Loss prevention in the petrochemical and chemical-process high-tech industries in Taiwan

Industrial safety has noticeably improved in recent years in Taiwan. Despite these improvements, however, serious accidents including explosions, chemical releases, and fires have still occurred in companies such as the Fu Guo Chemical Company (2001), Sin Hun Chemical Company (2005), Motech Industries, Inc. (2005) and Nanpao Resin Co. (2010). These accidents resulted in great loss of life and property, and further caused demands for improvement. Chemical disasters usually result from the combination of several mistakes or gross carelessness and are seldom caused by a single episode. To ensure the safety of operating, handling and storing chemicals, as well as to prevent chemical disasters, one must take many critical points into account, such as techniques, manufacturing processes, operators, chemicals, and emergency response. In Taiwan, the hazards and risks of high-tech companies are higher than in other industrial sectors. Therefore, a variety of safety management methods and regulations appropriate for high-tech companies have been generated. We studied the current status of the indigenous loss prevention protocols based on the safety management of petrochemical and chemical-process high-tech industries in Taiwan.     

Use of association rules to explore cause–effect relationships in occupational accidents in the Taiwan construction industry

Most models of the incidence of occupational accidents in the construction industry are composed of multiple factors. Although statistical techniques can be used to infer cause-and-effect relationships among these factors, the large number of factors involved and the complexity of the relationships among them make it difficult for managers to identify potential hazards in construction projects and thus develop effective safety procedures. This study addresses this problem by using the association-rule method of data mining in performing an analysis of 1347 accidents in the Taiwan construction industry during the period 2000–2007. The association-rule method enables potential cause-and-effect relationships to be identified among the many factors that play a role in occupational accidents in the construction industry. The study finds that such accidents tend to occur when certain combinations of hazards are present – especially working in high places without protective measures, loss of balance when in motion, failure to use protective equipment, insufficient experience, and injurious contact with unstable structures. These hazards are especially evident in small enterprises with less than 10 persons. The results can help management to formulate effective safety policies with regard to management shortcomings and staff training.     

Improved management practice and process hazard analysis techniques for minimizing likelihood of process safety incidents in Taiwan

In Taiwan, process safety accidents often occur despite the prior implementation of process hazard analysis (PHA). One of the main reasons for this is the poor quality of the PHA process; with the main hazards not being properly identified, or properly controlled. Accordingly, based on the findings of 86 process safety management (PSM) audits, dozens of post-accident site resumption review meetings, and hundreds of PSM review sessions, this study examines the main deficiencies of management practice and PHA implementation in Taiwan, and presents several recommendations for improved PHA assessment techniques and procedures. The study additionally examines the feasibility for using PSM-related information, such as process safety information and process incident information, as a tool for further enhancing the PHA quality. Overall, the study suggests that, in addition to following the basic rules of PHA and requirements of OSHA (1992),management in Taiwan should also provide training in the enhanced assessment techniques proposed herein and take active steps to incorporate PSM information into the PHA framework in order to improve the general quality of PHA and reduce the likelihood of process safety accidents accordingly.     

A method,DEB analysis,for proactive risk analysis applied to air traffic control

Introduction: Complex production systems as, for instance, those used in health care, in off shore industry, in nuclear power industry or in aviation suffer now and then from severe system breakdowns. Lessons learnt from these often lead to changes in the “system”. A more rational approach would be to identify these “system weaknesses” before accidents happen.A new proactive method, DEB analysis, for identifying hazards in a complex system was applied to an air traffic control unit in Malmoe, Sweden. The system weaknesses (i.e. latent system failures and insufficient safety barriers), which could cause these hazards, were identified. The effectiveness of the method was assessed by comparing these “prospective” identified system weaknesses with “retrospective” identified system weaknesses in a consecutive series of loss of separation cases (n=15), investigated by the central aviation administration.Main findings: The system weaknesses in 14 out of the 15 cases were found with the proactive method. One sub-task was missed.Discussion: The method is an effective tool in disclosing system weaknesses that can give rise to hazards. The method should be modified with increased engagement of operators. It might be applied to other complex systems as well.     

