Simple graphical method for inherent occupational health assessment

The concept of inherently safer design was introduced to design a fundamentally safer process so that hazards can be avoided or minimized rather than controlled or managed. The ideology has later been extended to the environmental, but not health criteria due to its complicated underlying principles. Even though health risk methods are already established, majority are for existing plants assessment. Early consideration of health aspect starting from process design stage however, has received much less attention. This paper introduces a simple graphical method to evaluate the inherent occupational health hazards of chemical processes during the R&D stage. A survey was conducted to identify the important health parameters for the graphical method development, involving nine world inherent safety and health experts. Based on their input, process mode, material volatility, operating pressure and chemical health hazard (toxicity and adverse effect) are the significant factors affecting inherent health hazards of chemical processes. The choice of parameters was bounded by the information availability at this stage. The method was applied on six routes to methyl methacrylate and ten routes to acetic acid. The parameters were plotted for each subprocess of the alternative routes. The ‘healthiest’ route was selected based on thorough hazards assessment across all the subprocesses. The first case study reveals the tertiary butyl alcohol as the ‘healthiest’ one as it poses relatively lower, or at least comparable hazards to the other routes due to exposure and health impacts. Meanwhile the acetic acid case study indicates ethanol oxide and ethyl oxide based routes as the inherently healthier as they operate at lower operating pressure besides posing comparable hazards level for the other three parameters, compared to the other routes. The case studies show that the inherent occupational health of a chemical process can already be evaluated easily in the R&D stage with the simple graphical method proposed.     

Computer-aided assessment of occupationally healthier processes during research and development stage

Each year more people die from occupational related diseases than are killed in industrial accidents. Therefore it is critical to start considering health aspect early when developing a new chemical process. In this paper, a computer-aided tool for assessing inherent occupational health is proposed for chemical process research and development stage. The method was developed based on the reaction chemistry data, which is the only data available at this stage. Three types of approaches were formulated to calculate the route index value using additive type, average type and worst case type calculations. The tool can be used to rank the alternative chemical synthesis routes by their health properties as well as characterize the hazard level of single process. Finally the tool was applied to six process routes for methyl methacrylate production for demonstration. The case study revealed hazards of the processes from different perspectives, e.g. the results from the additive-type calculation were mainly affected by the total number of steps in the route, which indicates the impact of process complexity on the level of hazard. The introduction of such tool provides a swift yet reliable means that will encourage health criteria to be considered earlier in process development besides economic, safety and environment.     

Assessing the likelihood of secondary crashes on freeways with Adaptive Signal Control System deployed on alternate routes

Introduction: Reducing the likelihood of freeway secondary crashes will provide significant safety, operational and environmental benefits. This paper presents a method for assessing the likelihood of freeway secondary crashes with Adaptive Signal Control Systems (ASCS) deployed on alternate routes that are typically used by diverted freeway traffic to avoid any delay or congestion due to a freeway primary crash. Method: The method includes four steps: (1) identification of secondary crashes, (2) verification of alternate routes, (3) assessment of the likelihood of secondary crashes for freeways with ASCS deployed on alternate routes and non-ASCS (i.e. pre-timed, semi- or fully-actuated) alternate routes, and (4) investigation of unobserved heterogeneity of the likelihood of freeway secondary crashes. Four freeway sections (i.e., two with ASCS deployed on alternate routes and two non-ASCS alternate routes) in South Carolina are considered. Results and Conclusions: Findings from the logistic regression modeling reveal significant reduction in the likelihood of secondary crashes for one freeway section (i.e., Charleston I-26 E) with ASCS deployed on alternate route. Other factors such as rear-end crash, dark or limited light, peak period, and annual average daily traffic contribute to the likelihood of freeway secondary crashes. Furthermore, random-parameter logistic regression model results for Charleston I-26 E reveal that unobserved heterogeneity of ASCS effect exists across the observations and ASCS are associated with the reduction of the likelihood of freeway secondary crashes for 84% of the observations (i.e., primary crashes). Location of the primary crash on the freeway is observed to affect the benefit of ASCS toward freeway secondary crash reduction as the primary crash’s location determines how many upstream freeway vehicles will be able to take the alternate route. Practical Applications: Based on the findings, it is recommended that the South Carolina Department of Transportation (SCDOT) considers deploying ASCS on alternate routes parallel to freeway sections where high percentages of secondary crashes are found.     

