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So, you cannot vent: A deep dive into other explosion protection methods 因此,不能排气:深入探讨其他防爆方法
IF 1 4区 工程技术 Q4 ENGINEERING, CHEMICAL Pub Date : 2024-08-31 DOI: 10.1002/prs.12639
Michelle Murphy
Current NFPA standards for managing combustible dust hazards require equipment with an explosion hazard to be protected from the effects of deflagration. These protections include deflagration venting in accordance with NFPA 68, Standard on Explosion Protection by Deflagration Venting, 2023 Edition, or oxidant concentration reduction, combustible concentration reduction, deflagration suppression, or deflagration pressure containment, via NFPA 69, Standard on Explosion Protection Systems, 2024 Edition. It makes sense to choose the simplest and most cost‐effective option based on the inherent design and risk of the operation. Implementation of any one of these protection methods requires an understanding of the method and all the associated requirements. While the basic methods are fairly straightforward, the associated requirements are often less understood. In this paper, the author will introduce the basic methods and take a deep dive into the associated requirements of each method of protection. Based on the author's experience in evaluating protection systems, common misunderstandings will be highlighted, for example, the margin of safety to apply and the operational limits required to be developed and documented for oxidant concentration reduction systems.
现行的 NFPA 可燃粉尘危险管理标准要求对有爆炸危险的设备进行保护,以防爆燃的影响。这些保护措施包括根据 NFPA 68《爆燃通风防爆标准》(2023 年版)进行爆燃通风,或根据 NFPA 69《防爆系统标准》(2024 年版)降低氧化剂浓度、降低可燃物浓度、抑制爆燃或抑制爆燃压力。根据作业的固有设计和风险,选择最简单和最具成本效益的方案是合理的。实施任何一种保护方法都需要了解该方法和所有相关要求。虽然基本方法相当简单明了,但相关要求往往不那么容易理解。在本文中,作者将介绍基本方法,并深入探讨每种保护方法的相关要求。根据作者在评估保护系统方面的经验,将重点介绍常见的误解,例如,氧化剂浓度降低系统应适用的安全系数以及需要制定和记录的操作限制。
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引用次数: 0
Numerical simulation study on propane gas leakage and diffusion law in slope terrain 斜坡地形中丙烷气体泄漏和扩散规律的数值模拟研究
IF 1 4区 工程技术 Q4 ENGINEERING, CHEMICAL Pub Date : 2024-08-27 DOI: 10.1002/prs.12646
Tingting Luan, Xiaoyun Li, Lixun Wang, Yun Chu, Qinghang Zhang, Xinyu Zhang
It is frequent that gas leakage accidents occur at chemical enterprises located in slope terrain. Meet the requirement of urgently studying the gas leakage and diffusion law in slope terrain. In this study, we utilize computational fluid dynamics (CFD) to simulate the scenarios of propane leakage and diffusion under four distinct slope conditions, which are 0°, 10°, 15°, and 20°. The gas diffusion law under different slopes is investigated, and the influence of wind speed and wind direction on the diffusion process is also further analyzed. The study indicates that when the slope exceeds 15°, the change in slope exerts a pronounced influence on the dispersion of propane leakage. Compared with diffusion on flat ground, there is a distinct propane aggregation area at the bottom of the slope terrain. Also, the steeper the slope, the more noticeable the aggregation phenomenon. The increase of wind speed makes propane gas lifted, and the gas aggregation at the bottom of the slope decreases. In particular, at a wind speed of 3.3 m/s, the aggregation of propane at the bottom of the first 15° and 20° slopes is more pronounced. Under the upwind condition, the propane gas is entrained at the slope surface, increasing the propane concentration in the area around the tank, which in turn increases the safety risk. The findings of this study have significant implications for the rational layout of chemical enterprises, gas leakage monitoring, and emergency evacuation planning for leakage accidents. They can also help enhance chemical enterprises' safety prevention abilities and the efficiency of their emergency response.
