Development of a loading dock safety evaluation tool

INTRODUCTION: Companies that use forklifts to load and unload trucks at loading docks are well aware of the main danger associated with this type of activity (i.e., the possibility of the forklift falling or tipping over when the truck suddenly moves away from the dock). Even if various truck restraint measures can be implemented to reduce the possibility of this type of accident, a number of hazardous incidents that result in a forklift tipping over from a loading dock still do occur regularly in day-to-day activities. This situation has brought experts to examine and evaluate the effectiveness of different measures and systems depending on the context in which they are used. METHODS: The present study touched upon both the technical and the organizational aspects of the restraint measures that could have an impact on safety. Certain elements were examined very closely, especially the failure of mechanical devices and their relation to the environment in which they are used, as well as the systemic interaction between people and the various restraint measures in use in a given context. CONCLUSION: This article presents a safety evaluation tool regarding restraint measures or systems for trucks docked at loading platforms - a tool that, of course, would take into consideration both the specific contextual aspects related to the docking bay itself, and to the plant. IMPACT ON INDUSTRY: This tool is designed to help companies choose the optimal safety measures to implement, while remaining realistic in terms of the technical and economic aspects of any given situation.     

Safety culture: analysis of the causal relationships between its key dimensions

INTRODUCTION: Several fields are showing increasing interest in safety culture as a means of reducing accidents in the workplace. The literature shows that safety culture is a multidimensional concept. However, considerable confusion surrounds this concept, about which little consensus has been reached. METHOD: This study proposes a model for a positive safety culture and tests this on a sample of 455 Spanish companies, using the structural equation modeling statistical technique. RESULTS: Results show the important role of managers in the promotion of employees' safe behavior, both directly, through their attitudes and behaviors, and indirectly, by developing a safety management system. IMPACT ON INDUSTRY: This paper identifies the key dimensions of safety culture. In addition, a measurement scale for the safety management system is validated. This will assist organizations in defining areas where they need to progress if they wish to improve their safety. Also, we stress that managers need to be wholly committed to and personally involved in safety activities, thereby conveying the importance the firm attaches to these issues.     

Fatal accidents in nighttime vs. daytime highway construction work zones

INTRODUCTION: Awareness about worker safety in nighttime construction has been a major concern because it is believed that nighttime construction creates hazardous work conditions. However, only a few studies provide valuable comparative information about accident characteristics of nighttime and daytime highway construction activities. METHOD: This study investigates fatal accidents that occurred in Illinois highway work zones in the period 1996-2001 in order to determine the safety differences between nighttime and daytime highway construction. The lighting and weather conditions were included into the study as control parameters to see their effects on the frequency of fatal accidents occurring in work zones. RESULTS: According to this study, there is evidence that nighttime construction is more hazardous than daytime construction. The inclusion of a weather parameter into the analysis has limited effect on this finding. IMPACT ON INDUSTRY: The study justifies establishing an efficient work zone accident reporting system and taking all necessary measures to enhance safety in nighttime work zones.     

Optimization of process parameters using response surface methodology for bioconversion of activated sludge by Penicillium corylophilum

The optimization of process parameters for the bioconversion of activated sludge by Penicillium corylophilum was investigated using response surface methodology （RSM）. The three parameters namely temperature of 33℃, agitation of 150 r/min, and pH of 5 were chosen as center point from the previous study of fungal treatment. The experimental data on chemical oxygen demand （COD） removal （%） were fitted into a quadratic polynomial model using multiple regression analysis. The optimum process conditions were determined by analyzing response surface three-dimensional surface plot and contour plot and by solving the regression model equation with Design Expert software. Box-Behnken design technique under RSM was used to optimize their interactions, which showed that an incubation temperature of 32.5℃, agitation of 105 r/min, and pH of 5.5 were the best conditions. Under these conditions, the maximum predicted yield of COD removal was 98.43%. These optimum conditions were used to evaluate the trail experiment, and the maximum yield of COD removal was recorded as 98.5%.     

Generalized analytical expressions for safety instrumented systems' performance measures: PFDavg and PFH

Safety Instrumented Systems (SIS) constitute an indispensable element in the process of risk reduction for almost all of nowadays' industrial facilities. The main purpose of this paper is to develop a set of generalized and simplified analytical expressions for two commonly employed metrics to assess the performance of SIS in terms of safety integrity, namely: the Average Probability of Failure on Demand (PFD_avg) and the Probability of Dangerous Failure per Hour (PFH). In addition to the capability to treat any K-out-of-N architecture, the proposed formulas can smoothly take into account the contributions of Partial Stroke Testing (PST) and Common Cause Failures (CCF). The validity of the suggested analytical expressions is ensured through various comparisons that are carried out at different stages of their construction.     

