Using a system theory based method (STAMP) for hazard analysis in process industry

Different hazard analysis techniques are used in the chemical process industry. Most of these techniques were developed long time ago. There is an argument that significant changes have occurred in the process industry but these techniques have not been modified accordingly. Therefore, there may be limitations in identifying hazards related to the modern process industry in complex sociotechnical environment using these techniques. Recently new hazard analysis techniques based on systems theory have been introduced. STPA (System-Theoretic Process Analysis) is one of these systemic techniques. It has been used in some fields with promising results but with limited application in the process industry. This paper applies STPA to a process plant as an industrial case study. Recommendations generated by STPA are compared with the HAZOP study of the process plant which is a traditional technique. Conclusions are presented on the application of systemic techniques to the process industry as a complementary study to analyze the safety of the system as a whole and also to capture interactions between component of the system. Further studies are required to study STPA in more details and evaluate if it can be used as an alternative to HAZOP.     

On the need for system-theoretic hazard analysis in the process industries

Most process hazard analysis (PHA) studies today are conducted using traditional methods such as the hazard and operability study (HAZOP). Traditional methods are based on a chain-of-events model of accident causality. Current models of accident causality are based on systems theory and provide a more complete representation of the causal factors involved in accidents. Consequently, it is logical to expect that PHA methods should reflect these models, that is, system-theoretic hazard analysis (STHA) should be used. Indeed, system-theoretic process analysis (STPA) has been developed as such a method. STPA has been used in a variety of industries but, at this time, it has not gained acceptance by the process industries. This article explores the reasons for this situation. Expectations for PHA in the process industries are examined and issues for the application of STPA in the process industries are discussed. It is concluded that a variety of matters must be addressed before STPA can be considered as a viable PHA method for the process industries and the case for the use of STHA in the process industries is not yet proven.     

基于STPA法的空中加油软管甩鞭安全性分析

为定量评价空中加油软管甩鞭(HWP)现象的安全性,使用系统理论过程分析(STPA)法查找出相关系统级危险、不安全控制行为和致因因素共计46条,确定与之对应的44项安全对接约束条件;依据空中加油飞行试验数据,定义可量化的安全检查点,依据安全检查点将安全约束条件分为17类,确定各检查点的安全区间和权重;根据飞行数据确定HW...     

Safety assessment of the film boiling chemical vapor infiltration (FB-CVI) process through a system-theoretic accident model and process (STAMP)

Film boiling chemical vapor infiltration (FB-CVI) is considered as one of the fastest process methodologies for manufacturing carbon-carbon (C–C) composite products and possesses various advantages compared to conventional methodologies. However, there are safety concerns associated with this process for large-scale manufacturing, mainly owing to the intrinsic nature of the precursor and the process conditions. Considering the multifunctional interactions of the various systems during the process, a system-theoretic process analysis (STPA)/system theoretic accident model and process (STAMP) model is used to perform a safety analysis of the hazardous states of the FB-CVI process at the system level. As a case study, the FB-CVI process equipment employed for the manufacturing of C–C composites is considered. The safety constraints present in the system are assessed for adequacy through a hazard analysis by STPA/STAMP. The analysis through STPA/STAMP demonstrated the capability to create proactive strategies for the design and realization of process equipment that can be employed to manufacture C–C composite products through the FB-CVI process.     

How can process safety and a risk management approach guide pandemic risk management?

The coronavirus disease (COVID-19) brought the world to a halt in March 2020. Various prediction and risk management approaches are being explored worldwide for decision making. This work adopts an advanced mechanistic model and utilizes tools for process safety to propose a framework for risk management for the current pandemic. A parameter tweaking and an artificial neural network-based parameter learning model have been developed for effective forecasting of the dynamic risk. Monte Carlo simulation was used to capture the randomness of the model parameters. A comparative analysis of the proposed methodologies has been carried out by using the susceptible, exposed, infected, quarantined, recovered, deceased (SEIQRD) model. A SEIQRD model was developed for four distinct locations: Italy, Germany, Ontario, and British Columbia. The learning-based approach resulted in better outcomes among the models tested in the present study. The layer of protection analysis is a useful framework to analyze the effect of different safety measures. This framework is used in this work to study the effect of non-pharmaceutical interventions on pandemic risk. The risk profiles suggest that a stage-wise releasing scenario is the most suitable approach with negligible resurgence. The case study provides valuable insights to practitioners in both the health sector and the process industries to implement advanced strategies for risk assessment and management. Both sectors can benefit from each other by using the mathematical models and the management tools used in each, and, more importantly, the lessons learned from crises.     