Evaluation of EHS hazard and sustainability metrics during early process design stages using principal component analysis

A principal component analysis (PCA) based methodology accounting for EHS hazard and sustainability metrics has been recently proposed in literature (Srinivasan and Nhan, 2008) to deal with the subjective weighting problem of existing index-based methods. In this study we evaluate the potential use of the PCA-based method during early phases of process design in the problem of selection between various synthesis paths, also called chemical routes, for the production of chemical compounds. The study also focuses on the impact of the methodology settings on the obtained chemical route rankings and their interpretation. Two case studies have been performed regarding the production of 4-(2-methoxyethyl)-phenol (MEP) and methyl methacrylate (MMA) using fifteen different evaluation categories capturing various sustainability metrics. The PCA-based method identified the most promising chemical routes as well as the most important evaluation categories. The necessity for normalization of the raw data was demonstrated, without the method being very sensitive to the type of normalization. Moreover, the effect of the transition approach from chemical step to chemical route scores is discussed. The results of the PCA-based method are also compared with an index-based method (Koller et al., 2000) sharing the same evaluation categories, as well as with other index-based frameworks in order to reveal the extent of similarities.     

Inherent occupational health assessment during process research and development stage

Occupational health studies the interaction of work and health, especially the long-term effect of chemicals to health. In this paper an Inherent Occupational Health Index has been developed for assessing the health risks of process routes during process research and development stage. The method takes into account both the hazard from the chemicals present and the potential for the exposure of workers to the chemicals. The index can be used either for determining the level of inherent occupational health hazards or comparing alternative process routes for these risks. The method is tailored for the process research and development stage by including only such properties of chemicals and operating conditions of process, which are available already in this early stage. In the end of this paper the approach is demonstrated by comparing the inherent occupational healthiness of six methyl methacrylate process routes using three different types of index calculations; additive-type, average-type, and worst case-type. The study discloses that the average- and worst case-based approaches analyze the characteristics of a route better than the additive calculation, which is greatly affected by the number of steps in the route. A quantitative standard scale for the index is also developed to allow health level assessment of a single process.     

基于集对分析的化工工艺本质安全性评价方法

为了提高化工工艺本质安全性评价的有效性和全面性,根据集对分析理论建立了四元联系数评价模型。模型选用传统的本质安全指标及其分级标准,对各指标进行赋权,以甲基丙烯酸甲酯合成工艺路线为例进行实用性验证,最终确定了多条工艺路线的本质安全程度优劣顺序,并明确各自的本质安全程度。结果表明,集对分析方法能够客观全面地评价化工工艺路线的本质安全性,可以用于化工工艺路线的优选过程,为工艺安全管理和技术改进提供指导。     

基于本质安全的化工工艺物质危险指数研究

建立了基于本质安全的化工工艺物质危险性的评价体系,包括火灾危险性、爆炸危险性以及毒性等3个评价指数.基于风险的思想,各个评价指数均包括概率指标与后果指标.为了全面反映化工工艺的实际情况,在各个评价指数中均对所有物质的相应指数值加和.参数的取值以以往的指数法为基础,为了消除边界波动效应,取值采用内插法.由于各个指数的量纲...     

环境风险源及其分类方法研究

环境风险源的分类是进行环境风险源识别和监管的基础.已有的以人的安全为主要关注对象的重大危险源管理,对事故的潜在环境危害考虑欠缺,无法体现事故可能产生的环境风险影响.阐明环境风险源的基本概念,比较环境风险源与危险源的区别,针对环境风险源的特点,从环境受体、危害物质状态和风险传播方式3个方面提出了环境风险源的分类方法.实际应用中,环境风险源的分类需综合考虑当地环境管理需求、环境受体状况、主要危害物质类别等,选择合适的分类方法.     

