A modified computer hazard and operability study procedure

The application of modifications of the hazard and operability study method (Hazop) to process facilities using computer-based control systems has led to the development of computer Hazop (Chazop) procedures. A number of the Chazop procedures cited in the literature broaden the method and depart from the base documentation of the Hazop method. It is suggested that a robust Chazop method requires implementation at the line-by-line level of detail and as a separate, complementary study using the same base documentation (piping and instrumentation diagrams) as that used in the Hazop method.     

Design and evaluation of safety measures using a newly proposed methodology “SCAP”

An increase in the number of accidents in the process industries and the concomitant damage potential is a cause of concern in many countries. In order to control the alarming risk posed by these industries, the United States government has asked each manufacturing facility to carry out a worst-case disaster study and to develop alternatives to control this high risk. Other developed and developing countries such as Canada and India have taken similar measures.Recently Khan and Abbasi (J. Loss Prevent. Process Ind. (2001a) in press) have proposed a maximum credible accident analysis with a maximum credible accident scenario approach, which scores over a worst-case scenario approach for being realistic and reliable. In another effort, Khan and Abbasi (J. Hazard. Mater. (2001b) in press) have developed an efficient and effective algorithm for probabilistic fault tree analysis. These two approaches have been combined to yield a new methodology for a more realistic, reliable, and efficient safety evaluation and the design of risk control measures. The methodology is named SCAP: Safety, Credible Accident, Probabilistic fault tree analysis. The methodology is comprised of four steps of which the last step is a feedback loop. This paper recapitulates this methodology and demonstrates its application to ethylene oxide (EO) plants. The application of SCAP to EO plants identifies five units as risky and needing more safety measures. Further, this study recommends safety measures and demonstrates through SCAP that their implementation lower the risk to an acceptable level.     

Challenges in performing technical safety reviews of modifications – A case study

The aim of the present study, is to identify strengths and weaknesses of the technical safety review process at a Swedish Nuclear Power Plant (NPP). In this context, the function of safety reviews are understood as expert judgements on proposals for design modifications¹ and redesign of technical systems (i.e. commercial nuclear reactors), supported by formalised safety review processes. The chosen methodology is using two complementary methods: interviews of personnel performing safety reviews, and analysis of safety review reports from 2005 to 2009.The study shows that personal integrity is a trademark of the review staff and there are sufficient support systems to ensure high quality. The partition between primary and independent review is positive, having different focus and staff with different skills and perspectives making the reviews, which implies supplementary roles. The process contributes to “getting the right things done the right way”. The study also shows that though efficient communication, feedback, processes for continuous improvement, and “learning organizations” are well known success factors in academia, it is not that simple to implement and accomplish in real life.It is argued that future applications of safety review processes should focus more on communicating and clarifying the process and its adherent requirements, and improve the feedback system within the process.     

Safer management of process changes in chemical reactors

Nowadays many chemical industries are SMEs where multi-purpose batch or semi-batch reactors are commonly used. Vent sizing for realistic runaway scenario is not an easy task for such enterprises since they have usually few resources and use multi-purpose reactors with fast process turnovers. As a consequence these batch and semi-batch reactors are usually equipped with emergency relief systems sized once forever when the reactor is designed. This can lead to a large underestimation of the vent area in case of runaway reactions occurring when processes different from the ones considered for originally sizing the vent are carried out.The approach proposed in this work aims to identify the maximum reactor load leading to safe conditions even in case of runaway phenomena to be handled with the emergency relief system already installed (or even with a smaller vent area). This approach allows avoiding the change of the emergency relief system with a larger vent area (as required every time a new more hazardous process has to be carried out on existing reactors) at the price of lower plant productivity.     