位于坡地的化工企业经常发生气体泄漏事故。为满足急需研究坡地气体泄漏和扩散规律的要求。本研究利用计算流体动力学(CFD)模拟了 0°、10°、15° 和 20°四种不同坡度条件下丙烷泄漏和扩散的情景。研究了不同坡度下的气体扩散规律,并进一步分析了风速和风向对扩散过程的影响。研究表明,当坡度超过 15°时,坡度的变化对丙烷泄漏的扩散有明显的影响。与在平地上的扩散相比,在斜坡地形的底部有一个明显的丙烷聚集区。而且,坡度越陡,聚集现象越明显。风速的增加会使丙烷气体上扬,坡底的气体聚集减少。特别是在风速为 3.3 米/秒时,丙烷在第一个 15°和 20°斜坡底部的聚集现象更加明显。在上风条件下,丙烷气体夹带在斜坡表面,增加了储罐周围区域的丙烷浓度,从而增加了安全风险。本研究的结果对化工企业的合理布局、气体泄漏监测和泄漏事故应急疏散规划具有重要意义。同时也有助于提高化工企业的安全防范能力和应急响应效率。
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引用次数: 0
Risk and consequence analysis of ammonia storage units in a nuclear fuel cycle facility 核燃料循环设施中氨储存装置的风险和后果分析
IF 1 4区 工程技术 Q4 ENGINEERING, CHEMICAL Pub Date : 2024-08-27 DOI: 10.1002/prs.12645
Biplab Das, Shekhar Kumar, S. P. Sivapirakasam
Industrial disasters, such as unintended toxic gas releases resulting in fires, explosion, and fatalities, are damaging both the global ecology and the social acceptance of the related technology. Risk and consequence analysis is the key feature of process safety measures for the protection of environment and human life. In this work, the risk and consequence analysis of unintended release of anhydrous liquid ammonia for one of the storage tanks, located inside the nuclear fuel cycle facility, was analyzed for leakages leading to exposure of surrounding human population and fire with allied thermal radiation risk. The risk assessment was performed using four methods: Fault tree, E&FI methodology, Probit, and ALOHA, It was observed that while the predicted hazard severities from fault‐tree analysis, Probit analysis, and ALOHA nearly converged, the conventional F&EI, the safety workhorse of the chemical industry estimated low numeric values of the respective hazard. A methodology was proposed to load this general F&EI value for the case of chemical plant being located inside a nuclear facility. Overloaded F&EI procedure estimated hazard value for envisaged unintended ammonia release in good agreement, with results from FTA, Probit, and ALOHA analyses.
工业灾难,如意外释放有毒气体导致火灾、爆炸和人员死亡,正在破坏全球生态环境和相关技术的社会认可度。风险和后果分析是保护环境和人类生命的工艺安全措施的关键特征。在这项工作中,对位于核燃料循环设施内的一个储罐意外释放无水液氨的风险和后果进行了分析,以确定泄漏是否会导致周围人群暴露和火灾以及相关的热辐射风险。风险评估采用四种方法进行:据观察,虽然故障树分析、Probit 分析和 ALOHA 预测的危害严重程度几乎趋于一致,但传统的 F&EI(化工行业的安全主力)估计的相应危害数值较低。针对化工厂位于核设施内的情况,提出了一种加载一般 F&EI 值的方法。过载的 F&EI 程序估算出了氨意外释放的危险值,与 FTA、Probit 和 ALOHA 分析的结果非常吻合。
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引用次数: 0
Diagnosing electrostatic problems and hazards in industrial processes: Case studies 诊断工业流程中的静电问题和危害:案例研究
IF 1 4区 工程技术 Q4 ENGINEERING, CHEMICAL Pub Date : 2024-08-27 DOI: 10.1002/prs.12644
Vahid Ebadat, Paul Cartwright
Static electricity is a phenomenon commonly encountered yet often misunderstood and underestimated in terms of its hazard potential; it continues to challenge the safety and reliability of industrial processes, particularly those involving flammable substances. This paper delves into the critical issue of electrostatic hazards in industrial settings by presenting two flash fire/explosion case studies, one involving biphenyl dust and the other gasoline vapor; both linked to electrostatic discharges. The first case study examines an explosion in a flaker and pack‐out hopper during biphenyl flake manufacturing. The investigation reveals the role of electrostatic charges in the incident and how well‐intentioned equipment changes created warning signs of increased risk that were missed. The second case study discusses a gasoline vapor flash fire, highlighting the common yet overlooked hazard of static electricity during the transfer of flammable liquids. It underscores how common activities involving people can generate sufficient electrostatic charge to ignite flammable vapor–air mixtures in industry. The outcomes of these studies highlight the importance of acting on early warning signs of static electricity and the crucial role of data‐driven diagnostic techniques in addressing and controlling those hazards. By dissecting the intricacies of electrostatic phenomena, safety professionals can formulate actionable strategies to adapt plant operations and prevent hazards from static electricity. The paper advocates for a proactive approach to identifying and mitigating electrostatic risks in industrial settings beginning with process hazard analyses that incorporate static electricity hazards analysis and continues through employee training to ensure that early warning signs are identified, understood, and acted upon. It stresses the need for comprehensive safety measures, including proper grounding and bonding, use of static dissipative materials, and regular maintenance of safety equipment, to prevent incidents. Through these case studies, the paper contributes to understanding of electrostatic hazards in industrial processes and highlights the importance of integrating electrostatic safety measures into routine industrial operations.
