A framework to estimate the risk-based shutdown interval for a processing plant

Petrochemical plants and refineries consist of hundreds of pieces of complex equipment and machinery that run under rigorous operating conditions and are subjected to deterioration over time due to aging, wear, corrosion, erosion, fatigue and other reasons. These devices operate under extreme operating pressures and temperatures, and any failure may result in huge financial consequences for the operating company. To minimize the risk and to maintain operational reliability and availability, companies adopt various maintenance strategies. Shutdown or turnaround maintenance is one such strategy. In general, shutdown for inspection and maintenance is based on the original equipment manufacturer's (OEM) suggested recommended periods. However, this may not be the most optimum strategy given that operating conditions may vary significantly from company to company.The framework proposed in this work estimates the risk-based shutdown interval for inspection and maintenance. It provides a tool for maintenance planning and decision making by considering the probability of the equipment or system for failure and the likely consequences that may follow. The novel risk-based approach is compared with the conventional fixed interval approach. This former approach, characterized as it is by optimized inspection, maintenance and risk management, leads to extended intervals between shutdowns. The result is the increase in production and the consequent income of millions of dollars.The proposed framework is a cost effective way to minimize the overall financial risk for asset inspection and maintenance while fulfilling safety and availability requirements.     

Loss prevention in turnaround maintenance projects by selecting contractors based on safety criteria using the analytic hierarchy process (AHP)

Turnaround maintenance (TAM) is a usual plant shutdown that is done by process industries to perform asset inspections, repairs, and overhauls. TAM engineering projects are needed on a periodic basis to optimize a plant's performance. Process industrial plants usually don't have enough in-house manpower to carry out needed TAM jobs; it is not uncommon for a process industrial plant to outsource its TAM manpower supply to external contractors. This will create a peculiar management challenge regarding how to assure orientation of safety practices for the newly hired labor. Although accidents during process plant shutdowns may have severe consequences, the safety management systems in place for many companies only cover normal operations and few explicitly address TAM projects. Usually, contractors are evaluated from a safety perspective after handling the project by monitoring safety indicators such as number of injuries, incidents, etc. This paper emphasizes safety attributes to be included in selecting contractors at the bidding stage to assure loss prevention and better safety orientation during TAM implementation. The paper starts with reviewing TAM literature and defining main needed safety attributes to prequalify contractors. It develops an analytic hierarchy process (AHP) model that is applied to rank TAM contractors' selection. A case study is presented for a petrochemical plant in Saudi Arabia to demonstrate the AHP model.     

Process chemicals – An ever present concern during plant shutdowns

Chemical accidents during process plant shutdowns may have severe consequences. In spite of this, the safety management systems in place in many companies still mainly cover the normal operations and little explicitly addresses the maintenance shutdown and plant start-up phases. A Finnish research project found that the level of safety during shutdowns is more closely related to the skills of key individuals at the plants and less due to the systematic safety management system of the companies. A guidebook on the topic in conjunction with tools to improve the situation were developed during the project in order to help the companies improve their documentation associated with chemical safety during shutdowns.     

Risk information in decision-making: definitions,requirements and various functions

Inappropriate decisions are often regarded as causes of major accidents in the process industries. To improve the quality of decisions, it is important to make the right information available at the right time. The objective of this work is to investigate what types of risk information is needed for risk-related decisions in various decision-making processes. A framework is proposed to facilitate future research for easing information deficiency. In this paper, risk information is examined through common decision-making processes, and is identified serving to 1) detect and characterize risk-related decision problems, 2) indicate the severity and urgency of decisions, 3) state requirements and constraints of workable solutions, 4) represent attributes for comparing and evaluating solutions, and 5) act as rules to maintain safety or control risk. These usages of risk information in different decision problems imply the large diversity in information needs for decision-making. An adaptive information support is thus suggested to provide targeted risk information to specific decision-makers for effective and efficient decision-making in accident prevention in the process industries.     

Decision on oil and gas exploration in an Arctic area: Case study from the Norwegian Barents Sea

This paper addresses how risks to the environment in the Arctic are handled in decisions regarding the exploration for petroleum resources. An exploration well in the Norwegian Barents Sea is used as a case to demonstrate how environmental risks are assessed together with technical and economic considerations in the Oil Company’s decisions to enter into a new area and drill a well. The paper outlines environmental challenges in petroleum activities in the Arctic, the different roles of the Authorities and Oil Companies in decisions about petroleum activities, and the Oil Company’s tools and decision criteria used in addressing risks in the decision making.It is concluded that environmental and associated reputation risks are not a major issue at the strategic level in the Oil Company, since the most controversial areas in the Norwegian Arctic offshore have already been kept out of the exploration acreage by the authorities. Risks and uncertainties penetrate every aspect of the exploration of petroleum resources, and environmental risks are not unique in this sense. The Oil Company has established technical and economic tools and decision criteria to address them, and the mitigation of environmental risks becomes an element in the technical and economic analyses that affect detailed design and operational procedures. Mitigation measures such as the minimization of discharges to the sea (the so-called “zero-discharge” policy) and oil spill contingency planning are dimensioned to meet authority requirements and expectations rather than on strict risk acceptance considerations. A significant concern is to avoid delays in the permit granting process.     

