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.     

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.     

A comparative analysis of process safety management (PSM) systems in the process industry

The root cause of most accidents in the process industry has been attributed to process safety issues ranging from poor safety culture, lack of communication, asset integrity issues, lack of management leadership and human factors. These accidents could have been prevented with adequate implementation of a robust process safety management (PSM) system. Therefore, the aim of this research is to develop a comparative framework which could aid in selecting an appropriate and suitable PSM system for specific industry sectors within the process industry. A total of 21 PSM systems are selected for this study and their theoretical frameworks, industry of application and deficiencies are explored. Next, a comparative framework is developed using eleven key factors that are applicable to the process industry such as framework and room for continuous improvement, design specification, industry adaptability and applicability, human factors, scope of application, usability in complex systems, safety culture, primary or secondary mode of application, regulatory enforcement, competency level, as well as inductive or deductive approach. After conducting the comparative analysis using these factors, the Integrated Process Safety Management System (IPSMS) model seems to be the most robust PSM system as it addressed almost every key area regarding process safety. However, inferences drawn from study findings suggest that there is still no one-size-fits-all PSM system for all sectors of the process industry.     

The effectiveness of U.S. OSHA process safety management inspection – A preliminary quantitative evaluation

This study attempted to evaluate the inspection effectiveness of the U.S. OSHA process safety management (PSM) standard using statistical correlation test. A total of 6578 citations of past 1277 OSHA PSM inspections from 1992 to 2006 were quantitatively compared with the findings of the U.S. Chemical Safety and Hazard Investigation Board (CSB) investigations on root and contributing causes of 19 major chemical accidents. Nonparametric Spearman's coefficient of rank correlation tests showed a moderately strong agreement between OSHA PSM inspection citations and CSB findings at p < .01 significant level, and the degree of agreement increased with time. These results suggested that past OSHA PSM inspections had cited the problems that were the accident root causes, and the effectiveness of PSM citations has been improved as more inspections were conducted since the standard promulgation. However, factors such as standard coverage, inspection frequency, inspection resources allocation, and inspection strategy, were critical for effective PSM standard enforcement and implementation. Future studies should include more aspects of PSM citations and CSB accident investigation data for better evaluation of inspection effectiveness. The results may be valuable to the PSM enforcement policy makers.     

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.     

Process loss prevention of petrochemical process: A case study of the flashing accident of the storage tank on acrylonitrile-butadiene-styrene powder in Taiwan

Qualitative analysis, process hazard analysis, thermal evaluation, and fault tree analysis were applied to a flashing accident involving a storage tank that contained acrylonitrile-butadiene-styrene (ABS) powder in Taiwan. The accident was caused by combustible powder attached to the inner wall of the tank reaching a high temperature and then melting. Thereafter, the molten powder became glue-like and dropped onto the ABS powder, burning at the tank bottom, causing decomposition of the styrene and butadiene derivatives as well as other combustible gases. The high concentration of combustible powder and low ignition temperature triggered the powder, initiating a dust explosion. Finally, we analyzed the findings of each method and examined the properties of ABS powder, realizing that the root cause of the accident included an insufficient understanding of the characteristics of ABS and the failure to comply with the management procedures of hot work. Recommendations and countermeasures were proposed that could proactively ameliorate process safety.     

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.     

PDE accident model from a safety information perspective and its application to Zhangjiakou fire and explosion accident

Accident models can provide theoretical frameworks for determining the causes and mechanisms of accidents, and thus are theoretical bases for accident analysis and prevention. The role of safety information in accident causation is profound. Thus, safety information is an important and essential perspective for developing accident models. This study presents a new accident model developed from a safety information perspective, called the Prediction—Decision—Execution (PDE) accident model. Because the PDE accident model is an emerging accident model that was proposed in 2018, its analysis logic and viability remain to be discussed. Thus, the main contributions of this study include two aspects: (i) detailed explanation of the analysis logic of the PDE accident model, and (ii) case-study examination of the Zhangjiakou fire and explosion accident, a serious accident that occurred in China in 2018, to demonstrate the viability of the PDE accident model. Results show that this is a safety-information-driven accident model that can provide a new and effective methodology for accident analysis and prevention, and safety management.     

Bi-directional connectivity diagram for accident propagation analysis considering the interactions between multiple-process units

An incident may propagate to an accident with different severity dependent on its propagation scenarios. Since the accident propagation is a two-way process, the current research is focusing on the one-way analysis. This paper aims to analyze the combined effect of multi-units sources and their interactions during the accident propagation. The bi-directional connectivity diagram (BDCD) is applied to visualize the interactions between multiple process units as hazardous sources. The deployed safety barriers interrupt the connection between the hazardous sources and thus minimize the influence of one BDCD node on another. Through which, the accident propagation is reduced. The proposed method can be suitable to the general accidents, and it is applied to a case study of the LNG terminal station to assess the potential consequences of explosion caused by the leakage, in which the cost of the safety barrier is also considered. The BDCD approach is found more effective than traditional single-hazardous source methods for analyzing the accident propagation of multi-units sources in the chemical plant and achieving intrinsic safety.     

