ProductionTeamHAZOPAwareness-revo

1、Why HAZOP?Historically, safe design of chemical plants based on:以前化工厂的安全设计工作基础是以前化工厂的安全设计工作基础是:Application of engineering design codes and standards 使用工程设计规范与标准。Wide experience and knowledge of professionals and experts involved in the design 依靠设计专家丰富的经验与专业知识。Use of design tools and checklists 利用设计工

2、具和核对清单。Experience has shown that Safety in Design techniques are not enough:过去的经验告诉我们所采用的安全设计手段还远远不能满足要求：过去的经验告诉我们所采用的安全设计手段还远远不能满足要求：Evident by multiple catastrophes in the Chemical Industry 化工厂许多灾难性事故很能说明问题。Increasing complexity of modern plants - highly integrated 现代化工厂变得越来越复杂 高度一体化。Traditional t

3、echniques are likely to miss design flaws 我们所采用的传统设计手段很容易忽略设计上的缺陷。Design groups focus on individual equipment not as much emphasis on how the process functions as a whole设计人员都把注意力集中在单项设备上 - 而不是重点把握工艺的整体效能。Range of knowledge and experience of designers 设计人员的专业知识面和设计经验问题。Flixborough, England - 1974 28

4、 died, 108 injured, losses 100M pound英国英国Flixborough- 1974年，年，28人死亡，人死亡， 108人受伤，损失一亿英镑。人受伤，损失一亿英镑。Amoco Chemical, New Castle - 1980 6 died, 20 injured, losses $40 million纽卡斯尔纽卡斯尔Amoco化工厂化工厂 - 1980年，年， 6人死亡，人死亡，20人受伤，损失人受伤，损失400万美元。万美元。Union Carbide, Bopal 1984 America 在印度在印度4000 died, 200,000 injure

5、dBopal的的Union Carbide厂厂 - 1984年年 4000人死亡，人死亡，20万人受伤。万人受伤。Marathon, Texas City - 1987HF release, 939 injured?, 3000 evacuated德克萨斯马拉松厂德克萨斯马拉松厂 - 1987年发生年发生HF泄露事件，泄露事件， 939人受伤，人受伤，3000人被疏散。人被疏散。Phillips Petroleum, Pasadena - 198923 died, 130 injured, losses $1.5 billionPasadena的菲力普石油化工厂的菲力普石油化工厂 - 1989

6、年年 23人死亡，人死亡，130人受伤，损失人受伤，损失15亿美元。亿美元。Arco, Channelview - 199017 diedChannelview的的Arco厂厂 - 1990年年 17人死亡。人死亡。Why Do Process Accidents Happen?为什么会发生工艺事件？为什么会发生工艺事件？Equipment failure设备故障。Design flaw设计缺陷。Incorrect operating conditions操作条件不正确。Unforeseen operating conditions不可预见的操作条件。Breakdown of hazard c

7、ontrols险情控制系统失灵。Human error人为因素。Events or Factors that Propagate Accidents造成事故发生的情况或者原因造成事故发生的情况或者原因Design errors (omission, commission)设计错误（设计漏项，试车）Incorrect diagnosis of situation对情况判断不正确。Operating errors (omission, commission)操作错误（失误，试车）。Alarm failures警报系统工作失灵。Shutdown system failures停机系统失灵。Ignit

8、ion sources点火源。Management system failures管理系统出现故障。Site-specific conditions特定的现场条件。lAlarms警报系统lSafety shutdown 安全停机系统lControl system response控制系统反馈lRelief valves/flare system泄漏阀 / 火炬系统lSecondary containment 事故预防二级外壳lFire protection systems 消防系统lOperator response 操作人员的反应lProcedures操作规程lTraining培训lPrev