电炉生产系统工伤事故控制技术的研究

本文是综合应用安全系统工程的原理和方法,控制生产系统的工伤事故,并采用系统辨识理论,辨识生产中的潜在危险和后果,定量评价潜在危险的危害程度和发生概率;综合应用数理统计、工程逻辑、故障树、事件树、管理失误和风险树等多种分析方法,对电炉炼钢生产的原料、冶炼、铸锭、天车、电气、机械等子系统进行了事故发生可能性的预分析和安全状况评价。据分析评价结果,结合生产实际和管理现状,制定了控制事故的综合技术对策,并开发了一系列适合于我国企业安全管理实际需要的计算机软件。     

Korean experience of process safety management (PSM) regulation for chemical industry

From the 1960s, Korean industries have been encouraged by the government to nurture heavy and chemical industry and to modernize the economics and industrial structures. The development of chemical industry particularly became the turning point in industrial development, and played a major role in the construction of a new industrialized country. However, the process systems in the chemical industry have become more complex and larger, and the inventories of dangerous chemicals that are produced or consumed have continuously increased. Therefore, the hazards from potential accidents such as fire and explosion or release of toxic chemicals have also increased. In fact, from the end of 1980s to the beginning of 1990s in Korea, a number of major industrial accidents such as ABS extruder explosion, TDI release and dryer explosion, etc. Occurred and caused many fatalities. As the chemical companies recognized the importance of preventing major hazards, PSM system, the prevention of major industrial accidents, was introduced in January 1995 by amending Industrial Safety and Health Act, and it has been enforced from January 1, 1996. According to the law, the business owner of a workplace with hazardous or dangerous equipment shall submit a process safety report to the Government to prevent any accidents, which could inflict an immediate damage on workers or on areas in the vicinity of the workplaces. As a result of PSM implementation for 19 years, chemical accident prevention system has been stabilized and various kinds of effectiveness and desirable customer satisfaction have been made.     

GIS在大型石化企业事故应急管理中的应用

在研究化工企业事故应急处理技术和地理信息系统的基础上,建立了事故应急管理系统。应用该系统进行风险管理,能方便、准确地表示、录入、检查及查询企业内各危险源的地理位置和属性信息;动态模拟各种燃烧、爆炸、泄漏事故发生、发展状况;给出相应的应急处理方案和人员疏散最佳路径。事故应急管理系统可为企业的安全生产、事故预防、事故应急救援的科学决策提供技术支持。     

针对瓦斯事故的安全投资效益评估方法研究

煤矿生产中瓦斯事故的发生及其危害程度的不确定性使得定量评价损失很困难.本文提出一种评估煤矿瓦斯事故严重程度和相关安全投资效益的方法.通过分析影响煤矿瓦斯事故发生的主要因素,利用专家调查法推断出瓦斯事故的发生概率和严重程度,进而估计出瓦斯事故的风险度并定量评价相关的安全投资效益.通过这种方法,可以提出各种安全投资方案并进行安全投资效益比较,据此选择安全投资效益最好的安全投资方案进行安全投资决策,最大限度地降低煤矿瓦斯事故的发生概率和危害程度.实例分析表明这种方法是有效的.     

乙炔干燥变温吸附装置安全性分析与燃爆事故预防对策

针对乙炔变温吸附装置的燃爆事故问题,采用HAZOP方法对该装置进行安全性分析,找出存在的安全隐患,提出整改措施,指出装置发生燃爆事故的可能性;又将该装置可能发生的燃爆事故作为顶上事件,利用FTA方法进行分析,得到了装置发生燃爆事故的可能原因,制定了预防发生燃爆事故的对策。通过将HAZOP和FTA分析方法结合使用,有效地识别出乙炔装置存在的隐患,降低了装置操作的危险性,预防了燃爆事故的发生,值得推广应用。     

The effectiveness of process safety management (PSM) regulation for chemical industry in Korea

From the 1960s, Korean industries have been encouraged by the government to nurture heavy and chemical industry and to modernize the economics and industrial structures. The development of chemical industry particularly became the turning point in industrial development, and played a major role in the construction of a new industrialized country. However, the process systems in the chemical industry have become more complex and larger, and the inventories of dangerous chemicals that are produced or consumed have continuously increased. Therefore, the hazards from potential accidents such as fire and explosion or release of toxic chemicals have also increased. In fact, from the end of 1980s to the beginning of 1990s in Korea, a number of major industrial accidents such as ABS extruder explosion, TDI release and dryer explosion, etc. occurred and caused many fatalities. As the chemical companies recognized the importance of preventing major hazards, PSM system, the prevention of major industrial accidents, was introduced in January 1995 by amending Industrial Safety and Health Act, and it has been enforced from January 1, 1996. According to the law, the business owner of a workplace with hazardous or dangerous equipment shall submit a process safety report to the Government to prevent any accidents, which could inflict an immediate damage on workers or on areas in the vicinity of the workplaces. As a result of PSM implementation for 7 years, various kinds of effectiveness have been made. Accident rate including number of fatalities has been decreased, and productivity has been increased as well as product quality.     