高科技制造业环安卫风险管理系统

只要有危害源就会存在一定的风险。由于生产过程的需要,高科技制造行业往往使用大量有毒、危险化学品,生产环境与生产设备也不同于传统产业,也因此,如何运用有效地环安卫(环境保护、工业安全、职业健康)风险管理机制来避免各种危害源可能对企业造成的负面冲击,以降低高科技行业营运过程可能遭遇的环安卫风险一直是高科技行业风险管理者所面临的挑战。本文将介绍如何以PDCA持续改善的架构来贯穿高科技行业环安卫风险管理流程与风险管理概念。     

基于动态SDG模型的间歇过程HAZOP方法研究

危险与可操作性分析（HAZOP）是目前应用最为广泛的安全评价方法之一。然而,通过对国内外已实施的生产过程安全评价方法及相关计算机辅助安全评价软件调查发现,目前对间歇过程HAZOP分析的研究还较少。因此,将Petfi网与符号定向图（SDG）相结合,以SDG模型为主,Petri网模型为辅,建立专门针对间歇过程HAZOP分析的动态SDG模型。由于Petfi网可以准确描述间歇过程的离散事件特性,而SDG能够恰当描述间歇过程的连续特性,二者结合使该模型成为间歇过程HAZOP分析的有力工具。     

工艺过程危险有害因素辨识的研究

鉴于化工企业工艺过程的特殊性,笔者建议其危险、有害因素的辨识可以在直观经验分析法和系统安全分析法的基础上,结合危险和可操作性研究(HAZOP)的思想来进行辨识。笔者尝试性地给出了相关术语的说明、介绍辨识方法和操作程序,并分别从生产过程(包括化学反应、化工操作单元和物料输送)和工艺设备、装置角度,对其中的所包含的具体内容进行剖析,最后以电解过程举例说明,该方法可用于化工企业进行危险性因素辨识。     

Critical runaway conditions and stability criterion of RDX manufacture in continuous stirred tank reactor

The energetic material cyclo-1,3,5-trimethylene-2,4,6-trinitramine (RDX) has been widely used as explosive and propellant ingredients in the military industry. It is usually produced by hexamine nitration reaction in continuous stirred tank reactor (CSTR). This manufacturing process is quite dangerous and always causes fire incidents or explosion owing to its thermal instability in its nitration reaction or purification processes. In this investigation, we used its reaction kinetics parameters to evaluate the thermal hazard conditions and stable reaction criteria in the reaction systems of continuous stirred tank reactor.     

Realistic evaluation as a new way to design and evaluate occupational safety interventions

Recent debates regarding the criteria for evaluating occupational health and safety interventions have focused on the need for incorporating qualitative elements and process evaluation, in addition to attempting to live up to the Cochrane criteria. Reflecting fundamental epistemological conflicts and shortcomings of the Cochrane criteria in evaluating intervention studies, the debate challenges the traditional (quasi-) experimental design and methodology, which are often used within safety research. This article discusses a revised ‘realistic evaluation’ approach as a way to meet these challenges.Evidence from the literature as well as examples from an integrated (leader-based/worker-based) safety intervention study (2008-2010) in a large wood manufacturing company are presented, with focus on the pros and cons of using randomised-controlled-trials and a revised realistic evaluation model.A revised realistic evaluation model is provided which includes factors such as role behaviour, leader and worker motivation, underreporting of accidents/injuries, production pressure, unplanned organisational change and accounting for multilayer effects. These can be attained through qualitative and/or quantitative methods, allowing for the use of realistic evaluation in both large and small scale studies, as well as in systematic reviews. The revised realistic evaluation model offers a promising new way of designing and evaluating occupational safety research. This model can help safety science move forward in setting qualitative and/or quantitative criteria regarding context, mechanisms and processes for single studies and for reviews. Focus is not limited to whether the expected results appear or not, but include suggestions for what works for whom, under what circumstances, in what respects and how.     

Risk analysis of Chongqing urban rail transit network

Urban rail network safety is a critical sector of urban public safety. However, there is no uniform standard for the safety evaluation of the urban rail network. This paper presents a novel methodology by integrating a multilevel decision tree with a fuzzy analytical approach to enhance urban rail network safety. The proposed methodology overcomes serious limitations such as subjectivity in the data and independence of the variables in decision-making processes. The proposed methodology is applied to the risk evaluation of the selected Chongqing rail transit lines and the Expo Line. The risk analysis is considered using the field data collected from these transit lines. The applied case studies confirm the general applicability of the methodology and the multilevel decision tree network. The main risk factors identified for the Chongqing rail traffic system are the terrorist threat, emergency management, and aging infrastructure which need to be investigated as a priority to mitigate risk associated with these infrastructures.     