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。     

Process Safety Management (PSM) for managing contractors in process plant

Accidents involving contractors continue to occur with regular frequency. By using the standard set within the PSM 29 CFR 1910.119(h) regulations, it has been identified that certain aspects of the way contractors do work are not up to the stipulated regulatory requirements especially regarding matters like not providing mandatory personal protective equipment (PPE) to the workers, not discussing hazards related to handling procedures with the workforce and improper control of non-routine activities during changes in shifts. The PSM 29 CFR 1910.119(h) regulations promulgated in 1992 provides standards that covered processes to obtain and evaluate data regarding contractors' health and safety programs as well as the contractors' performance evaluation. Many of the accidents involving contractors are direct result of poor training of contractors and/or poor control of the contracted work. Even though most organizations have their own contractor management systems, there are issues in meeting the requirements of PSM. The PSM standard only state “what to do” not “how to do it”. This is known as self-regulatory policy which depends on the industries understanding to interpret the standard that also contribute to this problem. This paper presents a structured and easy technique to plan and implement a practical and comprehensive contractors' management system in process industries that will comply with OSHA CFR 1910.119. A model has been developed based on this technique and its application has been tested in a pilot plant for compliance to PSM regulation. The model is beneficial to the process industries as any deficiencies in the PSM contractors' management program will be highlighted by the model which will then easily correct the identified deficiency so as to minimize and prevent catastrophic accidents.     

核电厂人因事故预防的定量化决策

人因事故的分析与预防是核电厂安全运行和管理的重要内容。笔者提出的系统安全性层次分析法主要从两种角度考虑系统的安全性:专家能力权值和安全性矩阵的建立。采用专家判断矩阵确定事故原因对系统安全性的重要度排序。举例某核电厂事故定量分析进行说明,在对事故进行原因分析基础上,构建事故影响因素层次模型,利用层次分析法分析得出事故原因重要度排序由高到低依次为组织管理、操作人员、人机界面、培训与设备状态,并据此提出了相应的预防与改进措施,为安全性要求较高的复杂工业系统提供事故预防的定量化决策依据。     

Safety leadership and safety performance in petrochemical industries: The mediating role of safety climate

This study examines the relationship among three latent variables: safety leadership, safety climate, and safety performance. Employees from 23 plants in seven departments of a petrochemical company in central Taiwan completed a questionnaire survey. From this, a sample of 521 responses was randomly selected. Structural equation modeling (SEM) analysis using the AMOS 5.0 was employed to test the hypothesized model relating the above-mentioned variables. The results indicate that the model was supported, and that safety climate mediated the relationship between safety leadership and performance. Practical implications of these results for process safety management in the petrochemical industries are discussed.     

煤矿本质安全化管理体系建立及其应用的探讨

运用安全系统工程中的事故树理论,以瓦斯爆炸事故为例分析了煤矿中的7类主要事故,并得出相应的事故树。通过对事故树的定性分析,得出事故树的最小径集和基本事件重要度排序。进而可预测基本事件的发生所能够导致的结果,可根据各基本事件的重要度排序,确定避免发生事故应采取的基本措施,并建立了煤矿本质安全化管理体系。设计出煤矿本质安全化管理体系的软件,并以瓦斯爆炸事故为例,分析了该管理体系在实际中的应用效果。     

Research on 3D dynamic visualization simulation system of toxic gas diffusion based on virtual reality technology

A three-dimensional (3D) model of toxic gas diffusion was advanced based on Monte Carlo method with the presupposition that toxic gas diffusion process can be considered as random walk process of a large number of toxic gas particles. Compared to other existing models, this model includes analysis of both movement and non-movement attributes of toxic gas particles, and can well meet the need of dynamic simulation. Then, a 3D gas diffusion visualization scene management subsystem, including leak hazard source (tank), leak background (ground and sky) and surroundings near the leak area, was developed based on virtual reality (VR) technology. In this system, diffusion scene can be designed in accordance with the reality, which embodies the reunification between VR technology and engineering application. Finally, according to OpenGL particle system theory, by using Delphi and OpenGL as main programming tools, the diffusion simulation subsystem of toxic gas diffusion process and real-time concentration prediction and consequence simulation subsystem was completed. Application shows that by using VR technology in the accident consequence simulation, the whole system is of real-time, lifelike and visual characteristics, which not only embodies the great engineering value of virtual reality technology in the field of safety engineering, but also provides references for accident impact prediction, assessment and emergency plan.     

Development of a 3D risk analysis technique for fire disaster and its application on accident simulation of a public site

In this research, we constructed a three-dimensional fire risk analysis technique (3D-FRAT) for common building fires. To demonstrate its effect, the 3D-FRAT employed a self-developed 3D risk-calculating module in combination with the Fire Dynamics Simulator (FDS) software to simulate the Welcome Restaurant accident that happened on February 15, 1995 in Taichung City, Taiwan. This study only focuses on thermal radiation and provide a preliminary method to quantify a fire risk. Different firefighting equipment that comply with the related building and fire-preventive regulations have been used in the simulations to test their mitigating effectiveness on the accident. The results were shown by animation, 3D pictures, and sliced pictures to facilitate the researchers’ understanding of human hazards caused by thermal radiation or smoke in a specific fire accident. The minimal personnel escaping times for different hazardous factors were estimated; various firefighting designs that can reduce loss of human life and property were also perused. According to the simulation results, the individual risk values in Welcome Restaurant were between 3.108 × 10⁻⁹ to 2.719 × 10⁻⁵ (deaths/year). It is foreseeable that the 3D-FRAT can become a useful tool for related organizations to choose better fire-resistant buildings or fire-fighting equipment in the future.     

Developing a Questionnaire for Measuring Safety Climate in the Workplace in Serbia

This study was conducted because a real method for measuring safety climate had never been developed and assessed in Serbian industry. The aim of this paper was to start the process of developing a safety climate questionnaire that could be used in Serbia. As a starting point a 21-item questionnaire was adopted after an extensive literature review. The questionnaire was distributed at several Serbian factories; 1098 workers responded. After a statistical analysis of the data obtained with the questionnaire and a critical comparison with the available reference results, a final questionnaire with 21 questions, divided into 7 groups, was developed. The 7 groups of questions (factors) were safety awareness and competence, safety communication, organizational environment, management support, risk judgment and management reaction, safety precautions and accident prevention, and safety training.     

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].