Risk-based shutdown management of LNG units

Global demand for natural gas may double by 2030, with Liquefied Natural Gas (LNG) growing perhaps fivefold - driven by continued cost reduction. Propane Pre-cooled Mixed Refrigerant (PPMR) of Air Products and Chemicals Inc. (APCI) currently holds 78% of the liquefaction plants on the market. Since the PPMR process has the largest production capacity, its operational reliability needs to be high as any failure may result in catastrophic consequences. Therefore, operational reliability has a key importance in LNG plants. To achieve an acceptable reliability, usually, a constant interval of a preventive maintenance method is used. The limitation of such a method is that the shutdown strategy is not optimum. This study focuses on determining a risk-based shutdown management strategy for APCI plants with capacity of 4.5 million tons per annum. To achieve the minimum risk for the expected life of an LNG plant, a combination of preventive maintenance, active redundancy and standby redundancy is considered. Results of this study reveal that such a combination can significantly reduce the operational risk. This combination improves the plant reliability and maintains it above a minimum operational reliability.     

Integrated framework to optimize RAM and cost decisions in a process plant

The research implications of reliability, availability and maintainability (RAM) aspects of engineering systems in recent years have increased substantially due to rising operation and maintenance costs. To strike a balance between the two the paper presents a framework which makes use of both qualitative and quantitative techniques to optimize RAM and cost decisions in a process plant. In the quantitative analysis, the imprecise and vague information regarding the system failure behavior is quantified by using the principles of fuzzy mathematics in terms of fuzzy and crisp values. Further, to manage the system reliability for best economic performance a resource optimization model based on multi-stage decision making (MSDM) has been proposed. The model makes use of crisp output values of unit's reliability along with relevant system information (number of components, manpower, cost ranges). In the qualitative analysis the in-depth analysis of the system is carried out using Root Cause analysis (RCA) and Failure Mode & Effects Analysis (FMEA). The ambiguities associated with the traditional FMEA are handled using Fuzzy Decision Making System (FDMS) and Grey Relation Analysis (GRA). The suggested framework has been illustrated with the help of a case.     

液碳生产企业安全监控与自控系统开发

液态二氧化碳生产企业快速发展,规模逐年增大,安全监控与自动化水平不高导致事故风险日益升高。通过对液碳企业危险和风险分析,利用数据采集、实时数据库、参数监控、视频监控、预警报警、通讯和网络等技术,构建安全监控与自控系统,完成对液碳生产流程、有毒、有害、易燃易爆物品以及关键设备设施的动态监测、安全管理、智能分析、联锁控制、报警、应急辅助决策和统计查询等功能。安全监控与自控系统建设和实施可实现液碳生产企业安全、稳定、长周期、经济运行。     

海上生产设施远程监控和管理系统的建设探讨

针对海洋石油行业面临的海上作业设施如何安全有效监控及管理的问题,从实际的安全生产管理需求出发,结合通信网络链路及传输特点,采用先进的远程监控技术和海洋石油应急管理理念,设计开发了海上生产设施远程监控和管理系统平台,并论述了总体框架、软硬件结构及发展趋势。系统已经作为保障安全生产的重要手段应用于海上作业平台及船舶运输,提高了安全生产管理水平,并取得了很好的效果。     

Integration of data analytics with cloud services for safer process systems,application examples and implementation challenges

Emerging sensors, computers, network technologies, and connected platforms result potentially in an immeasurable collection of data within plant operations. This creates the possibility of solving problems innovatively. Because most of the data appear to be unstructured or semi-structured, organizations shall design and adopt new strategies. Further, workflow architectures with data analytics are needed including machine learning tools and artificial intelligence techniques before proto-type solutions can be developed. We shall discuss several prospects of using (big) data analytics integrated with cloud services to produce solutions for improving plant operations. The paper outlines the vision and a systematic framework highlighting the data analytics lifecycle in the area of plant operation, process safety, and environmental protection. Four rather diverse example case studies are demonstrated including (1) deep learning-based predictive maintenance monitoring modeling, (2) Natural Language Processing (NLP) for mining text, (3) barrier assessment for dynamic risk mapping (DRA), and (4) correlation development for sustainability indicators. It further discusses the challenges in both research and implementation of proposed solutions in the industry. It is concluded that a well-balanced integrated approach including machine supporting decisions integrated with expert knowledge and available information from various key resources is required to enable more informed policy, strategic, and operational risk decision-making leading to safer, reliable and more efficient operations.     