Security Risk Assessment Methodology for the petroleum and petrochemical industries

The American National Standards Institute (ANSI)/American Petroleum Institute (API) Standard 780 Security Risk Assessment (SRA) Methodology was published in June 2013 as a U. S. standard for security risk assessments on petroleum and petrochemical facilities. The standard represents a model standard for evaluating all security risks of petroleum and petrochemical infrastructure and operations and assists industries in more thoroughly and consistently conducting SRAs. The 2013 Standard is an update from the previous API/NPRA SRA Methodology (2004) and focuses on expanding functional utility without changing the basic methodology.The methodology can be applied to a wide range of assets even beyond the typical operating facilities of the industry. This includes refining and petrochemical manufacturing operations, pipelines, and transportation operations including truck, marine, and rail, as well as worker and executive security, housing compounds, and remote operational sites. The new standard describes the most efficient and thorough approach for assessing security risks widely applicable to the types of facilities operated by the industry and the security issues they face. It is voluntary but has been adopted by the Kingdom of Saudi Arabia Ministry of Interior High Commission for Industrial Security as the mandatory security risk assessment methodology for industrial facilities.This paper examines the key elements of the ANSI/API SRA process and discusses how forward thinking organizations may use risk-based performance metrics to systematically analyze facility security postures and identify appropriately scaled and fiscally responsible countermeasures based on current and projected threats. The AcuTech Consulting Group developed the methodology under contract to the API, and the author was the project manager for the project.     

The feasibility of encouraging inherently safer production in industrial firms

Inherent Safety is generally recognised as an important concept in the design of chemical plants. It is, however, often regarded as the sole province of engineers. Inspired by the successful development in the last decade from cleaner technology towards Cleaner Production, we explored in this research the feasibility of what we call Inherently Safer Production. Four pilot cases were carried out, two in the Netherlands and two in Greece; three in existing plants, one at the design stage. A methodology to generate inherently safer technological options was developed and tested. In all four cases, a number of options for inherently safer production were identified, while more traditional safety options were also identified. The great majority of options was shown to have pay back times of less than 2 years. Overall, 25% of the options were implemented during the project.In existing plants, the option generation process can be organised as a collective learning and inspiring effort. This can be of considerable value on its own, apart from the implementation of the (technological) options identified. We conclude that Inherently Safer Production is a feasible concept, that it has great potential for simultaneous improvement of safety and economic performance, and that it deserves to be further developed.     

Dynamic model based safety analysis of a three-phase catalytic slurry intensified continuous reactor

Safety analysis like the HAZOP (HAZard OPerability) study can be much more efficient if a dynamic model of the system under consideration is available to evaluate the consequences of hazard deviations and the efficiency of the proposed safety barriers. In this paper, a dynamic model of a three-phase catalytic slurry intensified continuous chemical reactor is used within the context of its HAZOP (HAZard OPerability) study. This reactor, the RAPTOR®, is an intensified continuous mini-reactor designed by the French company AETGROUP SAS that can replace batch or fed-batch processes in the case of highly exothermic reactions involving hazardous substances. The highly hazardous hydrogenation of o-cresol under high pressure and temperature is taken as an example of application. Deviations as a temperature increase of the cooling medium or no cooling medium flow can produce an overheating of the reactor. Thus, three possible safety barriers are evaluated by simulation: shut off the gaseous reactant feed, shut off the liquid reactant feed or stop the agitation. The more efficient actions are the stopping of the agitation and/or of the gas reactant feed. The simulation results can efficiently help the reactor design and optimisation. Safety analysis can also be one of the criteria to compare batch and intensified continuous processes.     

Fundamentals of the Model Behind the COSMOS Methodology Used for Team Assessment in Simulator Training

Team working is the basic way of working in the control rooms of hazardous technologies and therefore its quality is a safety-relevant issue. In addition to the technological competence it is also crucial for the crews to have the necessary communicational skills. During simulator training these skills can only be improved if the simulator use is embedded in an appropriate setting. To support this skill acquisition a computer-supported methodology called COSMOS (COmputer Supported Method for Operators’ Self-assessment) has been developed. With its help more effective communication and more complete shared mental models can be fostered. This paper is a report on the psychological fundamentals and the mathematical model of the COSMOS methodology.     