9、entive Maintenance 预防性维护保养工作lTesting检测lInspection查验lEmergency Response 紧急状态反映系统lContingency planning 紧急事件处理预案How can we identify potential for an accident before it happens?我们如何才能在事故发生前查找到事故隐患？If we could identify problems, then we can prevent them!只要能查找到事故隐患，我们就能防止事故的发生！There are techniques办法还是有.Du

10、ring the 1960s ICI developed Hazard and Operability (HAZOP) studies as a technique to identify problems that traditional design approaches were likely to miss.What is HAZOP?A structured/systematic examination of each part of a chemical process对化工工艺每个部分都进行有序的 / 系统化的检验。Using a series of “guide words”使

11、用一系列引导词。Undertaken by an experienced multi-discipline team由经验丰富、多种专业人员组成的小组来负责。Identify all possible deviations from design intent that can have undesirable consequences concerning safety, operability, or the environment.查找所有可能与设计目的的不符点，避免因此而在安全生产、可操作性或者环境方面带来不良后果。HAZOPs have become more robust sinc

12、e it was developed by ICI.HAZOP方法自从由ICI研制出来后变得日益完善。HAZOPs are recognized world-wide by the Chemical Industry and Engineering and Construction Companies as a standard engineering practice to ensure integrity of the design and operation.HAZOP方法被全球范围内的化工生产企业和设计施工公司普遍接受，被认为是能够融合设计与生产需求的标准工程实践措施。Numerous

13、 countries require HAZOP (process hazard analysis) for the Chemical Industry as a critical part of programs for preventing major chemical accidents.众多国家在化工行业都需要HAZOP（工艺风险分析方法），他们运用这种方法主要是为了防止发生重大的化工企业生产事故。Benefits of HAZOP运用HAZOP分析方法所带来的好处More complete awareness of hazards by providing a structured

14、and systematic examination of a process for hazards运用层次分明、系统化的检验方法来检查工艺流程当中存在的风险事项，可以更全面地提高人们对危险的认识。Employee participation :员工的参与： - Gathers real input from team让团队成员真正地投入进来。 - Concerns are discussed and documented研究探讨问题并作好文字记录。 - Team is more informed on process hazards使团队成员更清楚地了解工艺 流程中存在的危险事项。 - I

15、ncorporates multiple perspectives从多种角度来看待问题。Assists management in risk decisions:有助于管理层作出风险决策：- Can be used to develop effective strategy to reduce risks 运用这一方法有助于制定出有效的降低风险的方案。- Provides input on how to better manage risks 提供关于如何改进风险管理工作的信息。- Provides basis for determining if risks are acceptable 提

16、供决策依据，以确定风险是否属于可接受范围。Benefits of HAZOP Ultimate Outcomes应用HAZOP方法所能带来的利益 - 最终结果Improved safety performance resulting in less risk to public, employees, assets, and the environment .提高安全生产水平，减少对公众、雇员、财产以及环境造成的危害。Ensures compliance with laws and regulations确保生产行为符合法律、法规的要求。Minimizes business interrupt

17、ions最大程度地降低对经营工作造成的影响和干扰。Provides forum for identifying opportunities to improve reliability of operations, reduce upsets, and improve product quality.研究并发现机会，来提高生产操作的可靠性、减小各种负面影响、并提高产品质量。Improves relations with public and employees改善企业和公众以及雇员之间的关系。Benefits of HAZOP For New Plants应用HAZOP方法给新建工厂带来的好处

18、 Excellent tool for predicting hazards & incorporating prevention methods into design有利于及早预见险情并在设计阶段将防范措施考虑进去。Increases the likelihood that the process will operate as intended有利于增加工艺流程按设计预期运转的可能性。Results in smoother startup and less time required to achieve design capacity有利于平稳开工，缩短达产时间。Reduces

19、 costly late changes to design and after startup有利于节省因设计变更以及工厂开工后进行变更而造成的巨大投入。Provides sound information for development of operating procedures有利于提供编制运行规程所需的可靠资料。Provides a higher level of understanding of the process by all有利于使全体员工更好地理解工艺流程。Critical Success Factors For HAZOP成功应用HAZOP方法的关键因素Accurac

