术的肉制品安全监控系统中肉制品物流流程和影响因素分析的基础上,运用模糊综合评价给出主因素权重的计算原理;结合企业肉制品安全监控系统的具体情况,选择了评价指标并进行综合分析,建立了肉制品监控体系安全现状评价模型;在确定因素权重时,采用定性和定量相结合的层次分析法(AHP),其结果表明:权重的赋值科学合理,较好地反映了各因素对企业安全程度的重要程度和评判等级,所建立的多层次评价体系客观地反映了肉制品企业的安全状况,对肉制品加工企业安全监控具有重要的参考价值。     

Epistemic uncertainty in fault tree analysis approached by the evidence theory

Process plants may be subjected to dangerous events. Different methodologies are nowadays employed to identify failure events, that can lead to severe accidents, and to assess the relative probability of occurrence. As for rare events reliability data are generally poor, leading to a partial or incomplete knowledge of the process, the classical probabilistic approach can not be successfully used. Such an uncertainty, called epistemic uncertainty, can be treated by means of different methodologies, alternative to the probabilistic one. In this work, the Evidence Theory or Dempster–Shafer theory (DST) is proposed to deal with this kind of uncertainty. In particular, the classical Fault Tree Analysis (FTA) is considered when input data are supplied by experts in an interval form. The practical problem of information acquisition from experts is discussed and two realistic scenarios are proposed. A methodology to propagate such an uncertainty through the fault tree up to the Top Event (TE) and to determine the belief measures is supplied. The analysis is illustrated by means of two simple series/parallel systems. An application to a real industrial safety system is finally performed and discussed.     

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.     

STAMP-based analysis on the railway accident and accident spreading: Taking the China–Jiaoji railway accident for example

Each hazard analysis technique is based on a model of accident causation. Most accident models regard accidents as resulting from a chain or sequence of events, such models are fit for accidents caused by failures of physical components and for relatively simple systems, but suffer from serious deficiencies when they are applied to software-intensive, complex engineering systems. Recently, a new accident model called System-Theoretic Accident Models and Process (STAMP) for system safety has been proposed, it is based on control theory and enforces constraints on hazards and thereby prevent accidents. In this paper, taking the China–Jiaoji railway accident happened on April 28, 2008 as an example, the STAMP approach has been used to analyze the railway accident and some improvement measures have been proposed. As the occurrence of one accident can cause many other accidents happen, based on the STAMP-based analysis, the accident spreading processes have also been discussed and modeled, which will be helpful to analyze accidents spreading in a broad sense and establish effective emergent measures for accident response management.     

STAMP模型在危化品道路运输事故分析中的应用研究

为保障危化品道路运输行车安全,基于STAMP模型构建危化品道路运输的分层安全控制结构,将安全问题看作是控制问题,并将系统工程思想融入事故预防中。在此基础上,引入沪昆高速湖南邵阳段“7.19”特别重大道路交通危化品爆燃事故并对其进行实证分析,从物理层、基础层、运营层及监管层动态分析导致事故发生的控制缺失。结果表明:基于STAMP模型的安全分析方法不仅可考虑由组件失效引起的事故,还可发现组件之间的组织问题及决策背景,并对事故致因做出更为详细的解释,为类似事故的分析和预防提供思路与参考。     

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.     

Modeling patterns of breakdown (or archetypes) of human and organizational processes in accidents using system dynamics

Systems approaches to safety have received growing attention in modern accident investigation techniques (e.g., STAMP, Accimap) with the emphasis shifted to the organizational dynamics (or archetypes) that may lead to an erosion of defenses and a drift out of the safety margins. Although the literature contains many applications of archetypes and system dynamics to safety, this richness comes at a cost of learning. It has become very difficult for safety practitioners to integrate the diverse studies of system dynamics with their diverging models. To provide a practical tool of system dynamics in accident investigation, this article reviews earlier studies and integrates them as a classification of patterns of breakdown (or archetypes) of both human and organizational processes on the basis of two control models, that is, the Extended Control Model (ECOM) and the Viable System Model (VSM). In this article, archetypes are represented as variants of two generic templates of performance which exploit many elements of complexity theory and system control. Apart from providing a practical tool to safety practitioners to access the literature on archetypes, the generic templates of ECOM and VSM can be used in building simulators of individual and organizational processes for risk analysis.     

机械制造企业安全现状模糊综合评价

为完善机械制造企业安全现状综合评价指标体系及评价方法,建立了包括人、物、环、管四个方面的机械制造企业安全现状综合评价指标体系,提出了模糊综合评价方法;运用层次分析法计算指标权重,采用专家评价和隶属度函数相结合的方法来确定各指标的评语等级隶属度;将该方法应用于湖南某汽车制造企业的安全现状综合评价中,得出企业安全现状等级为较好,明确了该企业在人员素质和作业环境方面存在的不足,为制定安全对策措施提供了指导。     

Building an Executive Information System for Maintenance Efficiency in Petrochemical Plants—An Evaluation

This study used the manufacturing process in the petrochemical industries as an example and developed a dedicated maintenance programme and executive information system (EIS) for this industry. The software for EIS was established on a CMMS platform, with logical and extractive analysis used to store the information in a KPI databank. The system developed can provide plant managers and engineers with a complete summary of information and keep them updated regarding the present status of their maintenance efforts. The objective of this study was to establish a management system for maintaining knowledge in the petrochemical industries, such as the management of standard operating procedures (SOPs), historical records and the analysis of data for the facility. To design the software, a review of petrochemical facility was purposed to enhance the maintenance efforts and facilitate the decision-making process. The main functions of the system include asset reliability analysis, failure analysis and maintenance benefit cost analysis. For the petrochemical industry, the impact of safety and environment caused by equipment malfunction is more substantial than that of other industries. If executives can manage essential points effectively and make decisions according to a key performance index, risks to safety and environment, which result from equipment malfunction, can be decreased and safety can be enhanced for petrochemical refineries.     

基于STPA的城市埋地燃气管道第三方破坏风险因素分析

城市埋地燃气管道输送介质易燃易爆、埋设环境人口密集、施工频繁,极易受到来自第三方的破坏,直接威胁人们的生命财产安全,因此对第三方破坏的风险因素分析和防治十分必要。系统理论过程分析法(STPA)是一种基于系统理论的风险分析方法,该方法不同于传统的风险分析方法——将事故视为由初始事件诱发的一系列事件造成的后果,而是对燃气系统从设计、开发和运行过程进行分析,建立系统安全控制结构,通过分析控制缺陷和缺陷致因实现对风险因素的分析。研究分析出24个燃气管道第三方破坏的风险因素,针对风险因素提出了建议,为燃气管道第三方破坏的风险控制提供依据。     

基于层次分析-模糊综合评判的电解车间安全现状评价研究

根据电解车间安全评价存在的模糊性和随机性的特点,建立涵盖职工素质、工艺过程、生产设备、职业卫生、安全管理一级指标的安全现状综合评价指标体系;运用层次分析(AHP)理论,用标度取值方法、分根法分别构造模糊判断矩阵和计算各单因素的权重值;运用模糊综合评判(fuzzy comprehensive evaluation)理论,提出安全现状二级模糊综合评价方法;在组织专家对评价指标打分和确定模糊等级的基础上,结合前面得出的权重值,对某电解车间的安全现状进行了综合评价,得出其安全状况为"一般";在评价过程中,分析了指标体系中一级指标的状况,为制定安全措施提供了指导。笔者认为,该方法对于提高电解车间安全现状综合评价的客观性和准确性具有理论意义和实用价值。