油罐区泄漏及火灾危险危害评价

对某大型油罐区进行泄漏及火灾的危险危害评价.采用毒性物质泄漏扩散模型模拟油罐的泄漏事故,得出了泄漏介质在罐区附近的等质量浓度分布曲线;采用池火火焰与辐射强度模型,计算油罐、输油管道、汽车装油栈台等发生池火灾时的热辐射强度,并结合不同辐射强度值对人和设备的影响程度,给出了池火灾的影响范围.     

HAZOP研究与故障树分析在合成氨装置危险辨识中的应用

合成氨装置的原料、产品危险性高,并且生产过程复杂,因此在运行过程中可能导致火灾、爆炸、中毒等事故,有些事故甚至给社会和环境造成严重破坏.对HAZOP研究与故障树分析进行组合,应用在合成氨装置的危险辨识中.通过HAZOP研究,合成氨主体装置共发现风险因素23项,其中合成氨装置的合成气压缩单元安全隐患较多,因此对其进行故障树分析,合成气压缩机单元火灾、爆炸故障树的最小割集为72个,最小径集为6个.从基本事件结构重要度结果来看,压缩机三级出口压力探测器( PIA3-2)故障,对压缩机发生火灾、爆炸的影响程度最大,应重点防范.     

Noise and neurotoxic chemical exposure relationship to workplace traumatic injuries: A review

IntroductionMore than 5,000 fatalities and eight million injuries occurred in the workplace in 2007 at a cost of $6 billion and $186 billion, respectively. Neurotoxic chemicals are known to affect central nervous system functions among workers, which include balance and hearing disorders. However, it is not known if there is an association between exposure to noise and solvents and acute injuries. Method: A thorough review was conducted of the literature on the relationship between noise or solvent exposures and hearing loss with various health outcomes. Results: The search resulted in 41 studies. Health outcomes included: hearing loss, workplace injuries, absence from work due to sickness, fatalities, hospital admissions due to workplace accidents, traffic accidents, hypertension, balance, slip, trips, or falls, cognitive measures, or disability retirement. Important covariates in these studies were age of employee, type of industry or occupation, or length of employment. Discussion: Most authors that evaluated noise exposure concluded that higher exposure to noise resulted in more of the chosen health effect but the relationship is not well understood. Studies that evaluated hearing loss found that hearing loss was related to occupational injury, disability retirement, or traffic accidents. Studies that assessed both noise exposure and hearing loss as risk factors for occupational injuries reported that hearing loss was related to occupational injuries as much or more than noise exposure. Evidence suggests that solvent exposure is likely to be related to accidents or other health consequences such balance disorders. Conclusions: Many authors reported that noise exposures and hearing loss, respectively, are likely to be related to occupational accidents. Practical applications: The potential significance of the study is that findings could be used by managers to reduce injuries and the costs associated with those injures.     

可移动危险源动态安全监控的探索与展望

简述近年来可移动危险源的严重事故及惨痛教训,究其重要原因之一就是缺乏对可移动危险源的动态安全监控,指出开展可移动危险源动态安全监控的迫切性;从而对建立可移动危险源动态安全监控体系的指导思想与功能设计进行了比较深入的探索,利用全球移动通信系统(GSM),全球定位系统(GPS),地理信息系统(GIS)和计算机网络技术相结合,对可移动危险源实施动态安全监控,以实现对其严重事故的有效控制,并对完善可移动危险源动态安全监控体系作了进一步的展望。     

Managing process chemicals,technology and equipment information for pilot plant based on Process Safety Management standard

Injuries, accidents or even fatalities while working in pilot plant are reported worldwide. The OSHA Laboratory Standard and Hazard Communication Standard have been used as a guideline to manage safety of laboratories and pilot plant. In spite of the implementation of these standards, incidents which result in injuries and property loss are continuously occurring. The implementation of OSHA Process Safety Management (PSM) Standard in pilot plant is expected to further reduce the risks of accidents. This paper presents a new system for managing process chemicals, technology and equipment information in pilot plant and the concept is developed based on Process Safety Information (PSI) element of PSM 29 CFR 1910.119(d). It provides organized strategies to manage documentations, communicate information, and written program for maintaining, revising and updating related information. Process and Instrumentation Diagram (P&ID) is used as a foundation for data management. Implementation of this system at the CO₂ Hydrocarbon Absorption System pilot plant as a case study is examined and discussed.     