20、y of design drawings and other data used in the study分析过程中设计图纸与其它数据资料的准确性。The technical skills and expertise of the team on the process工艺组工作人员的技术水平与专业知识。The ability of the team to use the approach as an aid to visualize possible deviations, causes, consequences, and relevant safeguards小组成员是否能够很好地应用这

21、一方法，来帮助查找可能出现的任何偏差、成因、结果以及相关保障手段。The ability of a the team to maintain a sense practicality when assessing the seriousness of identified hazards and recommending corrective actions小组成员能否很好地应用这一方法，采取审慎而实际的工作态度，对查找到的危险隐患严重性进行评估，并提出正确的处理措施。Management commitment to the HAZOP process有利于使管理部门投入精力来研究HAZOP方

22、法。Preparation for a HAZOP应用HAZOP分析方法前的准备事项P&Ids - Focus of the HAZOP review must be accurateP&IDS - HAZOP方法的核心 - 必须准确可靠。Important information for HAZOP studies:进行HAZOP分析时应注意的重要事项：Physical and hazardous properties of chemicals, reactivity, instability, mixing hazards, MSDS, corrosive properti

23、es化学药品、化学反应、不稳定性、混合性危险因素、MSDS、以及腐蚀性成分中的物理性能与危险特质。Process chemistry工艺过程的化学特性。Process description, material and energy balance, process limits工艺过程简述、材料与能耗均衡情况、工艺流程的局限性。Equipment design information, materials of construction, and limits设备的设计资料、施工材料与其局限性。Plant layout or plot plans工厂平面布置或者土地使用规划。Control

24、strategy/philosophy控制措施 / 方案。Preparation for a HAZOP应用HAZOP分析方法前的准备事项Important information for HAZOP studies:进行HAZOP分析时应注意的重要事项：Relief system design and design basis风险缓解系统设计与设计依据。Design basis and location of protective devices and safety equipment防护措施与安全设备的设计依据与布置。Ventilation system design通风系统设计。Ope

25、rating, maintenance, and safety procedures and policies操作、维修、安全生产规程与规定。Previous incident information, inspection reports, operating logs以往事故记录资料、检查报告以及生产日志。Team Membership for a HAZOP Study进行HAZOP分析的小组成员素质要求HAZOP Leader facilitates the review, ensures methodology is followed, helps team to stay focu

26、sed and achieve consensus. The leader must be independent of the process being reviewed.HAZOP分析小组组长 - 协调审核工作，确保分析方法得到应用，帮助小组成员集中精力、步调一致。选择组长人选时，必须选择与接受审核的工艺流程无关的人员。HAZOP Scribe Proficient in recording HAZOP studies and using HAZOP recording software. Aids leader in helping to bring team discussions

27、to a conclusion.HAZOP分析纪录员 - 精通HAZOP录入方法、与HAZOP软件的应用知识。协助组长总结小组讨论的结果。HAZOP team is a multi-discipline team representing core disciplines that support plant operationsHAZOP小组应由多种专业人员构成，他们能代表保证工厂运营所需的关键专业。HAZOP Team MembersHAZOP小组的成员素质要求Operations Representative Extensive hands-on experience in operat

28、ing the process being reviewed生产操作代表 - 具有在接受审核的工艺流程中丰富的一线生产经验。Process/Chemical Engineer In depth knowledge of the process, process chemistry, and the chemical process unit operations工艺/化学工程师 - 精通有关工艺流程、工艺化学以及化工工艺装置生产方面的知识。Design/Mechanical Engineer Extensive knowledge on the equipment physical desig

29、n and limits, materials of construction and current status of equipment设计 / 机械工程师 - 对设备物理性能设计与其局限性、施工材料和设备现状了如指掌。Control/I&E Engineer/Technician Knowledge of control and safety systems design and control philosophies控制 / I&E工程师 / 技术员 - 了解控制与安全系统的设计与控制工作原理。HAZOP Team MembersHAZOP小组的成员素质要求Main

