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。     

生产过程危险有害因素辨识方法与流程

危险有害因素辨识、危险等级评定与安全对策措施的提出是安全评价的主要任务,是发现危险源头的重要手段.生产过程危险有害因素的辨识工作是一项系统工程,作为安全评价工作的重中之重,辨识的全面与否和深度直接影响评价结果的好坏和措施的针对性.根据危险有害因素存在的特点,从危险源分析人手,同时考虑工艺条件、操作环境、危险故障状态等因素,提出危险辨识的基本要素和流程,从而使辨识人员避免在危险辨识过程中由于操作不规范而发生遗漏的现象发生.     

接地系统危险辨识及其对策措施

接地工程作为一种电气减灾技术,在易燃易爆场所、变电站、发电厂及高大建筑物上都有着广泛的应用。该技术的使用可以有效地避免因过电压和人身触电造成的设备损坏和人身伤害,有效的接地装置可以减少生产事故的发生,但由于接地工程是一种交叉科学,涉及知识面广,生产的诸多环节许多致害因素常常被使用者忽视,而造成设备过电压事故和人身触电。因此对接地系统进行危险辨识具有重要的现实意义。本文将各类接地视为一个大系统,采用系统安全分析危险辨识方法对防雷接地、工作接地、保护接地、静电接地进行危险辨识,在安全技术与管理方面提出了对策措施与建议。文章最后,对接地工程技术发展方面需要重点解决的问题进行了总结,以便为接地工程与技术的发展提供积极的借鉴作用,更好地为安全生产服务。     

性能化设计思想在化工设施布局安全设计中的应用

指令性规范是目前化工设施平面布局安全设计的主要依据,但其在应用中存在着条款僵化、安全理论基础不全面、可拓展性不明确等问题。本文将性能化设计思想引入到化工企业平面布局安全设计中,初步提出了一种包含危险辨识、性能化目标确定、后果评估及安全设施效用评估等主要组成部分的基于性能化设计思想的平面布局安全设计体系。对体系中最重要的部分—性能化目标确定进行了重点分析,将化工设施布局安全设计分为装置内设备之间的位置设计、厂区内装置区之间的位置设计以及厂区与外部单位之间的位置设计三个级别,从工艺关联性等角度对各级别布局设计中事故场景选择及设施可接受受损水平进行分析,并提出了通过匹配事故场景和设施可接受受损水平来确定性能化目标的方法。     

如何有效提升研究所安全发展能力

论文结合兵器研究所安全生产特点及安全现状,提出通过"本质安全性设计、危害辨识"技术措施和"落实安全主体责任、实施安全精益管理"等管理措施,加强事故预防,提升研究所安全发展能力。     

危险化工工艺风险辨识方法研究

在安监总局划分的15类危险化工工艺的基础上,参考日本劳动省"六阶段"的定量评价表以及危险度评价法,提出了一种新的危险化工工艺辨识方法.此方法更便于区别化工企业生产工艺是否属于危险化工工艺,从而为政府及企业更好地管理提供便利,进一步实现本质安全化.     

化工装置火灾、爆炸、毒物扩散危险快速辨识方法

化工装置火灾、爆炸、毒物扩散的危险辨识是进一步进行定量化风险评估等安全分析的基础,笔者提出考虑该3种破坏效应显著的11种事故模式,以化工装置的介质性质、操作条件等参数作为基本事件对各种事故模式进行事故树分析;从而得到各基本参数对不同事故模式发生的影响并以其为依据建立了一种基于危险分析调查表和事故模式-字符串映射表的问卷式快速危险辨识体系;最后采用VB6.0作为开发平台,对该辨识系统进行了软件化实施。     

运输系统中的危险辨识及其安全控制

笔者将运输系统的危险分为两类 :固有危险、变动危险 ;并给出两类危险的定义 ;对构成两类危险的因子进行了深入的讨论 ;提出辨识运输系统两类危险的基本方法 ,即静态辨识法和动态辨识法 ;对两种方法的应用范围及条件进行了初步界定。在对运输系统进行危险辨识的基础上 ,就如何运用控制论的理论与方法解决运输系统的安全控制问题进行探讨 ;提出系统安全状况的恶化实际上是系统中危险因素失控的结果。保证系统安全的核心任务是对系统危险因子进行控制。就运输系统而言 ,对系统变动危险因子的控制要比固有危险系统困难。     