An extension to Fuzzy Fault Tree Analysis (FFTA) application in petrochemical process industry

Fault Tree Analysis (FTA) is an established technique in risk management associated with identified hazards specific to focused fields. It is a comprehensive, structured and logical analysis method aimed at identifying and assessing hazards of complex systems. To conduct a quantitative FTA, it is essential to have sufficient data. By considering the fact that sufficient data is not always available, the FTA method can be adopted into the problems under fuzzy environment, so called as Fuzzy Fault Tree Analysis (FFTA). This research extends FFTA methodology to petrochemical process industry in which fire, explosion and toxic gas releases are recognized as potential hazards. Specifically, the case study focuses on Deethanizer failure in petrochemical plant operations to demonstrate the proposed methodology. Consequently, the study has provided theoretical and practical values to challenge with operational data shortage in risk assessment.     

A new method for the prediction of flash points for ternary miscible mixtures

The flash point is one of the most important physicochemical parameters used to characterize the fire and explosion hazard for flammable liquids. The flash points of ternary miscible mixtures with different components and compositions were measured in this study. Four model input parameters, being normal boiling point, the standard enthalpy of vaporization, the average number of carbon atoms and the stoichiometric concentration of the gas phase for mixtures, were employed and calculated based on the theory of vapor–liquid equilibrium. Both multiple linear regression (MLR) and multiple nonlinear regression (MNR) methods were applied to develop prediction models for the flash points of ternary miscible mixtures. The developed predictive models were validated using data measured experimentally as well as taking data on flash points of ternairy mixtures from the literature. Results showed that the obtained average absolute error of both the MLR and the MNR model for all the datasets were within the range of experimental error of flash point measurements. It is shown that the presented models can be effectively used to predict the flash points of ternary mixtures with only some common physicochemical parameters.     

Risk assessment of safety and health (RASH) for building construction

In this research Risk Assessment of Safety and Health RASH method for building construction has been developed with risks classified into Safety Risks and Health Risks. 11 factors representing safety risks and 8 factors representing health risks were identified based on field survey in Oman. 40 Safety and Health specialists were involved in carrying out risk assessment using the existing method of risk analysis RA and the proposed RASH method. It was found that RASH method resulted in superior accuracy for assessment of risk zones than the existing RA method. The accuracy by RASH was almost twice the accuracy by RA. The overall percentages of the correct answers for the four scenarios using the RASH method and the RA method were 72.5 percent and 40 percent respectively. The proposed RASH method gave fewer errors than the existing RA method for all scenarios. Two scenarios were found to be the most problematic ones with largest overestimation of risks occur when using the existing RA method. Wilcoxon Ranked Test showed that the two methods are significantly different (z = −3.357, p > 0.01). The new method RASH is statistically acceptable and it resulted in better response in terms of estimating the risk than the RA method.     

Advanced process control system with MPC as a new approach for layer of protection analysis

Layer of protection analysis (LOPA) is a widely used method to support process safety in the chemical industries. In the LOPA, the process is classified into many layers, one of such layers considers the basic process control system (BPCS) which commonly uses PID controllers. This kind of controllers cannot deal with constraints. For this reason, the main purpose of this work is to provide a framework to enhance the control layer in the LOPA, which consists of a model predictive control (MPC) with safety features. These features include: sublayers in the controller system (such as real time optimization, target calculation, and MPC), safety constraints, and guarantee of stability by adopting an Infinite Horizon MPC (IHMPC). Here, we propose an approach for control-inspired view to process safety, replacing the BPCS by an Advanced Process Control System (APCS). Moving forward with these concepts, first, a literature review emphasizes the content, showing two perspectives for the APCS. The APCS is designed for two varieties of controllers, a basic IHMPC and IHMPC with zone control to compare the performance. In this framework, the first sublayer consists of a real time optimization (RTO) structure, that calculates the optimal operating condition for the process controller, which computes the control action. Besides, RTO has an additional constraint called the safety index, based on the protection of process operational. RTO and basic IHMPC communicate directly, while for IHMPC with zone control there is an inner sublayer called Target Calculation, it computes a feasible target to the controller, working as another safety strategy in APCS. After that, we demonstrate both structures applied to a CSTR reactor. From the case study, we compared both controllers, and evaluated the effect that the safety index constraint causes in the setpoints, outputs, and control actions. The use of safety constraint in RTO proved to be a safe strategy for the control layer, as well as IHMPC with zone control presented a safer profile than basic IHMPC. Furthermore, the results show that safety constraint affect the economic goal, decreasing its value.