30、tenance Representative Extensive hands-on experience in maintaining the equipment, understanding of maintenance and mechanical integrity processes, and equipment maintenance history维修代表 - 具有丰富的设备维护一线工作经验，了解维护与机械整体工艺知识，并了解设备的维修历史。HSE representative (can be part-time) Sets tone for acceptable and unac

31、ceptable HSE performanceHSE代表-（可兼任）编制HSE验收条件，决定哪些可以接受，哪些不可接受。Other Specialists Called in to answer technical questions related to equipment and their function, process chemistry, etc. Can be rotating equipment experts, electrical experts, research chemist, furnace experts, process safety expert, ven

32、dor experts for proprietary equipment其他专家 - 请来解答有关设备及其功能等方面的技术问题。可以是循环作业的设备专家、电气专家、化学研究专家、炼炉专家、工艺安全生产专家以及专有设备供货商派来的专家。HAZOP MechanicsHAZOP工作方法1. The P&ID to be reviewed is divided into NODES, based on design intent. 审核P&ID时应根据设计内容要求按章节进行。2. The HAZOP Team discusses the design intent of the n

33、ode, limits of process, process chemistry, and the equipment design HAZOP小组对各章节的设计内容、工艺局限性、工艺化工以及设备的设计等问题进行研究探讨。3. The team takes a guide word/deviation and identifies all of the causes for the deviation. 小组按照引导词 / 偏差，查找造成偏差的各类成因。4. The team then determines the consequences of each identified cause.

34、 If the consequence is serious, the team identifies applicable safeguards for the cause and/or consequence.小组随后落实每个查找到的成因可能造成的结果。如果属于严重结果，小组则应找出适当的安全保证措施，预防该成因及/或防止发生该结果。HAZOP Mechanics HAZOP工作方法5. If the team determines that the consequence is unacceptable and the safeguards are inadequate, then th

35、e team develops a recommendation to address the concern. Recommendations could be:如果小组认为结果不可接受，保证措施也不得力，那么，小组则应提出解决这一问题的建议方案。建议方案应包括以下内容：Modify the design修改设计。Address concern through procedures or other administrative controls通过各项规程或者行政控制手段来处理这一问题。Evaluate and determine solution for the problem分析并确定

36、解决问题的方法。6. Once the team finishes its analysis of all of the causes, it proceeds to the next guide word/deviation 小组完成了对所有成因的分析后，则继续进行下一个引导词 / 偏差的查找工作。HAZOP MechanicsHAZOP工作方法7. Once the team finishes examining all of the guide words, it starts reviewing the next node.小组结束对所有引导词的检查工作后，则应开始审核下一个章节的内容

37、。8. This process is followed until all of the process P&IDS have been reviewed 按照这一程序来完成对P&ID所有流程的审核工作。No Flow无流无流Instrumentation仪表仪表Corrosion/Erosion锈蚀锈蚀 / 腐蚀腐蚀Reverse Flow逆流逆流 Relief减压减压Equipment Siting设备定位设备定位More Flow流量过高流量过高Contamination污染污染Previous Incidents前次事故前次事故Less Flow流量不足流量不足Pro

38、perties of Chemicals化学成分化学成分Human Factors人为因素人为因素More Pressure压力超量压力超量Rupture/Leak断裂断裂 / 泄漏泄漏Safety安全安全Less Pressure压力不足压力不足Ignition点火点火Environment环境环境More Level 水位过高水位过高Service Failure服务故障服务故障Less Level水位过低水位过低Abnormal Operation非正常操作非正常操作More Temperature温度偏高温度偏高Sampling取样取样Less Temperature温度偏低温度偏低M