Practical safety management for small or medium enterprises

The article is intended for those who are not safety professionals but are responsible for safety management in a small or medium enterprise (SME) of the process industry. It assumes that a SME is loosely coupled and of low complexity and has a small number of major hazards present in it. The article describes Elementary Safety Management (ESM) as a combination of activities that maintain openness to safety impulses with Elementary Risk Control (ERC). ERC uses four milestones and three rules to get to the necessary and sufficient selection of control measures, which will achieve an acceptable level of risk. To make the ESM scheme as simple as possible, the term causal event is used, which is derived from the term causal factor. Practical Safety Management (PrSM) adds to the ESM the knowledge and skills that a person, who is supposed to design and implement a safety management system, needs. The PrSM procedure is developed to identify optimum controls. The procedure recognizes the unavoidable role of commitment to safety, respects the role of hazard identification, and integrates prospective and retrospective analyses and current knowledge of safety management systems. Examples of application of the procedure are given in the article.     

论安全学科的内涵与本科教育课程体系建设

安全学科的内涵是该学科本科教学课程体系建设的基础。学科内涵包括学科研究对象、研究目的、学科属性、研究方法、研究范围、研究内容、基本概念和基本公理。就安全学科来说 ,其研究对象可以简单地认为是损失程度范围非常宽广的事故 ,研究目的当然就是预防事故和控制事故损失 ;由于事故的发生既有社会、人文方面的原因 ,也有自然方面的原因 ,所以安全学科的研究方法就不可能是单一的 ,学科的属性也就具有人文、社会、自然等多重性。由于社会组织最有可能控制事故发生的原因 ,所以安全学科的研究范围一定是一个大到国家、地区 ,小到企业的社会组织 ,组织之内预防事故和控制事故损失的各种方法构成了安全学科的研究内容。该学科有危险源、风险、事故、安全和危险 5个基本概念 ,也可以识别出至少 4条基本公理。以上述学科内涵为理论基础 ,可以构建出近年来作为讨论焦点的安全学科本科教学课程体系。     

Thermal hazard accident investigation of hydrogen peroxide mixing with propanone employing calorimetric approaches

Hydrogen peroxide (H₂O₂), historically, due to its broad applications in the chemical industries, has caused many serious fires and explosions around the world. Its thermal hazards may also be incurred by an incompatible reaction with other chemicals, and a runaway reaction may be induced in the last stage. This study applied thermal analytical methods to explore the H₂O₂ leading to these accidents by incompatibility and to discuss what might be formed by the upset situations. Thermal hazard analysis contained a solvent, propanone (CH₃COCH₃, so-called acetone), which was deliberately selected to mix with H₂O₂ for investigating the degree of thermal hazard. Differential scanning calorimetry (DSC) and vent sizing package 2 (VSP2) were employed to evaluate the thermal hazard of H₂O₂. The results indicated that H₂O₂ is highly hazardous while mixed with propanone, as a potential contaminant. The time to maximum rate (TMR) was used as emergency response time in the chemical industries. Therefore, TMR of H₂O₂ was calculated to be 70 min for runaway reaction (after T₀) and TMR of H₂O₂/propanone was discovered to be 27 min only. Fire and explosion hazards could be successfully lessened if the safety-related data are properly imbedded into manufacturing processes.     

Arabian,Asian, western: a cross-cultural comparison of aircraft accidents from human factor perspectives

Introduction. Rates of aviation accident differ in different regions; and national culture has been implicated as a factor. This invites a discussion about the role of national culture in aviation accidents. This study makes a cross-cultural comparison between Oman, Taiwan and the USA. Method. A cross-cultural comparison was acquired using data from three studies, including this study, by applying the Human Factors Analysis and Classification System (HFACS) framework. The Taiwan study presented 523 mishaps with 1762 occurrences of human error obtained from the Republic of China Air Force. The study from the USA carried out for commercial aviation had 119 accidents with 245 instances of human error. This study carried out in Oman had a total of 40 aircraft accidents with 129 incidences. Results. Variations were found between Oman, Taiwan and the USA at the levels of organisational influence and unsafe supervision. Seven HFACS categories showed significant differences between the three countries (p?<?0.05). Conclusion. Although not given much consideration, national culture can have an impact on aviation safety. This study revealed that national culture plays a role in aircraft accidents related to human factors that cannot be disregarded.