An approach for domino effect reduction based on optimal layouts

An approach to reduce the probability of producing a domino effect in process industry is developed in this work. It is assumed that optimal layouts should include appropriate analysis to reduce risk during the process design stage. The model developed for this approach combines the estimation of probability of damage due to overpressure, proposed by Mingguang and Juncheng (2008), and escalation threshold values defined by Cozzani, Gubinelli, and Salzano (2006). These equations are combined with other typical layout constraints as well as bounding the probability constraint, which has resulted in a highly non-linear MINLP problem. Solving a case study used by other authors provides evidence for reliability of the developed approach. In this way, layouts are designed to reduce the escalation probability yielding safe distributions.     

Key parametric analysis on designing an effective forced mitigation system for LNG spill emergency

Concerns over public safety and security of a potential liquefied natural gas (LNG) spill have promoted the need for continued improvement of safety measures for LNG facilities. The mitigation techniques have been recognized as one of the areas that require further investigation to determine the public safety impact of an LNG spill. Forced mitigation of LNG vapors using a water curtain system has been proven to be effective in reducing the vapor concentration by enhancing the dispersion. Currently, no engineering criteria for designing an effective water curtain system are available, mainly due to a lack of understanding of the complex droplet–vapor interaction. This work applies computational fluid dynamics (CFD) modeling to evaluate various key design parameters involved in the LNG forced mitigation using an upwards-oriented full-cone water spray. An LNG forced dispersion model based on a Eulerian–Lagrangian approach was applied to solve the physical interactions of the droplet–vapor system by taking into account the various effects of the droplets (discrete phase) on the air–vapor mixture (continuous phase). The effects of different droplet sizes, droplet temperatures, air entrainment rates, and installation configurations of water spray applications on LNG vapor behavior are investigated. Finally, the potential of applying CFD modeling in providing guidance for setting up the design criteria for an effective forced mitigation system as an integrated safety element for LNG facilities is discussed.     

Integrating major accidents hazard into occupational risk assessment: An index approach

Major Accident Hazard (MAH) and Occupational Safety and Health (OSH) are two separated topics in both industrial practice and legislation; recently, interest is increasing toward an integrated risk assessment mainly forced by the tendency to a more efficient safety management system. The present study proposes a semi-quantitative approach to integrate MAH in OSH risk assessment. The two risk types are characterized by opposite features: the OSH analysis is usually task-based and focused on job profiles, while the MAH analysis is space-based and focused on plant characteristics. The basic idea of the proposed approach is to merge spatial information and job profile features in order to improve OSH assessment; thus, a risk index derived by the recent standard ISO 12100 (2010) has been adapted. In detail, the proposed index combines exposure times of each worker at each plant unit – derived from the OSH analysis – with damage areas derived from MAH analysis allowing a quantitative assessment of the MAH risk level for each individual job profile. The model has been tested in a large petrochemical plant; several hypotheses have been developed in order to validate the model. Results have showed the potentiality of the proposed approach in providing a common and coherent representation of both MAH and OSH risks, according to job profiles and plant units.     

Analysis of underlying causes of investigated loss of containment incidents in Dutch Seveso plants using the Storybuilder method

In the Netherlands there are around 400 “Seveso” sites that fall under the Dutch Major Hazards Decree (BRZO) 1999. Between 2006 and 2010 the Dutch Labour Inspectorate's Directorate for Major Hazard Control completed investigations of 118 loss of containment incidents involving hazardous substances from this group. On the basis of investigation reports the incidents were entered in a tailor-made tool called Storybuilder developed for the Dutch Ministry of Social Affairs and Employment for identifying the dominant patterns of technical safety barrier failures, barrier task failures and underlying management causes associated with the resulting loss of control events. The model is a bow-tie structure with six lines of defence, three on either side of the central loss of containment event. In the first line of defence, failures in the safety barriers leading to loss of control events were primarily equipment condition failures, pre start-up and safeguarding failures and process deviations such as pressure and flow failures. These deviations, which should have been recovered while still within the safe envelope of operation, were missed primarily because of inadequate indication signals that the deviations have occurred. Through failures of subsequent lines of defence they are developing into serious incidents. Overall, task failures are principally failures to provide adequate technical safety barriers and failures to operate provided barriers appropriately. Underlying management delivery failures were mainly found in equipment specifications and provisions, procedures and competence. The competence delivery system is especially important for identifying equipment condition, equipment isolation for maintenance, pre-start-up status and process deviations. Human errors associated with operating barriers were identified in fifty per cent of cases, were mostly mistakes and feature primarily in failure to prevent deviations and subsequently recover them. Loss of control associated with loss of containment was primarily due to the containment being bypassed (72% of incidents) and less to material strength failures (28%). Transfer pipework, connections in process plant and relief valves are the most frequent release points and the dominant release material is extremely flammable. It is concluded that the analysis of a large number of incidents in Storybuilder can support the quantification of underlying causes and provide evidence of where the weak points exist in major hazard control in the prevention of major accidents.     