39、aintenance维护维护For each Guide Word/Deviation the team has a list of possible issues to help promote thought. Example:对每一组引导词 / 偏差，小组都备有一份潜在问题清单，以协助工作人员发现问题。例如：More Flow流量过多流量过多Bypass valve open旁路阀开启 - increased pumping capacity 增加泵压能力 - operation of pumps in parallel 多台泵同时运行 - reduced delivery head 减

40、弱扬程 - change in fluid density 改变液体浓度 - exchanger tube leaks交换管泄漏 - worn or deleted restriction orifice plates 限制孔板磨损或者被拆除 - cross connection of systems 截面连接系统 - control faults 控制缺陷 - control valve trim changed 控制阀边沿改变 - control valve fails open 控制阀无法开启 - burst pipe 爆裂管 - large leak 重大泄漏 - wrong valv

41、e open 阀门开启错误 - fugitive emissions 挥发物排除 - slug flow废渣流出Record Keeping记录The study is recorded by the HAZOP scribe:分析工作由HAZOP记录员负责记录：Use of a software package specifically designed for efficient recording of HAZOP proceedings. This is in column format, listing causes, consequences, safeguards, and re

42、commendations运用专用软件包，提高HAZOP过程的编入效率。该软件以竖列格式，列有成因、结果、保证措施以及建议方案等内容。All team deliberations are recorded. 小组进行的所有谈论结果都记录在案。Each cause and significant consequence is brought to closure.每一个成因与重大结果都最终形成闭合。Team fully agrees with the documented HAZOP proceedings小组成员都认可HAZOP程序文件内容。Upon completion of a HAZOP

43、, the leader issues a HAZOP report一次HAZOP分析结束后，组长签发一份HAZOP报告。Recommendation Resolution建议解决方案The report will contain recommendations that the management team must address and develop an action plan.报告中应提出建议方案，管理组必须审阅并据此编制出行动方案。An action plan identifies responsibility and schedule to take action on ea

44、ch recommendation and to document actions taken.每个行动方案都针对每个建议实施方案以及记录程序明确岗位职责与工作进度。Open recommendations must be tracked to closure.没有最终结论的建议方案必须进行跟踪调查, 直至妥善处理完毕。Management Commitments管理层承诺1. HAZOPs are time consuming (1 P&ID/Day) Do not underestimate resource requirements for the HAZOP. 如果不了解HAZ

45、OP方法所需的资源配置，那么采用HAZOP方法则会很耗时（每天只能完成一个P&ID）。2. Make sure that you do not set conflicting priorities for HAZOP team members between the HAZOP and their existing job. Recognize the importance of HAZOP and give team members the capability to focus on the HAZOP. HAZOP小组成员在进行HAZOP分析与他们现有的工作之间，在工作次序安排上

46、，管理层应保证不出现冲突现象。应认识到HAZOP工作的重要性，让小组成员能够集中精力进行此项工作。3. Select the right team members for the HAZOP. The best people give the best results. The quality of the recommendations are dependent of the competency and expertise of the HAZOP team. 选择好HAZOP小组的工作人选。人选好了就能获得最好的工作结果。建议方案提的好与坏，就看HAZOP小组成员工作能力与专业知识如何

47、。Management Commitments管理层承诺4.Pay close attention to team burn-out. HAZOP is intense and people burn-out quickly. The efficiency and effectiveness of HAZOP teams decline rapidly after 4 hours/day of HAZOP. 应密切关注小组工作热情的变化。HAZOP工作强度大，人们对此很容易丧失激情。每天进行HAZOP工作四个小时，会使HAZOP小组的工作效率与效果急剧下降。5.Be prepared to a

48、ddress a LOT of recommendations for improving safety, environment performance, and operability of the process. Do not underestimate resource requirements for addressing HAZOP recommendations. 时刻准备审阅一大堆旨在提高安全生产、改善环境、提高工艺工作效率的建议方案。切勿低估处理HAZOP建议方案所需的支持性资源配置。6.Be proactive and establish high priority fo

