Analysis and assessment of the Qingdao crude oil vapor explosion accident: Lessons learnt

A devastating crude oil vapor explosion accident, which killed 62 people and injured 136, occurred on November 22, 2013. It was one of the most disastrous vapor cloud explosion accidents that happened in Qingdao's storm drains in China. It was noted that blast overpressure and flying debris were the main causes of human deaths, personal injuries and structure damages. Two months after the accident, it was reported that there were three contentious issues in the investigation report. First issue was the discrepancy between the temperature of the crude oil vapor explosive limits which were measured by the investigation panel and the temperature reported by the local fire department. Second issue was the contradiction between the upper explosive limit and vapor pressure of the crude oil vapor. The last issue was the location of the ignition source which led to the explosion.In the present study some specific features of this accident and various causes led to the explosion, high casualties and severe damages were analyzed. Three contentious issues in the official investigation report were investigated and tested in detail. The first element tested was the explosive limits and limiting oxygen concentration of the crude oil vapor at different temperatures. Based on theoretical analysis and field investigations, the last two elements in the report were analyzed from multiple perspectives. Based on the TNO Multi-Energy model and PROBIT equations, damage probability of affected people at the leaking site was also estimated. The investigation concluded with a result that precautions need to be taken to prevent flammable gas explosions in the drainage systems. Key steps were explicitly discussed for improving the hazard identification and risk assessment of similar accidents in the future.     

Trends in chemical hazards in Japan

In the past, the chemical industry in Japan has been the cause of a number of major industrial accidents. Subsequent to each accident, specific lessons have been learned. These lessons learned have been implemented in terms of safety education of the employees and/or safety measures of the equipment and facilities resulting in a rapid decrease of corresponding accident frequencies. In this paper, we summarized both recent and past major accidents caused by chemical substances in fixed installations in Japan. Case studies show that runaway reactions are among the main causes of major accident occurrences in the chemical process industry in Japan. A recent fatal poisoning accident caused by H₂S gas generated during maintenance work again highlights the necessity of adequate safety management in a chemical factory. Therefore, even if hazard evaluation of chemical substances and chemical processes is necessary to prevent runaway reactions, human error is also an important factor contributing to reaction hazards [Wakakura, M. (1997) Human factor in chemical accidents, J. Safety Eng. High Press. Gas. Safety Inst. Japan, 34, 846].     

近年来山西省煤矿事故特点及对策措施

为掌握近年来山西省煤矿事故的发生特点,基于2015年—2018年山西省煤矿事故数据并结合全国煤矿事故数据进行对比,对事故等级、类型、地点、企业性质、煤矿辖区5个维度进行统计分析。结果表明:煤炭价格与煤矿安全形势有正负影响;近年来山西省煤矿安全总体形势好于全国,但机电、运输事故频发,水害事故时有发生,需要对该类事故加强防范措施;回采工作面为事故多发地点,这与全国煤矿事故特点不尽相同;国有重点煤矿的事故起数、死亡人数均高于地方煤矿企业,这主要是由于国有重点煤矿数量多、产量大的原因。应同时努力提高员工素质,坚决落实安全责任制,实现煤矿企业的安全生产。     

轧钢厂煤气泄漏事故应急救援预案

轧钢厂是大型冶金联合企业产成品后续加工单位,具有生产过程连续、工艺复杂的特点,其生产的原料坯须经过加热后,才能进行生产轧制.而加热燃料是高焦炉混合煤气,属易燃易爆、易中毒能源介质.为消除煤气在生产使用中出现的突发事故,最大限度地减少人员伤亡和财产损失需制定应急救援预案.     