基于STPA的城市埋地燃气管道第三方破坏风险因素分析

城市埋地燃气管道输送介质易燃易爆、埋设环境人口密集、施工频繁,极易受到来自第三方的破坏,直接威胁人们的生命财产安全,因此对第三方破坏的风险因素分析和防治十分必要。系统理论过程分析法(STPA)是一种基于系统理论的风险分析方法,该方法不同于传统的风险分析方法——将事故视为由初始事件诱发的一系列事件造成的后果,而是对燃气系统从设计、开发和运行过程进行分析,建立系统安全控制结构,通过分析控制缺陷和缺陷致因实现对风险因素的分析。研究分析出24个燃气管道第三方破坏的风险因素,针对风险因素提出了建议,为燃气管道第三方破坏的风险控制提供依据。     

Major Health Risk Factors in Iranian Hand-Woven Carpet Industry

This paper reviews the role and importance of small-scale industries together with the issue of occupational health problems and their causes in Iranian hand-woven carpet industry as a typical informal small-scale industry in an industrially developing country. The objective ofthis paper is to review health risk factors and related occupational health and ergonomic problems in the carpet industry. Since the overwhelming majority of weavers’ health problems originate from ergonomic risk factors, it is concluded that any improvement program in this industry should focus on ergonomic aspects. To assess ergonomic conditions in weaving workshops, a checklist has been developed and an ergonomics index indicating the ergonomic conditions of the workshop has been proposed. To test and verify the checklist, 50 weaving workshops were visited and their ergonomic conditions were assessed. Based on the results some modifications were made and the checklist was shown to be an effective tool.     

Test case based risk predictions using artificial neural network

INTRODUCTION: The traditional fuzzy-rule-based risk assessment technique has been applied in many industries due to the capability of combining different parameters to obtain an overall risk. However, a drawback occurs as the technique is applied in circumstances where there are multiple parameters to be evaluated that are described by multiple linguistic terms. METHOD: In this study, a risk prediction model incorporating fuzzy set theory and Artificial Neural Network (ANN) capable of resolving the problem encountered is proposed. An algorithm capable of converting the risk-related parameters and the overall risk level from the fuzzy property to the crisp-valued attribute is also developed. Its application is demonstrated by a test case evaluating the navigational safety within port areas. RESULTS: It is concluded that a risk predicting ANN model is capable of generating reliable results as long as the training data takes into account any potential circumstance that may be met. IMPACT ON INDUSTRY: This paper provides safety assessment practitioners with a novel and flexible framework of modelling risks using a fuzzy-rule-base technique. It is especially applicable in circumstances where there are multiple parameters to be considered. The proposed framework also enables the port industry to manage navigational safety in a rational manner.     

TOPHAZOP: a knowledge-based software tool for conducting HAZOP in a rapid, efficient yet inexpensive manner

Hazard and operability (HAZOP) studies constitute an essential step in the risk analysis of any chemical process industry and involve systematic identification of every conceivable abnormal process deviation, its causes and abnormal consequences. These authors have recently proposed optHAZOP as an alternative procedure for conducting HAZOP studies in a shorter span of time than taken by conventional HAZOP procedure, with greater accuracy and effectiveness [Khan, F. I. and Abassi, S. A., optHAZOP. An effective and efficient technique for hazard identification and assessment Journal of Loss Prevention in the Process Industries, 1997, 10, 191–204]. optHAZOP consists of several steps, the most crucial one requires use of a knowledge-based software tool which would significantly reduce the requirement of expert man-hours and speed up the work of the study team. TOPHAZOP (Tool for OPTmizing HAZOP) has been developed to fulfil this need.

The TOPHAZOP knowledge-base consists of two main branches: process-specific and general. The TOPHAZOP framework allows these two branches to interact during the analysis to address the process-specific aspects of HAZOP analysis while maintaining the generality of the system. The system is open-ended and modular in structure to make easy implementation and/or expansion of knowledge. The important features of TOPHAZOP and its performance on an industrial case study are described.     