路堑施工中的爆破设计及安全对策

路堑施工中的爆破在我国目前的工程爆破中占很大的比例,施工中存在很多安全隐患,一旦发生事故,将会导致人员伤亡和财产损失.针对具体的路堑工程,选择合理的爆破设计参数,设计爆破网络,进行爆破施工的设计,然后确定爆破方案,进行安全校核,并运用安全评价的方法辨识施工中存在的危险有害因素,提出适当的合理的安全对策措施.     

煤矿区域探查治理工程安全风险评估应用研究

针对煤矿区域探查治理工程中危险因素概念不清、辨识对象多,安全风险评价环节繁杂、危险因素分级与安全风险分级混用等问题,在现有安全风险研究理论基础上,提出适用公司的危险因素和事故隐患概念,明确了危险因素辨识对象和安全风险评价对象并分别进行分级,将危险因素辨识对象和安全风险评价对象从数百项缩减至几十项,优化了危险因素辨识环节和安全风险评估环节;在安全风险分布图方面提出将平面布置图、安全风险分布图、应急疏散平面图“三图”合一,对类似工程安全风险评估具有较强的实践指导作用。     

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.     

Strategies for assessing and reducing inherent occupational health hazard and risk based on process information

Over the last few decades, the concept of inherent occupational health has gained increasing attention to reduce occupational hazards that may adversely impact workers’ health. In order to assess occupational hazards in the chemical process, different inherent occupational health assessment methods have been developed at the early stages of process development and design. The methods in the order of process information availability – ranging from the detailed piping and instrumentation diagrams to a simple sketch of process concepts are the: occupational health index (OHI), health quotient index (HQI) and inherent occupational health index (IOHI). This paper proposes systematic heuristic frameworks to assist process designers and engineers in assessing and reducing inherent occupational health hazards or risks based on process information availability. Strategies for reducing health hazards or risks in the OHI, HQI and IOHI methods based on inherently safer design (ISD) keywords of minimization, substitution, moderation and simplification are included in this study. It is worth mentioning that the proposed frameworks act as guidelines for design engineers in systematically selecting the appropriate index and methodology to assess and reduce health hazards/risks based on the availability of the process information. A case study is solved to illustrate the proposed framework.     

Study of chemical supply system of high-tech process using inherently safer design strategies in Taiwan

The photoelectric, semiconductor and other high-tech industries are Taiwan's most important economic activities. High-tech plant incidents are caused by hazardous energy, even when that energy is confined to the inside of the process machine. During daily maintenance procedures, overhauling or troubleshooting, engineers entering the interior of the machines are in direct contact with the source of the energy or hazardous substances, which can cause serious injury. The best method for preventing such incidents is to use inherently safer design strategies (ISDs); this approach can fully eliminate the dangers from the sources of hazardous energy at a facility.This study first conducts a lithography process hazard analysis and compiles a statistical analysis of the causes of the fires and losses at high-tech plants in Taiwan since 1996, the aim being to establish the necessary improvement measures by using the Fire Dynamics Simulation (FDS) to solve relevant problems. The researchers also investigate the lithography process machine in order to explore carriage improvement measures, and analyse the fires' causes and reactive materials hazardous properties, from 1996 to 2012. The effective improvement measures are established based on the accident statistics. The study site is a 300 mm wafer fabrication plant located in Hsinchu Science Park, Taiwan.After the completion of the annual maintenance jobs improvement from September 2011 to December 2012, the number of lithography process accidents was reduced from 6 to 1. The accident rate was significantly reduced and there were no staff time losses for a continuous 6882 h. It is confirmed that the plant safety level has been effectively enhanced. The researchers offer safety design recommendations regarding transport process appliances, chemical storage tanks, fume cupboard devices, chemical rooms, pumping equipment, transportation pipelines, valve manual box (VMB) process machines and liquid waste discharge lines. These recommendations can be applied in these industries to enhance the safety level of high-tech plants, facilities or process systems.     