易燃易爆氢氧车间生产、贮气柜系统危险性评价

通过某动力公司氢氧车间生产、贮存系统危险性因素分析 ,对氢氧车间氢气生产、贮存各工艺环节进行了火灾爆炸危险性评价 ,并针对氢氧车间生产工艺系统和湿式贮气柜的火灾爆炸事故隐患 ,提出了事故防范的安全对策。     

基于F-N曲线的煤矿重特大瓦斯爆炸事故伤亡规律研究

为研究煤矿瓦斯爆炸事故的伤亡规律,以2000-2014年发生的230起重大及以上瓦 斯爆炸事故为样本,运用统计学和F-N曲线法对事故特征进行了研究。首先,对事故起 数和伤亡情况的时间特征进行了统计;其次,对事故起数和伤亡数量的地域性特征进行 了研究;最后,基于F-N曲线法,对事故的死亡人数和受伤人数进行了规律分析。研究 结果表明:15年间的瓦斯爆炸事故起数总体上呈逐年下降的趋势,但在2005年出现了峰 值,死亡人数与事故起数的变化趋势接近,受伤人数变化趋势不太明显;重特大瓦斯爆 炸事故主要发生在中部和西南地区,且尤以山西省最为显著,其事故起数和伤亡人数都 是最多的;大多数事故造成了10～30人的死亡,其累计概率曲线在对数坐标中的梯度是 -1.642,受伤人数最频繁的区间是1～10人,其累计概率曲线在对数坐标中的梯度是- 0.652。     

New investigation findings on the 2006 Danvers,MA explosion

On November 22, 2006 the largest explosion in the history of Massachusetts occurred in Danvers, MA at approximately 2:46 am. This paper presents a detailed analysis into the potential causes and lessons learned from the Danvers explosion. Other investigative groups concluded that the cause of the explosion was an overheated production tank. However, the analyses presented here demonstrate that their proposed scenario could not have occurred and that other potential causes are more likely.Using the computational fluid dynamics tool FLACS, it was possible to investigate the chain of events leading to the explosion, including: (1) evaluating various leak scenarios by modeling the dispersion and mixing of gases and vapors within the facility, (2) evaluating potential ignition sources within the facility of the flammable fuel–air mixture, and (3) evaluating the explosion itself by comparing the resulting overpressures of the exploding fuel–air cloud with the structural response of the facility and the observed near-field and far-field blast damage. These results, along with key witness statements and other analyses, provide valuable insight into the likely cause of this incident. Based on the results of our detailed analysis, lessons learned regarding the investigative procedure and methods for mitigating this and future explosions are discussed.     

碳纤维复合材料粉尘爆炸强度特性研究

碳纤维复合材料是应用于航天、航空领域的高性能材料之一,对于该材料的粉尘爆炸特性还未有相关研究报告。为了研究碳纤维复合材料粉尘的爆炸强度特性,本文采用20L球形粉尘爆炸测试实验系统开展了相关实验研究。实验测得碳纤维复合材料粉尘爆炸下限浓度为50g/m 3,最大爆炸压力为0.48MPa。在测试浓度范围内,最大压力上升速率和爆炸指数均随浓度的增大而变大。另外,在其爆炸强度特性研究的基础上,对产尘车间的环境风险进行了初步辨识,提出了相应的防护措施。本文的研究成果对此类碳纤维复合材料粉尘的工业防护具有实际的指导作用,对于该粉尘的爆炸机理的深入研究也具有一定的参考价值。     

粉尘爆炸事故模式及其预防研究

随着粉体工业的发展,粉尘爆炸发生的危险性也随之增大。为了探讨粉尘爆炸发生的规律,笔者对粉尘爆炸发生的点火源类型、事故原因进行了统计、排序;在对已发生的典型的粉尘爆炸事故分析的基础上,总结、归纳了影响粉尘爆炸发生的,诸如粉尘自身的可燃性、粉尘所处的状态、粉尘所处的外部环境等因素;提炼出了7种粉尘爆炸事故模式,并对各种模式下粉尘爆炸发生的条件、机理进行了初步研究分析,然后提出了相应的事故预防措施。笔者所研究的成果,对粉体工业的安全生产具有实际的指导作用,对今后防灾决策的深入研究也具有一定的参考价值。     

低瓦斯矿井瓦斯爆炸事故的主要原因及防治对策

从理论和实际两方面分析了近期发生在一些低瓦斯矿井的瓦斯爆炸事故,结合对福建煤矿曾经发生的瓦斯爆炸事故的分析和研讨,认为发生瓦斯爆炸事故的主要原因有:对瓦斯防治重视不够、未能准确地确定瓦斯的爆炸下限浓度及瓦斯混合气体在强点火能下会降低瓦斯爆炸浓度下限等主观上的原因,还有因采深加大致使瓦斯涌出量增加、瓦斯监测系统不到位等客观上的原因。着重从大量的试验证明了在强点火能下瓦斯混合气体爆炸浓度下限大幅降低的事实,并提出了相关的防治对策。研究成果对瓦斯防治具有重要的实际意义。     