A societal risk study for transportation of class-3 hazmats – A case of Indian state highways

United Nations Class-3 hazardous materials (hazmats) are basically liquid products and transported in road tankers under ambient temperature and atmospheric pressure. They are mostly flammables and some of them are toxic (e.g. benzene) as well. The spillages due to collision related incidents involving the road tankers, carrying such hazmats through highways, pose not only flammability hazards due to pool fire, flash fire and vapor cloud explosion (VCE), but create substantial toxic hazards also. The paper presents the risk-based study of route evaluation of two state highways and one urban city road in western India on account of transportation of class-3 hazmats, namely benzene, toluene, p-xylene, methanol, cyclohexane and acetone. A comparative evaluation of study routes was undertaken based on their societal risks presented in terms of F–N curves and assessed against HSE, UK as well as VROM, The Netherlands risk acceptance criteria. Societal risks contribution of cyclohexane to the overall flammability risk mainly VCE is found to be the highest followed by acetone and benzene compared to other study hazmats. This is due to highly explosive nature of cyclohexane resulting into vapor cloud explosion. While acetone and methanol pool fires are likely to cause larger area of damage compared to others, benzene supersedes others as far as toxicity risk is concerned and larger evacuation area is encountered, as it poses greater Immediately Dangerous to Life or Health (IDLH) distance than others. Besides, study of initial isolation distance following an accident in case of benzene tanker found that benzene spillage requires larger initial isolation distance than others and so are the day and night protective action zone distances.     

“积木式做法”研究及对我国实施GHS范围的建议

从分析我国实施GHS的问题出发,详细研究GHS的"积木式做法",指出实施GHS可以根据实际情况有选择地采用其危险性分类。同时分析我国现阶段化学品相关实验室技术支撑能力,结合目前化学品监管范围,提出实施GHS的重点,要先实现我国化学品监管范围与GHS相关危险性的分类统一,再逐步将GHS其他危险性分类引入我国危险化学品监管范围,并对现阶段实施GHS的危险性种类和类别提出启动物理化学性质引起的危险、急性毒性和皮肤腐蚀/刺激性、危害水生环境分类标准的实施工作建议。     

火电厂液氨泄漏事故影响分析及对策研究

主要对火电厂液氨泄漏事故后对周围大气环境的影响进行了预测分析研究,并给出了相应安全对策。研究以陕西某电厂2×660MW燃煤机组为例,使用详实可靠的参数对该电厂可能发生的液氨储罐泄漏事故进行了不同气象条件下的风险模拟预测,并根据预测结果画出了可供应急救援参考使用的最不利气象条件下液氨储罐最大可信事故泄漏后不同时刻的影响范围动态图。研究还根据收集到的施工设计资料及参数对200-1000MW级火电厂的液氨泄漏进行了预测,给出各级别火电机组液氨泄漏事故后可能出现的最大致死半径范围。为降低火电厂液氨泄漏风险提出了相应的安全对策和应急救援要求,对避免和减少液氨中毒伤亡事故具有指导意义。     

Qualitative Assessment for Inherently Safer Design (QAISD) at preliminary design stage

Conventional hazard evaluation techniques such as what-if checklist and hazard and operability (HAZOP) studies are often used to recognise potential hazards and recommend possible solutions. They are used to reduce any potential incidents in the process plant to as low as reasonably practicable (ALARP) level. Nevertheless, the suggested risk reduction alternatives merely focus on added passive and active safety systems rather than preventing or minimising the inherent hazards at source through application of inherently safer design (ISD) concept. One of the attributed reasons could be the shortage of techniques or tools to support implementation of the concept. Thus, this paper proposes a qualitative methodology that integrates ISD concept with hazard review technique to identify inherent hazards and generate ISD options at early stage of design as proactive measures to produce inherently safer plant. A modified theory of inventive problem solving (TRIZ) hazard review method is used in this work to identify inherent hazards, whereby an extended inherent safety heuristics tool is developed based on established ISD principles to create potential ISD options. The developed method namely Qualitative Assessment for Inherently Safer Design (QAISD) could be applied during preliminary design stage and the information required to apply the method would be based on common process and safety database of the studied process. However, user experiences and understanding of inherent safety concept are crucial for effective utilisation of the QAISD. This qualitative methodology is applied to a typical batch reactor of toluene nitration as a case study. The results show several ISD strategies that could be considered at early stage of design in order to prevent and minimise the potential of thermal runaway in the nitration process.     