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.     

基于RBI的碳五石油树脂装置风险评估分析

从技术特点、实施效用等方面,对QRA与RBI两类风险评估技术进行比较,选择使用RBI技术方法对碳五石油树脂装置内静设备及管道实施风险评估。运用挪威船级社的ORBIT Onshore软件定量计算评估范围内设备、管道风险值,评定风险等级,辨识隐患设备,然后从后果、可能性两方面分析产生风险的主要影响因素,经分析得知碳五石油树脂装置受H2S、HCl腐蚀减薄影响轻微,但NaOH导致的碱应力腐蚀对聚合反应后序工段中部分管道设备失效可能性影响较大。最后根据装置内存在的不同损伤机理提出检验优化策略,为装置定期检验工作提供科学的决策支持。     

Process analysis of an industrial waste-to-energy plant: Theory and experiments

Thermal conversion is fundamental in an integrated waste management system due to the capability of reducing mass and volume of waste and recovering energy content from unrecyclable materials. Indeed, power generation from industrial solid wastes (ISW) is a topic of great interest for its appeal in the field of renewable energy production as well as for an increasing public concern related to its emissions. This paper is based on the process engineering and optimization analysis, commissioned to the University Campus-Biomedico of Rome by the MIDA Tecnologie Ambientali S.r.l. enterprise, ended up in the construction of an ISW thermo-conversion plant in Crotone (Southern Italy), where it is nowadays operating. The scientific approach to the process analysis is founded on a novel cascade numerical simulation of each plant section and it has been used initially in the process design step and after to simulate the performances of the industrial plant. In this paper, the plant process scheme is described together with the values of main operating parameters monitored during the experimental test runs. The thermodynamic and kinetic basics of the mathematical model for the simulation of the energy recovery and flue gas treatment sections are presented. Moreover, the simulation results, together with the implemented parameters, are given and compared to the experimental data for 10 specific plant test runs. It was found that the model is capable to predict the process performances in the energy production as well as in the gas treatment sections with high accuracy by knowing a set of measurable input variables. In the paper fundamental plant variables have been considered such as steam temperature, steam flow rate, power generated as well as temperature, flow rate and composition of the resulting flue gas; therefore, the mathematical model can be simply implemented as a reliable and efficient tool for management optimization of this kind of plants.     

Use of safety barriers in operational safety decision making

Operational personnel in complex hazardous industries are regularly called upon to make decisions that balance the production and safety objectives of their organisation. Regulations and industry standards focus on defining and complying with operating limits of various kinds as the primary method of achieving the right balance. Such limits remove the need in many cases for in-the-moment judgements about safety and production priorities.Focussing solely on the compliance with a pre-defined envelope underestimates the direct contribution to safety from operational managers based on their professional judgement. Research in a chemical plant, a nuclear power station and an air navigation service provider has identified a “line in the sand” approach taken by experienced operating personnel when abnormal situations arise. In developing these situation-specific self-imposed limits, operational managers focus on the status of safety barriers, rather than considering risk from first principles. This approach could form the basis of a new procedure, which lays out the process to be followed in determining how best to proceed (similar to job safety analysis or permit to work). This would acknowledge that such decisions are necessary, assist operational personnel in making better choices and open such decisions to appropriate audit and scrutiny.     

Inherent safety tool for explosion consequences study

The lack of formal integration between process design stages with risk and consequence estimation is a hurdle to designing inherently safe process plants. Conventional risk assessment methodologies are often not carried out concurrently with process design. Therefore, process designers lack the information about risk levels and consequence that may result from the process conditions being considered in a particular process route until the design is completed. Hence, effects of changes in process conditions on risk levels and consequence cannot be studied in a time effective manner during the design stages. Few studies have been identified on the possibility and viability of integrating risk estimation with process design. But viable framework and methodology for doing so has not yet been reported. This paper presents a feasible framework in which risk and consequences estimation can be part of design stages. A demonstrative tool named as integrated risk estimation tool (iRET) was developed by using process simulation software, HYSYS and spreadsheet, MS Excel as the platforms. iRET estimates risk due to explosions by using TNT equivalence method and the TNO correlation method. iRET has a potential to be extended to include all forms of risk such as fire, explosion, toxic gas releases and boiling liquid expanding vapour explosion (BLEVE). The paper also presents case studies to demonstrate the functionality and viability of using iRET in conjunction with process design. The results of these case studies have successfully shown that the risk due to explosion can be assessed during the initial design stage ensuring a safer plant. The framework and iRET there by presented here provide systematic methodology and technology to design inherently safer plants.     