Prioritizing highway safety improvement projects: A multi-criteria model and case study with SafetyAnalyst

This paper presents a multi-criteria model for prioritizing highway safety improvement projects, in which a set of criteria related to the project’s technical, economic, and social impacts are properly weighted in consideration. The proposed model features an Analytical Hierarchy Process (AHP) framework to tackle the multi-criteria decision making problem. Different from the conventional AHP, this paper adds a fuzzy scale level between the criteria level and the alternative level, which offers the advantage of preventing the vagueness and uncertainty on judgments of the decision-maker(s). Such a unique modeling feature is further embedded with a non-linear optimization formulation to maximize the consistency in pair-wise comparison and weight estimation for each criterion. Case study results reveal that the proposed model is efficient not only for selecting the most suitable project for a specific site, but also for determining the priorities for implementing those suitable projects among multiple sites given the budget constraint. Comparative study between the proposed model and the existing ranking methods has also indicated its capability to capture the comprehensive impacts of all contributory factors which have been neglected by most existing single multi-criteria approaches during the safety project selection process. The clarity of model inputs, ease of synthesizing the final score of each candidate project, and the interpretation of results with respect to different selection criteria offer its best potential to be used as an effective tool for highway safety managers to assess and refine the safety improvement investments.     

3-Parameters SPW technique: A new method for evaluation of target safety integrity level

Introduced by IEC-61508 standard, safety integrity levels (SIL) have been used for assessing the reliability of safety instrumented functions (SIF) for protection of the system under control in abnormal conditions. Different qualitative, semi-qualitative and quantitative methods have been proposed by the standard for establishing target safety integrity levels amongst which “Risk Graph” has gained wide attention due to its simplicity and easy-to-apply characteristics. However, this method is subject to many deficiencies that have forced industry men and experts to modify it to fit their demands. In this paper, a new modification to risk graph parameters has been proposed that adds more flexibility to them and reduces their subjective uncertainties but keeps the method as simple as before. Three parameters, namely severity (S), hazard avoidance probability (P), and demand rate (W) are used instead of former four parameters. Hence, the method is named SPW. The outcome results of this method can be directly converted to probability of failure on demand (PFD) or risk reduction factor (RRF). The proposed method has been tested on an example case that has been studied before with conventional risk graph and LOPA techniques. The results show that new method agrees well with LOPA and reduces costs imposed by conservative approximations assumed during application of conventional risk graph.     

A cross-validation of safety climate scale using confirmatory factor analytic approach

PROBLEM: Given the lack of a consistent factor structure of safety climate, this study tested the stability of a factor structure of a safety climate scale developed through an extensive literature review using confirmatory factor analytic approach and cross-validation. METHODS: A cross-sectional sample of 722 U.S. grain industry workers participated in the questionnaire survey. RESULTS: The safety climate scale developed through the generation of an item pool based on a table of specifications, subsequent scientific item reduction procedures, reviews from experts, and pilot test yielded adequate reliabilities for each dimension. Each item showed proper discriminative power based on both internal and external criteria. Criterion validity was manifested by the significant positive correlation of the scale with five criteria. Evidence of construct validity was provided by both exploratory and confirmatory factor analyses. Both calibration and validation samples supported a consistent factor structure. Management commitment and supervisor support were found to influence other dimensions of safety climate. DISCUSSION: This study provides an insight into the primary reason why previous attempts have failed to find a consistent factor structure of safety climate: No specification of the influence of management commitment and supervisor support on other dimensions of safety in their models. IMPACT ON INDUSTRY: The findings of this study provide a framework upon which accident prevention efforts can be effectively organized and underscore the importance of management commitment and supervisor support as they affect employee safety perceptions.     