城市排水有限空间爆炸性气体产生机理与防治对策

易燃性气体爆炸是城市排水系统时有发生的一类有限空间事故,而人们通常更多的只关注有限空间中毒窒息事故,对该类事故关注度不够。通过分析城市排水系统涉及的有限空间和易于产生的爆炸性气体种类与危害性,阐述了防范该类事故的必要性和意义。同时,通过将沼气发酵机理与城市排水系统有限空间易于具备的条件进行对比,说明了城市排水系统有限空间爆炸性气体产生的过程与机理以及爆炸产生的危害。最后针对城市排水的特点与爆炸性气体的产生过程与机理,提出了相应的防治对策,为有效控制和减少该类事故的发生提供了技术支持。     

强化林业企业木材生产现场安全管理

通过生产实践，论述了林业企业强化木材生产现场安全管理的五条措施。从而减少从业人员的人机伤害事故，确保安全生产。     

药物混粉爆炸事故及防范对策的研究

从近几年制药行业频繁爆炸事故出发,分析制药行业爆炸事故的种类,从粉尘爆炸入手,以某制药企业为研究对象,对其爆炸粉体克拉维酸钾进行了爆炸参数测试,运用20L球形粉尘爆炸测试装置测定其爆炸下限为40g/m3。同时运用差热扫描热分析法对其进行放热反应进行研究,再利用毛细管气相色谱法对该混合物中是否存在可燃气体进行了评定,发现其存在丙酮可燃气体,但含量较低为9.3×10-5。针对上述特点,从技术和管理角度出发,分析应对措施以及常见的问题,设计了混粉机械人机界面,编制了安全检查表,对该类共性问题进行了归纳,以供防范药物混粉事故发生参考。     

杭州高速公路交通事故流行病学特点分析

目的:研究杭州高速公路交通事故的流行病学特点。方法:收集了2003—2006年杭州高速公路交通事故资料并对其进行流行病学分析。结果:①2003—2006年期间,发生交通事故8906起,涉及车辆12692辆,死亡115人,受伤1976人,造成直接经济损失1.15亿元;②交通事故以10月和1月发生最多,每周事故数呈逐渐上升趋势,9:00—11:00点和14:00—16:00点为事故的高发时段;③因驾驶员造成的交通事故超过事故总数的90%,主要原因为未保持安全的纵向距离和操作不当;车辆原因主要为爆胎和制动问题、天气及照明对事故有一定影响;④在高速公路交通事故中,乘客与驾驶员受到的危害程度相同。结论:研究高速公路交通事故的流行病学特点将有利于采取科学的措施减小高速公路交通事故给社会带来的危害。     

露天采石场边坡稳定因素浅析

忽视对露天采石场边坡稳定问题的分析研究,放松管理必然导致重大事故的发生。通过对1984—2001年河南省露天采矿场重、特大事故分析得出如下结论:18年间重特大事故共发生27起。分为两类,一类是放炮事故,一类是边坡坍塌事故。放炮事故3起、死亡13人,事故起数和死亡人数分别占11.11%和10.08%;坍塌事故24起、死亡116人,事故起数和死亡人数分别占88.89%和89.92%。统计分析和经验告诫:深入了解露天采石场边坡稳定因素,加强边坡管理是实现露天采石场安全生产的重中之重。     

Lessons learned for process safety management in China

A number of chemical accidents have occurred in China over the past two decades with significant impact on humans and the environment. It is expected that lessons will have been learned from these accidents that will help industries to reduce the risk that catastrophic chemical accidents occur in future. In fact, to some extent there is evidence that lessons have been learned, to the extent that the Chinese government has substantially strengthened legislation and regulatory standards. Nonetheless, there remains a concern that much more still needs to be done to reduce chemical accidents risks in China. Important progress in this area requires not only government support but a commitment across all hazardous industries to learn from past accidents that may in many cases require establishment or considerable improvement of their safety management systems. To assist small and medium-sized enterprises (SMEs), in this effort, results of an analysis of common causes of the chemical accidents reported in the Major Accident Information (MAI) website of Chinese State Administration of Work Safety (SAWS) are presented in this paper In particular, inadequate process hazard analysis (PHA), training and emergency response planning (ERP) were identified as the top three process safety management (PSM) elements that contribute to most of the SMEs accidents in China. Seven recommendations are proposed in order to improve the effectiveness of lesson learning for government agencies and SMEs.     