Building an Executive Information System for Maintenance Efficiency in Petrochemical Plants—An Evaluation

This study used the manufacturing process in the petrochemical industries as an example and developed a dedicated maintenance programme and executive information system (EIS) for this industry. The software for EIS was established on a CMMS platform, with logical and extractive analysis used to store the information in a KPI databank. The system developed can provide plant managers and engineers with a complete summary of information and keep them updated regarding the present status of their maintenance efforts. The objective of this study was to establish a management system for maintaining knowledge in the petrochemical industries, such as the management of standard operating procedures (SOPs), historical records and the analysis of data for the facility. To design the software, a review of petrochemical facility was purposed to enhance the maintenance efforts and facilitate the decision-making process. The main functions of the system include asset reliability analysis, failure analysis and maintenance benefit cost analysis. For the petrochemical industry, the impact of safety and environment caused by equipment malfunction is more substantial than that of other industries. If executives can manage essential points effectively and make decisions according to a key performance index, risks to safety and environment, which result from equipment malfunction, can be decreased and safety can be enhanced for petrochemical refineries.     

石化企业个体防护用品信息动态管理与监控系统研究

石油化工行业从原料、中间体到产品存在多种危害,防护不到位可能引起人体伤害。建立劳动系统可实现个体防护用品的计划、采购、发放、使用全过程管理,可以实现劳保费用预算和决算管理以及劳保信息的预警监控、统计汇总等一整套信息化管理,促使中国石化上、中、下游各企业个体防护用品信息管理规范、流程统一,更加有效的落实个体防护用品配备标准、合理制定采购和发放计划、控制费用核销、监督员工正确使用等环节,确保劳保用品落实到每一个基层单位,每一个班组,甚至每一名员工。同时强大信息汇总、预警监控、查询统计,为管理决策提供技术支撑。     

基于低空飞艇的突发事件应急监测系统

稳定高效的高点监控对应急处置有非常重要的作用。该文提出了一种基于低空飞艇的突发事件应急监测系统,实现在复杂环境下应急现场的实时监测。系统包含三个部分：视频预处理和目标追踪;目标的自动照准和定位;远程探测监测。利用稳像和跟踪技术实现视频预处理和目标跟踪,应用基于Harris角点的帧间运动估计稳定视频,使用基于GPS航迹信息的Kalm an-平均滤波方法分离主观运动和非主观运动,使用基于M ean Sh ift方法跟踪目标。通过三维云台电机的自动控制以及艇载GPS和三维罗盘实现对目标的自动照准及定位,利用小型投掷系统实现远程探测监测。该文提出的低空飞艇应急监测系统为突发事件现场实时监测提供了新的有效的解决方案,为应急响应提供了有力支持。     

Emergency shutdown of fluidized bed reaction systems

With several industrial applications of fluidized bed technology recently commercialized worldwide, it becomes essential to develop safe operation methods for fluidized bed reaction systems (FBRSs) to prevent any influence on their process values, which lead to accidents. To preventing any disaster or malfunction in an FBRS, an emergency shutdown system (ESD) is initiated, closing the reaction system in case of any abnormality by effectively isolating the flammable gas. However, an ESD is also prone to the “inactivation problem,” in which in the case of failure it initiates the emergency shutdown, even when the operating conditions of the reaction system are abnormal. It is also vulnerable to a “malfunction problem,” where the emergency shutdown is performed even when the operating conditions of the reaction system are normal. In this study, these problems were solved by investigating a reaction system through the monitoring of appropriate parameters and setting up of trigger levels, which reflect the uniqueness of an FBRS using an ESD. The parameters were identified by analyzing the scenario leading to an accident. The trigger levels were determined as the points at which the loss is smaller in the presence of an ESD, as compared to the value of the loss function in the presence or absence of an ESD. Furthermore, the ESD design model was applied as a case study in the ammoxidation process of propylene. The results showed that an ESD can prevent an approximately 8 billion yen of loss due to accidents in plant operations, against an investment of 200 million yen.     

关于石油管道企业HSE管理体系、环境管理体系和职业安全健康管理体系的整合探讨和建议

石油管道企业已经建立了HSE管理体系。为了提高企业的管理水平 ,适应企业的发展和参与国际石油管道建设市场的竞争 ,在近几年内 ,石油管道企业计划建立ISO140 0 0和职业安全健康管理体系。为了提高企业管理效率 ,便于 3个体系的运行和操作 ,笔者提出了企业在建立体系中将EMS、HSEMS、OSHMS整合的思路 ,并对整合的可能性作了探讨 ,提出了体系整合后的基本框架。