A review of the past,present and future of the European loss prevention and safety promotion in the process industries

In 2013, the European Federation of Chemical Engineering (EFCE) celebrates its 60th anniversary. EFCE has continually promoted scientific collaboration and supported the work of engineers and scientists in thirty European countries. As for its mission statement, EFCE helps European Society to meet its needs through highlighting the role of Chemical Engineering in delivering sustainable processes and products. Within this organizational framework the Loss Prevention Symposium series, organized throughout Europe on behalf of the Loss Prevention Working Party of the EFCE, represents a fruitful tradition covering a time span of forty years. The tri-annual symposium gathers experts and scientists to seek technical improvements and scientific support for a growingly safer industry and quality of life. Following the loss prevention history in this paper, a time perspective on loss prevention and its future is presented.     

Seismic fragility analysis of a coupled tank-piping system based on artificial ground motions and surrogate modeling

The catastrophic consequences of recent NaTech events triggered by earthquakes highlighted the inadequacy of standard approaches to seismic risk assessment of chemical process plants. To date, the risk assessment of such facilities mainly relies on historical data and focuses on uncoupled process components. As a consequence, the dynamic interaction between process equipment is neglected. In response to this gap, researchers started a progressive integration of the Pacific Earthquake Engineering Research Center (PEER) Performance-Based Earthquake Engineering (PBEE) risk assessment framework. However, a few limitations still prevent a systematic implementation of this framework to chemical process plants. The most significant are: (i) the computational cost of system-level simulations accounting for coupling between process equipment; (ii) the experimental cost for component-level model validation; (iii) a reduced number of hazard-consistent site-specific ground motion records for time history analyses.In response to these challenges, this paper proposes a recently developed uncertainty quantification-based framework to perform seismic fragility assessments of chemical process plants. The framework employs three key elements: (i) a stochastic ground-motion model to supplement scarcity of real records; (ii) surrogate modeling to reduce the computational cost of system-level simulations; (iii) a component-level model validation based on cost-effective hybrid simulation tests. In order to demonstrate the potential of the framework, two fragility functions are computed for a pipe elbow of a coupled tank-piping system.     

阶跃响应模型在三容水箱中的预测控制

本文应用一种工业上易于获取的阶跃响应模型，根据其预测控制算法对有约束的三容水箱系统进行模型预测控制。并编制Matlab软件进行仿真实现，结果证明控制效果良好。     

Major accident prevention and management of information systems security in technology-based work processes

The oil and gas industry in Norway has taken into use and is developing ICT-based work processes to improve efficiency and safety. Protection of information resources and technology; ensuring safe and secure processing of information; and ensuring reliable and safe flow of information is essential for both production and protection in such ICT-intensive organizations. Information systems security (IS) thus matters for major accident prevention. In the ICT-based work processes in the oil and gas industry new challenges for IS security occur related to: increased need for availability and integrity of information; merge of process safety systems and ICT-systems; manual use of information resources; and flow of information between distributed actors. These challenges imply new requirements for IS management: More focus on availability and integrity as protection principles; resilience-based approaches as a supplement to formal management approaches; validation of information flows; and integration of loss prevention approaches.     

People or systems? To blame is human. The fix is to engineer

Person-centered safety theories that place the burden of causality on human traits and actions have been largely dismissed in favor of systems-centered theories. Students and practitioners are now taught that accidents are caused by multiple factors and occur due to the complex interactions of numerous work system elements, human and non-human. Nevertheless, person-centered approaches to safety management still prevail. This paper explores the notion that attributing causality and blame to people persists because it is both a fundamental psychological tendency as well as an industry norm that remains strong in aviation, health care, and other industries. Consequences of that possibility are discussed and a case is made for continuing to invest in whole-system design and engineering solutions.     

Cost-based fire risk assessment in natural gas industry by means of fuzzy FTA and ETA

Fire is the most prevalent accident in natural gas facilities. In order to assess the risk of fire in a gas processing plant, a fault tree analysis (FTA) and event tree analysis (ETA) has been developed in this paper. By utilizing FTA and ETA, the paths leading to an outcome event would be visually demonstrated. The framework was applied to a case study of processing plant in South Pars gas complex. All major underlying causes of fire accident in a gas processing facility determined through a process hazard analysis (PHA). Fuzzy logic has been employed to derive likelihood of basic events in FTA from uncertain opinion of experts. The outcome events in event tree has been simulated by computer model to evaluate their severity. In the proposed methodology the calculated risk has the unit of cost per year which allows the decision makers to discern the benefit of their investment in safety measures and risk mitigation.