The role of situation awareness in accidents of large-scale technological systems

In the last two decades, several serious accidents at large-scale technological systems that have had grave consequences, such as that at Bhopal, have primarily been attributed to human error. However, further investigations have revealed that humans are not the primary cause of these accidents, but have inherited the problems and difficulties of working with complex systems created by engineers. The operators have to comprehend malfunctions in real time, respond quickly, and make rapid decisions to return operational units to normal conditions, but under these circumstances, the mental workload of operators rises sharply, and a mental workload that is too high increases the rate of error. Therefore, cognivitive human features such as situation awareness (SA)—one of the most important prerequisite for decision-making—should be considered and analyzed appropriately. This paper applys the SA Error Taxonomy methodology to analyze the role of SA in three different accidents: (1) A runaway chemical reaction at Institute, West Virginia killing two employees, injuring eight people, and requiring the evacuation of more than 40,000 residents adjacent to the facility, (2) The ignition of a vapor cloud at Bellwood, Illinois that killed one person, injured two employees, and caused significant business interruption, and (3) An explosion at Ontario, California injuring four workers and caused extensive damage to the facility. In addition, the paper presents certain requirements for cognitive operator support system development and operator training under abnormal situations to promote operators’ SA in the process industry.     

火炸药、弹药工厂和企业中重大事故隐患的定量评估:爆炸危险源系统的现实危险度方程

火药、炸药、弹药工厂和企业存在着极大的燃烧爆炸危险性,对这类企业的重大事故隐患进行危险性评估是非常必要的。提出了危险源现实危险度(DAH)即事故隐患严重度的判据H的评估方程,而火炸药燃烧爆炸危险源系统的现实危险度H与下列因素有关,即与火炸药的危险指数W、系统的固有危险度B、未受控系数K、以及距该系统安全距离不足的建筑物和设施受危险源爆炸事故影响的破坏程度等因素有关。讨论了对这些因素的评估和计算。     

聚烯烃工业粉尘静电爆炸的危险与应对策略

随着我国聚烯烃粉体生产的迅猛发展,粉体生产过程中的静电爆炸事故也相应增多。该文介绍了国外粉尘静电爆炸研究的进展和国内粉尘静电爆炸事故的主要现象。近期国外的研究特点主要是逐渐采用工业规模的实验装置取代实验室的基础研究,着重开展了料仓放电的危险研究和与放电燃爆有关的基础研究,包括安全评价和工业控制条件的推荐研究。国内粉尘静电爆炸事故主要存在的现象有设计缺欠或不合理,装置扩能改造时忽视了脱挥或通风的配套改造,处理不合格料或过渡时应急处理不当,操作失误或不规范,破坏料仓通风控制,料位计选型不当,增加高能放电引燃几率。针对分析出的问题和现象,文章提出了查清运行装置的具体事故隐患,进行防止聚烯烃料仓粉尘静电爆炸的可接受研究和可操作性研究,开展粉尘静电爆炸的危险教育,提高员工的安全意识和应急处理能力等应对策略。     

Dust explosion incidents and regulations in the United States

The U.S. Chemical Safety and Hazard Investigation Board (CSB) investigated three fatal dust explosions that all occurred in 2003. These explosions caused the deaths of 14 people and injured hundreds more. Two of the facilities were damaged beyond repair, and several hundred employees lost their jobs.

CSB's investigations revealed that the explosions had common causes, despite their geographic and industrial diversity. Consequently, CSB commissioned a study of combustible dust fire and explosion hazards. This paper presents a summary of CSB's findings and recommendations developed during that study.