静电是一种经常遇到的现象,但就其潜在危害而言,却经常被误解和低估;它继续对工业流程的安全性和可靠性提出挑战,尤其是那些涉及易燃物质的流程。本文通过介绍两个闪燃/爆炸案例研究,深入探讨了工业环境中的静电危害这一关键问题,一个涉及联苯粉尘,另一个涉及汽油蒸气;两者都与静电放电有关。第一个案例研究探讨了联苯薄片生产过程中焙烧炉和包装出料斗发生的爆炸。调查揭示了静电荷在事故中的作用,以及用心良苦的设备改动是如何造成风险增加的警告信号却被忽视的。第二个案例研究讨论了一起汽油蒸汽闪燃火灾,强调了在易燃液体转移过程中常见但却被忽视的静电危险。它强调了涉及人员的普通活动是如何产生足够的静电电荷来点燃工业中的易燃蒸汽-空气混合物的。这些研究成果强调了对静电早期预警信号采取行动的重要性,以及数据驱动诊断技术在应对和控制这些危害方面的关键作用。通过剖析错综复杂的静电现象,安全专业人员可以制定可行的策略,以调整工厂运营并预防静电危害。该论文提倡采取积极主动的方法来识别和降低工业环境中的静电风险,首先进行工艺危害分析,将静电危害分析纳入其中,然后通过员工培训来确保识别、理解早期预警信号并采取相应措施。它强调了采取全面安全措施的必要性,包括正确接地和接合、使用静电消散材料和定期维护安全设备,以防止事故发生。通过这些案例研究,本文有助于人们了解工业流程中的静电危害,并强调了将静电安全措施纳入常规工业操作的重要性。
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引用次数: 0
Artificial intelligence (AI) and process safety: Some cautionary observations 人工智能(AI)与工艺安全:一些警示性意见
IF 1 4区 工程技术 Q4 ENGINEERING, CHEMICAL Pub Date : 2024-08-21 DOI: 10.1002/prs.12641
Walter Frank
Artificial intelligence (AI) has become a vogue topic in the press, and descriptions of its potential impact range from apocalyptic to salvational. Interest in the topic will no doubt stimulate the search for applications to support both the technical and management systems aspects of process safety management. Within our industries, maintaining institutional memory and technical capability is made increasingly challenging by more frequent job movement among younger staff and the loss to the retirement of more senior staff. One would hope that AI could help fill the gaps caused by these factors. However, the author's sampling of current AI capabilities suggests that AI is not yet ready to do so. This paper provides some examples of errors and insufficiencies identified when seeking AI assistance in addressing process safety issues. It also suggests some existing challenges to better “training” of AI to support the needs of the process safety community. It concludes that caution should be applied, especially by less experienced personnel, when seeking AI assistance in addressing process safety–related technical matters.