危险品道路运输风险分级指数法研究

危险品道路运输过程风险影响因素多,随机性和不确定性大,定量风险评价比较复杂,至今没有统一的风险评估模型.为了有效预防危险品运输事故和进行快速风险评估,基于运输危险品本身特性和相关的风险影响因素探讨了运输危险品现实风险分级指数法.该方法由危险品风险分级指数、路线影响因素和安全措施补偿因子3部分构成.危险品风险分级指数由危险品加权平均风险等级和运输危险品量、泄漏点与居民区距离以及危险品扩散因子等级确定.危险品加权平均风险等级涉及其健康危害性、可燃性、化学反应活性以及特殊危险性(氧化性和与水反应性)等级的确定.路线影响因素包含运输道路特征、气象条件、交通状况和影响人员分布4类.安全措施补偿因子为车辆、设备、容器、包装因子,人员素质因子和安全管理因子3类.该方法可对运输危险品的潜在风险进行快速分级,有利于采取有效的安全预防和控制措施,降低运输事故概率和沿线影响人员风险.     

基于模糊综合评价的化工工艺本质安全指数研究

建立化工工艺的本质安全评价指标体系,包括可燃性、爆炸性、毒性、反应性、温度、压力、储量等7个指标。为解决前人指数法中的边界波动效应,采用模糊综合评价建立化工工艺本质安全评价指数模型,确定各指标的权重、危险分级及对各分级的隶属函数。以甲基丙烯酸甲酯的5条工艺路线为例进行分析,结论与前人提出的指数方法的评价结果相吻合,表明该指数方法可以用来进行化工工艺的本质安全评价,以指导设计初期的本质安全型工艺路线选择。     

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.     

化工过程开发中本质安全化设计策略

本质安全化设计是预防人为失误及设备失效、降低化工过程风险应优先采用的技术。在比较传统设计方法与本质安全化设计方法的基础上,讨论了化工过程开发各阶段实现本质安全的机会,认为在开发初期,实施本质安全化的成本低,难度小;通过分析可行性研究、工艺研究、概念设计、基础设计、工程设计等阶段本质安全化设计的影响因素、设计目标和设计方法,探索化工过程开发中本质安全化设计策略,提出了化工过程本质安全化设计流程。通过工艺过程本质安全设计、工艺流程的简化和优化、不同设计方案的本质安全度评估等措施,可提高化工过程本质安全水平。     

设计初期化工过程本质安全化设计策略

该文提出了一种在设计初期进行化工过程本质安全化设计的策略。首先进行危险物质与危险能量两类共计11种危险类型的危险辨识。针对辨识出的危险类型,通过与相应的临界条件比较进行快速的危险评价,对于不可接受的危险必须采取本质安全化措施,可接受的危险可有选择性地进行本质安全化设计。在设计初期可以使用的本质安全化原则主要是消除、最小化、替代和缓和,针对11种危险类型可以应用不同的本质安全化设计模型,以使实际进行本质安全化设计时更加简单与快捷。该文把提出的本质安全化设计策略应用到一个甲苯硝化制硝基甲苯的工艺,形成了多种本质安全化措施,可以用来在设计初期消除或减少危险。     

存在多种化学有害物质作业场所危害性评价

作业场所同时存在多种化学有害物质的情形并不少见,如何对这类作业场所的危害性进行科学合理的综合评价是一个重要的课题。本文针对这类作业场所提出了一种简便可行的危害性评价方法,该方法以危害物质自身的危害特性如毒性、危害器官、吸收途径、致癌性和检测浓度为评价依据,较全面地反应了有害物质的危害性,对同时存在多种化学有害物质的作业场所的危害性评价与职业危害治理具有一定的现实意义。