49、r completing HAZOP recommendations. Make sure there are no conflicting priorities. Reward/recognize people for their work on HAZOP items. Make sure safety recommendations on project HAZOPs are completed before startup of a project. 积极支持并高度重视完成HAZOP建议方案这项工作。保证不出现工作层次安排上的冲突。对HAZOP小组的工作应给予鼓励 / 认可。保证在项目

50、启动之前，通过HAZOP分析完成项目安全建议方案。Management Commitments管理层承诺Worst situations:最糟糕的情况：1. Not conducting the HAZOP because it is not a priority item ie resource demands too high - ESSO Longford Incident 2 people killed, irreputable damage to ESSO loss of asset 不进行HAZOP分析，因为这不是工作中的头等大事 - 亦即资源配置要求太高 - ESSO Longf

51、ord事故 - 2人丧生，有损于 ESSO的声誉 - 财产损失。2. Conducting HAZOP with an ineffective team - waste resources, and have to deal with a poor quality recommendations 进行HAZOP分析的工作小组效率低下 - 浪费资源，并且还得处理很对组织不力的建议方案。3. Conducting a HAZOP not placing priority on addressing recommendations Employees quickly see that safety

52、is not the first priority. Overall safety performance and attitude decline 进行了HAZOP分析工作 - 不重视审阅建议方案 - 员工很快发现安全问题并非头等大事。总体安全生产水平与对安全生产的重视程度均下降。Case Study: Pasadena Plant LAO FireBP Pasadena Plant, owned and operated by Albemarle Corp. in 1992 at the time of the incident.BP在在Pasadena的工厂的工厂1992年事故发生时的场

53、年事故发生时的场景，当时该厂属于景，当时该厂属于Albemarle 公司并由该公司并由该公司运营。公司运营。(see notes for incident description)（详见备注中的事故描（详见备注中的事故描述内容）述内容）Case Study: Pasadena Plant LAO Fire个案分析： Pasadena工厂LAO车间火灾 A HAZOP had not been performed on the process. 没有对工艺流程进行过没有对工艺流程进行过HAZOP分析。分析。 How could a HAZOP study of the process have

54、helped prevent the incident? 对工艺流程进行对工艺流程进行HAZOP分析，为何有助于预防发生该事故？分析，为何有助于预防发生该事故？1. HAZOP would have found that there was only one valve between a high pressure process and the low pressure system flush system. Misalignment or leaking valve could overpressure the low pressure flush system. 经过进行经过进行HA

55、ZOP分析，则可能会发现在高压工艺系统与低压系统冲洗系分析，则可能会发现在高压工艺系统与低压系统冲洗系统之间只有一个闸阀。闸阀安装不当或者出现泄漏则会增加低压冲洗系统统之间只有一个闸阀。闸阀安装不当或者出现泄漏则会增加低压冲洗系统的压力。的压力。2. HAZOP would have found that the low pressure flush system needed relief protection. 如果进行如果进行HAZOP分析，则可能会发现应在低压冲洗系统里安装减压保护分析，则可能会发现应在低压冲洗系统里安装减压保护装置。装置。Case Study: Pasadena Pl

56、ant LAO Fire个案分析： Pasadena工厂LAO车间火灾 How could a HAZOP study of the process have helped prevent the incident?:对工艺流程进行对工艺流程进行HAZOP分析，为何有助于预防发生该事故？分析，为何有助于预防发生该事故？3. The high pressure ethylene feed line ran directly over the pumps containing pyrophoric chemicals. HAZOP would have identified the potential for ethylene decomposition if the line was exposed to fire. HAZOP would have identified a lack of ability to isolate the ethylene feed line 高压乙烯进料生产线直接布置在装有自燃化学物品的泵站上方。如果经高压乙烯进料生产线直接布置在装有自燃化学物品的泵站上方。如果经过过HAZOP分析，则可能会发现当该生产线与火接触时可能会导致乙烯分析，则可能会发现当该生产线与火接