Small-scale physical explosions in shock tubes in comparison with condensed high explosive detonations

A series of small-scale experiments involving physical explosions in a 1.6 l pressure vessel was carried out. Explosions were initiated by spontaneous rupture of an aluminium membrane on one side of the vessel at a pressure in the range 1–1.2 MPa. The pressure waves released were measured at different distances along two separate shock tubes, one 10 m long and 200 mm in diameter (closed at one end by the high pressure vessel) and the other 15 m long and 100 mm in diameter.TNT equivalency was used for predicting the blast wave characteristics after vessel rupture. TNT equivalency was used because equations for prediction of peak pressure and impulse of the blast wave in 1-D geometry after detonations of condensed explosives are known. Some experiments with an equivalent amount of real explosive were carried out for comparison with the theoretical and experimental data obtained. The applicability of the TNT equivalency method presented for calculations of maximum pressure and shock wave impulse generated after rupture of the pressure vessel in 1-D geometry is discussed.     

Worst-case identification of gas dispersion for gas detector mapping using dispersion modeling

To quickly and accurately quantify the material release in process units, gas detectors may be placed according to the results of gas dispersion modeling. DNV's PHAST software is one of the most useful and reliable tools for material dispersion modeling. In this software, fluid dispersion is modeled based on the process conditions, the weather conditions and the specifications of the material release point. However, varying weather conditions throughout the year and the exact determination of the release point on the plot plan and the release elevation are problematic; these issues cause the results to be non-exact and non-integrated. Choosing the most appropriate conditions is challenging. In this paper, a scheme was provided to select the most appropriate conditions for gas dispersion modeling. This scheme approaches modeling based on the worst-case scenario (the situation in which the dispersed gas reaches the detector later in comparison to the other cases). Therefore, different weather conditions, release elevations and release points on the plot plan were modeled for an absorber tower of the Gonbadli Dehydration Unit of the Khangiran Refinery. The worst case of each release condition was then chosen. Finally, gas detectors were placed using the gas dispersion modeling results based on the worst-case scenario.     

A new approach for layout optimization in maintenance workshops with safety factors: The case of a gas transmission unit

In this study, an Integrated Simulation-Data Envelopment Analysis (DEA) approach is presented for optimum facility layout of maintenance workshop in a gas transmission unit. The process of repair of incoming parts includes various operations on different facilities. The layout problem in this system involves determining the optimum location of all maintenance shop facilities. Layout optimization plays a crucial role in this type of problems in terms of increasing the efficiency of main production line. Standard types of layouts including U, S, W, Z and straight lines are considered. First, the maintenance workshop is modeled with discrete-event-simulation. Time in system, average waiting time, average machine utilization, average availability of facilities, average queue length of facilities (AL) and average operator utilization are obtained from simulation as key performance indicators (KPIs) of DEA. Also, safety index and number of operators are considered as other KPIs. Finally, a unified non-radial Data Envelopment Analysis (DEA) is presented with respect to the stated KPIs to rank all layouts alternatives and to identify the best configuration. Principle Component Analysis (PCA) is used to validate and verify the results. Previous studies do not consider safety factor in layout design problems. This is the first study that presents an integrated approach for identification of optimum layout in a maintenance workshop of gas transmission unit by incorporating safety and conventional factors.     

RAPID-N: Rapid natech risk assessment and mapping framework

Natech accidents at industrial plants are an emerging risk with possibly serious consequences. For the mitigation of natech risk, authorities need to identify natech prone areas in a systematic manner. In order to facilitate probabilistic natech risk mapping, a unified methodology was developed that is based on the estimation of on-site natural hazard parameters, determination of damage probabilities of plant units, and assessment of probability and severity of possibly triggered natech events. The methodology was implemented as an on-line, extensible risk assessment and mapping software framework called RAPID-N, which allows rapid local and regional natech risk assessment and mapping with minimal data input. RAPID-N features an innovative data estimation framework to complete missing input data, such as on-site natural hazard parameters and plant unit characteristics. The framework is also used for damage assessment and natech consequence analysis, and allows easy modification of input parameters, dynamic generation of consequence models according to data availability, and extension of models by adding new equations or substituting existing ones with alternatives. Results are presented as summary reports and interactive risk maps, which can be used for land-use and emergency planning purposes by using scenario hazards, or for rapid natech consequence assessment following actual disasters. As proof of concept, the framework provides a custom implementation of the U.S. EPA's RMP Guidance for Offsite Consequence Analysis methodology to perform natech consequence analysis and includes comprehensive data for earthquakes. It is readily extendible to other natural hazards and more comprehensive risk assessment methods.     

RETRACTED:

Jianfeng Li  Sandra M.Y. Lee  Wenmao Liu 《Process Safety and Environmental Protection》2013,91(3):213-220

A new integrated treatment for the reduction of organic and nitrogen loads in methanogenic landfill leachates

Because of their high organic and nitrogen loads and the presence of toxic and phytotoxic compounds, methanogenic landfill leachates are not easily biodegradable; therefore, direct biological treatment of these wastewaters in conventional treatment plants is not recommended.In the present paper, we report the results of an experimental investigation conducted with the aim of defining an innovative integrated process that is low in cost and easily manageable and that is able to substantially improve the characteristics of methanogenic leachates.Thus, an initial oxidation process was developed using hydrogen peroxide without a catalyst, which, operating under ambient conditions, reduces the phytotoxic compound content to 10% of the initial level, reduces the COD (chemical oxygen demand) content by 50% and increases the rapidly biodegradable substrate content by 50%. Next, nitrogen removal is accomplished by means of struvite precipitation using seawater bittern and bone meal as sources of magnesium and phosphorus, respectively, with this process, abatements were reached of approximately 90% of the ammonia nitrogen, which was recovered as struvite powder.