人工智能(AI)已成为新闻界的热门话题,对其潜在影响的描述从世界末日式的到救世主式的不一而足。对这一话题的兴趣无疑会刺激人们寻求应用,以支持工艺安全管理的技术和管理系统方面。在我们的行业中,由于年轻员工的频繁调动和资深员工的退休,保持机构记忆和技术能力变得越来越具有挑战性。人们希望人工智能能够帮助填补这些因素造成的空白。然而,作者对当前人工智能能力的抽样调查表明,人工智能还没有准备好这样做。本文举例说明了在寻求人工智能协助解决工艺安全问题时发现的一些错误和不足。本文还提出了在更好地 "培训 "人工智能以支持工艺安全领域的需求方面存在的一些挑战。本文的结论是,在寻求人工智能协助解决工艺安全相关技术问题时,尤其是经验较少的人员应谨慎行事。
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引用次数: 0
Improving Process Hazard Analysis (PHA) outcomes to better manage critical controls in mining industry: From PHA to verification in the field 改进工艺危害分析 (PHA) 结果,更好地管理采矿业的关键控制:从 PHA 到现场验证
IF 1 4区 工程技术 Q4 ENGINEERING, CHEMICAL Pub Date : 2024-08-17 DOI: 10.1002/prs.12640
Christophe Catala, Laura Anato, Luis Carrero, Catherine Morar
Process safety management in the mining and metals industry is relatively new compared to other high‐hazard process industries such as oil and gas or chemicals. Practices are less mature and are developing, transferring from other industries, and using the International Council on Mining and Metals (ICMM) guidance to manage critical controls. This paper shares how Rio Tinto, a leading mining and metals company, has improved its critical controls management practices. Focus is put on how the company has improved the quality of its process hazard analyses (PHAs) and critical controls management activities through a series of actions. This covers clarification of the methodology used, development of training packages, revision of the methodology used to identify critical controls, development of a PHA facilitation approval process and a PHA facilitation approval committee, implementation of a training and coaching program for internal candidates, and development of assurance activities to monitor effectiveness of the process. These actions have resulted in very encouraging results in terms of overall quality of the PHAs, effectiveness of the PHA approval process to support the new methodologies introduced, and the development of internal facilitation capabilities.
与石油和天然气或化工等其他高危险工艺行业相比,采矿和金属行业的工艺安全管理相对较新。其实践还不太成熟,正在发展中,从其他行业借鉴,并使用国际采矿和金属理事会 (ICMM) 的指导来管理关键控制。本文分享了领先的采矿和金属公司力拓如何改进其关键控制管理实践。重点介绍了该公司如何通过一系列行动提高工艺危害分析 (PHAs) 和关键控制管理活动的质量。这包括明确所使用的方法、开发培训包、修订用于识别关键控制的方法、开发 PHA 促进审批流程和 PHA 促进审批委员会、实施针对内部候选人的培训和辅导计划,以及开发用于监控流程有效性的保证活动。这些行动在 PHA 的总体质量、支持新方法的 PHA 批准程序的有效性以及内部促进能力的发展方面取得了非常令人鼓舞的成果。
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引用次数: 0
Process Safety Maturity Assessment Tool 过程安全成熟度评估工具
IF 1 4区 工程技术 Q4 ENGINEERING, CHEMICAL Pub Date : 2024-08-12 DOI: 10.1002/prs.12637
Joey Cranston
Due to rapid change from divestitures, acquisitions, and greenfield startups, Albemarle found it challenging to communicate and assess our Process Safety expectations. We decided we needed a tool that would both guide site management through the milestones related to process safety management systems and one that would allow senior management to assess progress. In addition, a tool was needed to challenge existing sites with continuous improvement goals in process safety management. For this reason, one key aspect of the tool is applicability to every site in the company; even though the maturity of the process safety program is diverse.