Inherent risk assessment methodology in preliminary design stage: A case study for toxic release

At preliminary design stage, process designers normally lack of information on the risk level from process plant. An inherently safer process plant could be designed if the information of risk levels could be known earlier at the preliminary design stage. If the risk level could be determined, there is a possibility to eliminate or reduce the risk by applying the well-known concept: inherent safety principle. This paper presents a technique to determine the risk levels at preliminary process design stage using a 2-region risk matrix concept. A model to calculate the severity and likelihood of a toxic release accident was developed in Microsoft Excel spreadsheet. This model is integrated with process design simulator, iCON to allow for data transfer during preliminary design stage. 2-region risk matrix is proposed and used to evaluate the acceptability of the inherent risk based on the severity and likelihood rating. If the inherent risk level is unacceptable, modification for improvement can be done using the inherent safety principles. A case study has been carried out to illustrate the benefit of applying this newly developed technique. It was successfully shown that an inherently safer plant could easily be designed by applying this technique.     

Inherent risk assessment—A new concept to evaluate risk in preliminary design stage

Quantitative Risk Assessment (QRA) has been a very popular and useful methodology which is widely accepted by the industry over the past few decades. QRA is typically carried out at a stage where complete plant has been designed and sited. At that time, the opportunity to include inherent safety design features is limited and may incur higher cost. This paper proposes a new concept to evaluate risk inherent to a process owing to the chemical it uses and the process conditions. The risk assessment tool is integrated with process design simulator (HYSYS) to provide necessary process data as early as the initial design stages, where modifications based on inherent safety principles can still be incorporated to enhance the process safety of the plant. The risk assessment tool consists of two components which calculate the probability and the consequences relating to possible risk due to major accidents. A case study on the potential explosion due to the release of flammable material demonstrates that the tool is capable to identify potential high risk of process streams. Further improvement of the process design is possible by applying inherent safety principles to make the process under consideration inherently safer. Since this tool is fully integrated with HYSYS, re-evaluation of the inherent risk takes very little time and effort. The new tool addresses the lack of systematic methodology and technology, which is one of the barriers to designing inherently safer plants.     

Inherently safer design review and their timing during chemical process development and design

This paper discusses the enhancement of inherent safety review and its implementation in the chemical process development and design. The aim is to update and improve the existing inherently safer design review (ISDR) practices during design of chemical process plant by exploiting major accident cases from the U.S. Chemical Safety Board (CSB) and Failure Knowledge Database (FKD). Although the basic guidelines to conduct ISDR during design phase are available, however they are too general and incomplete. The review criteria and their best timing for application are still missing. This paper attempts to develop the accident-based ISDR for chemical process plant design. The proposed accident-based ISDR is supported with detail review criteria for each phase of process design. The timing of ISDR application is corresponding to the common design tasks and decisions made in the design project. Therefore, timely design review could be done at the specific design task and the findings help designer to make a correct decision making.     

Inherently safer design in offshore oil and gas projects

Like all hazardous installations, inherently safer design (ISD) is one of the key tools in offshore oil and gas projects to minimize risks in offshore facilities. As the life cycle of offshore facilities is relatively short compared with onshore counterparts and there are many projects running every year, the potential is high for raising inherent safety standards and lowering safety risks throughout the offshore industry as old facilities are phased out. This paper gives an overview of offshore facilities and examples of implementation of ISD. Good examples of ISD are numerous. Industry guidance on ISD implementation abound. Yet, the systematic implementation of it in the industry is patchy. There are many reasons for factors which impede the effective, efficient and consistent implementation of ISD in projects. This paper describes some of them and proposes solution to address them. They include (a) the effective integration of ISD into hazard management systems with appropriate language to engage all disciplines in projects, (b) the phasing of resources to enable the project to capture ISD measures which are only available during early phases, (c) application of appropriate ISD goals and ISD performance metrics at various stages and (d) the appropriate use of quantified risk assessment to support ISD.     

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...