超滤膜技术在环境工程水处理中的应用

随着我国经济水平的不断提高,也给我国环境带来了巨大的影响。与此同时,科技水平的不断发展,也使我国水处理技术日臻完善。目前,在环境工程水处理的过程中不仅可以通过物理、化学方法,还可以通过超滤膜技术来对环境工程水处理的质量进行监控,其是以传统水处理工艺为基础,通过全面的改革及调整,形成的一种新型的处理技术,能够确保水环境具备理想的可行性和适宜性,从而提升水处理效果。     

Conceptual compression discussion on a multi-linear (FTA) and systematic (FRAM) method in an offshore operation’s accident modeling

Risk assessment can be classified into two broad categories: traditional and modern. This paper is aimed at contrasting the functional resonance analysis method (FRAM) as a modern approach with the fault tree analysis (FTA) as a traditional method, regarding assessing the risks of a complex system. Applied methodology by which the risk assessment is carried out, is presented in each approach. Also, FRAM network is executed with regard to nonlinear interaction of human and organizational levels to assess the safety of technological systems. The methodology is implemented for lifting structures deep offshore. The main finding of this paper is that the combined application of FTA and FRAM during risk assessment, could provide complementary perspectives and may contribute to a more comprehensive understanding of an incident. Finally, it is shown that coupling a FRAM network with a suitable quantitative method will result in a plausible outcome for a predefined accident scenario.     

MOC scoping—Ensuring that MOC action items are correctly and completely described

Shortly after initiating a Management of Change instance, the owner develops a list of action items that need to be accomplished in order to successfully complete the MOC. This activity is termed “scoping the MOC”. A well-scoped MOC is efficient and lower risk; a poorly-scoped MOC is inefficient and higher risk.The quality of MOC scoping depends largely on the methodology used, with different sites using anything from no scoping at all, guesswork approaches, checklist approaches, to very sophisticated asset-based scoping.This paper reviews the various scoping methodologies using examples from actual MOC processes currently in use at chemical plants and refineries. The scoping techniques are then evaluated in terms of cost and error susceptibility of the resulting MOCs, using quantitative assessment tools. The results of this research provide specific guidelines on how to optimize scoping for small, medium and large MOCs.     

Inherent occupational health assessment during preliminary design stage

Chemical process routes can already be assessed as early as in the development and design phases. Process screening should not look at economic and technical aspects only, but also the safety, health, and environmental performances. In this paper, a method called the Health Quotient Index (HQI) is presented for the preliminary process design phase. The HQI provides a simple approach to quantify workers' health risk from exposure to fugitive emissions e.g. in petrochemical plants. The method utilizes process data from flow sheet diagram, which is already available at the preliminary design stage. Since the mechanical details of the process are still unknown, a database of the precalculated fugitive emissions for typical operations in chemical plants was created to simplify the assessment. The HQI can be used to rank alternative process concepts or to quantify the risk level of processes. As a case study, six process routes for producing methyl methacrylate are discussed. Three health indexes are compared in the case study. The HQI is able to highlight the difference of hazard levels between the routes better as a result of more detailed assessment of the exposures.     

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.     

基于人因可靠性的间歇装置SIL分析与改进

IEC 61508和IEC 61511等标准针对连续工艺装置提出了安全仪表系统安全完整性等级评估方法。但对于间歇装置的SIL评估,受人因因素影响水平并未明确,且没有提出相应计算模型。以某六氟磷酸锂间歇生产装置典型SIS为例,采用HAZOP结合LOPA方法对其进行风险分析,在明确间歇生产装置存在人员中毒、窒息及燃烧爆炸风险的基础上,确定并验证其安全仪表系统的SIL,再依据间歇生产装置人工依赖性高,即部分安全仪表系统未接入自动联锁且需人工手动触发的特点,建立人因可靠性模型,来分析人因可靠性对安全仪表系统SIL的影响,并进行改进研究。研究结果表明:人因因素对安全仪表系统SIL有显著影响;可通过改变SIS元件冗余结构、测试策略并结合改进人因管理措施来提高SIL。