由于剥离、收购和新建项目带来的快速变化,Albemarle 发现沟通和评估我们的工艺安全预期具有挑战性。我们决定需要一种工具,既能指导工厂管理层完成与工艺安全管理系统相关的里程碑,又能让高级管理层评估进展情况。此外,我们还需要一种工具来挑战现有的现场,以实现工艺安全管理的持续改进目标。因此,尽管工艺安全计划的成熟度各不相同,但该工具的一个关键方面就是适用于公司的每个现场。
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引用次数: 0
Process Safety News 工艺安全新闻
IF 1 4区 工程技术 Q4 ENGINEERING, CHEMICAL Pub Date : 2024-08-07 DOI: 10.1002/prs.12638
Bruce K. Vaughen
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引用次数: 0
Reliability in mass alert system for dam emergencies: Case study of Vale S/A 大坝紧急情况群体警报系统的可靠性:淡水河谷公司案例研究
IF 1 4区 工程技术 Q4 ENGINEERING, CHEMICAL Pub Date : 2024-08-07 DOI: 10.1002/prs.12629
Flávio Thimotio da Silva, Cilene Faria, Flávio Morais, Germano Ferraz, Roberto Delamora, Priscila Guedes, Daniela de Miranda Souza
In its iron ore operations, Vale, the largest mining company in Brazil and the fourth largest mining company in the world by market value, has 77 dams considered with high potential damage in case of a failure in the stability controls. This classification follows the criteria of the sector regulatory agency in Brazil and determines that, for this class, a mass alert system is necessary for the resident population and workers immediately downstream of the dam within a region preset by legislation, considering a simulated flood area. For Vale, the mass alert system for dam emergencies is part of a critical mitigating control for a business risk analysis considering the hypothetical dam break as an unwanted material event. Therefore, both the probability of failure on demand, spurious failure, and availability of the assets of this protection barrier are important elements for this purpose, as well as the emergency response plan and the evacuation simulation of flood areas, which are part of a risk management system that require continuous verification and continuous improvement. Currently, Vale has 375 sirens, and it is planned to reach 420 sirens by the end of 2024. The purpose of this article is to present how the safety concepts applied to these systems were developed, the good practices applied from this study, and the lessons learned from the dam emergency management arising from the break of the Brumadinho dam in 2019. The reliability analyses of the systems involved and the main contributors to the Safety Critical Unavailability are presented, as well as the results of the reduction in the maintenance time and increase in system availability.
淡水河谷公司是巴西最大的矿业公司,也是全球市值第四大的矿业公司,在其铁矿石业务中,有 77 座大坝被认为在稳定性控制失效的情况下具有高潜在破坏性。这种分类遵循巴西部门监管机构的标准,并确定对于这种等级的大坝,有必要在法律规定的区域内,考虑模拟洪水区域,为大坝下游的居民和工人建立大规模警报系统。对于淡水河谷来说,大坝紧急情况集体警报系统是业务风险分析中关键的缓解控制措施的一部分,将假定的大坝决堤视为不希望发生的重大事件。因此,按需故障概率、虚假故障概率和这一保护屏障的资产可用性都是这方面的重要因素,同时也是应急响应计划和洪水区域疏散模拟的重要因素,这些都是需要持续验证和不断改进的风险管理系统的一部分。目前,淡水河谷有 375 个警报器,计划到 2024 年底达到 420 个警报器。本文旨在介绍这些系统的安全概念是如何形成的、这项研究中应用的良好做法,以及从 2019 年布鲁马迪尼奥大坝决堤引发的大坝应急管理中吸取的经验教训。文章还介绍了相关系统的可靠性分析、造成安全临界不可用的主要原因,以及减少维护时间和提高系统可用性的结果。
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引用次数: 0
Testing and approval standard development of online dissolved gas analysis monitors for oil‐filled transformers—Part I hydrogen monitors 油浸变压器在线溶解气体分析监测器的测试和批准标准制定--第 I 部分氢气监测器
IF 1 4区 工程技术 Q4 ENGINEERING, CHEMICAL Pub Date : 2024-08-02 DOI: 10.1002/prs.12636
Paul Su, Rajni Madan, Sujit Purushothaman
The failure of mineral oil‐filled transformers has been involved in numerous fire and explosion incidents during operations. The power industry has developed online dissolved gas analysis (DGA) monitoring systems capable of diagnosing transformer faults continuously. This study has established new test procedures and pass/fail criteria to evaluate the accuracy of online H2 monitors, resulting in the creation of a new approval standard.
矿物油填充变压器的故障曾多次引发火灾和爆炸事故。电力行业已经开发出能够连续诊断变压器故障的在线溶解气体分析 (DGA) 监测系统。这项研究制定了新的测试程序和合格/不合格标准,以评估在线 H2 监测器的准确性,从而制定了新的审批标准。
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引用次数: 0
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Process Safety Progress
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