Evaluation methods, storage devices and systems for critical safety facilities in the chemical industry

Abstract

The present invention discloses a method, storage device and system for evaluating key safety facilities in the chemical industry, and relates to the technical field of risk evaluation and control of petrochemical devices in the chemical industry. It includes five modules: a risk analysis module, which analyzes the potential risks of the device and determines the risk level; a risk level screening module, which extracts risk events of a certain risk level; an accident scene protection measure hierarchical module, which manages the protection measures of the accident scene in a hierarchical manner; a key safety facility document module, which determines the protection measures that play a key role in the petrochemical device; a key safety facility analysis module, which analyzes the protection measures in the event chain based on the events screened by the risk level screening module, determines the list of key safety facilities of the device, and performs high-level inspection and maintenance on the key safety facilities of the device to ensure that they play a role when required. The present invention can determine the key safety facilities of the device, improve the protection level of the key safety facilities, and avoid the occurrence of major safety accidents.

Description

Technical Field

[0001] The present invention relates to the technical field of risk assessment and control of petrochemical plants in the chemical industry, and in particular to a method, storage device and system for assessing key safety facilities in the chemical industry. Background Art

[0002] In recent years, major safety accidents involving hazardous chemicals in the chemical industry have caused serious losses to people's lives and property, and have caused serious pollution to the environment. Frequent accidents have made chemical companies aware of the importance of safe production. Risk analysis methods such as HAZOP / LOPA analysis, SIL rating and verification, and bow-tie analysis have been continuously promoted and applied in my country's petrochemical companies, forming a unified risk analysis and risk rating standard.

[0003] After conducting risk analysis, enterprises ensure that the protective measures of the device to prevent or mitigate accidents can play a role when required, so as to truly reduce the possibility of accidents and the severity of accident consequences. At present, enterprises regularly inspect and maintain the protective measures of the device to ensure that the protective measures of the device play a role when required. The same level of indiscriminate inspection and maintenance consumes a lot of manpower and material resources, and the enterprise cannot ensure that all the protective measures of the device are well maintained and effectively prevent or mitigate the occurrence of accidents.

[0004] For risk events of the device, the device has multiple protection measures to prevent or mitigate the occurrence of the risk event or mitigate the severity of the consequences of the event. Based on the device risk event occurrence chain, after the initial risk event is triggered, the event protection measures are required to be activated. When the first layer of protection measures fails, the subsequent protection measures will be activated, but when the last layer of protection measures fails, the accident can only be allowed to occur. Summary of the invention

[0005] The purpose of the present invention is to provide a method for evaluating key safety facilities in the chemical industry. For risk events that can cause major or above safety accidents, the last layer of protection measures of risk events are identified, and high-level inspection and maintenance are performed on them with priority to ensure that the last layer of protection measures play a role when required, effectively curbing the occurrence of risk events or reducing the severity of the consequences of the events.

[0006] To achieve the above object, the present invention adopts the following technical solutions:

[0007] A method for evaluating key safety facilities in the chemical industry comprises the following steps in sequence:

[0008] S1. Obtain risk events of the device and determine the risk level value of the device risk events according to the risk matrix;

[0009] S2. Screening the risk level values ​​to screen out risk events where the risk level values ​​exceed preset values;

[0010] S3. Analyze the risk events one by one to determine the list of key safety facilities of the device;

[0011] S4. List the key safety facilities of the device and determine the key safety activities for the key safety facilities of the device.

[0012] In the above-mentioned critical safety facility assessment method for the chemical industry, in step S2, the above-mentioned risk level values ​​are screened to screen out risk events with risk level values ​​of D and above.

[0013] In the above-mentioned chemical industry key safety facility assessment method, the above-mentioned risk events are analyzed one by one, including:

[0014] For a risk event with a risk level value of D or above, determine the independent protection layer of the risk event, compare the above independent protection layer with the key safety facility documents, and analyze whether the independent protection layer belongs to the above key safety facility documents.

[0015] In the critical safety facility assessment method for the chemical industry, if the above-mentioned independent protection layer belongs to the above-mentioned critical safety facility document, then the independent protection layer of the risk event is the critical safety facility of the device;

[0016] For independent protection layers that are not part of the key safety facility documents, determine whether there is a sixth layer of protection - physical protection in the independent protection layer according to the accident scenario chain process:

[0017] If so, the independent protection layer is a key safety facility of the device; for the remaining independent protection layers, determine whether they are independent protection layers of the last line of defense to prevent / mitigate accident scenarios. The independent protection layer of the last line of defense is a key safety facility of the device; the remaining independent protection layers in the accident scenario do not belong to the key safety facilities of the device.

[0018] In the critical safety facility assessment method for the chemical industry, after the key safety activities for the critical safety facilities of the device are determined, they are given a high priority level of inspection and maintenance.

[0019] Another object of the present invention is to provide a critical safety facility assessment system for the chemical industry.

[0020] A critical safety facility assessment system for the chemical industry, comprising:

[0021] Risk analysis module, risk level screening module, accident scenario protection measures layering module, key safety facility documentation module and key safety facility analysis module.

[0022] The above-mentioned chemical industry key safety facility assessment system and the above-mentioned risk analysis module are used to analyze the potential risks existing in the device, determine the risk level of the device, and further obtain the device risk events;

[0023] The risk level screening module is used to extract risk events with risk levels of D and above based on the risk matrix for the device risk events obtained by the risk analysis module;

[0024] The above-mentioned accident scenario protection measures stratification module classifies and stratifies the possible protection measures in the accident scenario according to the event chain process of the risk event;

[0025] The above-mentioned key safety facility document module is used to directly identify the equipment and facilities that play a key role in the risk events of the device as key safety facility documents in combination with the actual situation of the petrochemical enterprise.

[0026] The above-mentioned critical safety facility analysis module is used to analyze the risk event protection measures one by one for the device risk events obtained by the risk level screening module, and determine the list of critical safety facilities of the device.

[0027] The above-mentioned critical safety facility assessment system for the chemical industry analyzes the potential risks of the device. Professional risk analysts use the HALOPA method to analyze the risks of the device and derive the risk level of the device risk events.

[0028] The above-mentioned chemical industry critical safety facility assessment system, the above-mentioned accident scenario protection measure layered modules include: intrinsic safety design, basic process control system-safety control loop, key alarm and personnel response, basic process control system-safety interlock, SIS interlock, physical protection, other independent protection layers-prevention, post-release protection and other independent protection layers-mitigation, and the independent protection layers are set in sequence as the first to ninth layers of protection for the accident scenario.

[0029] The above-mentioned chemical industry critical safety facility assessment system, after determining the list of critical safety facilities of the device, formulates key safety activities based on the list of critical safety facilities of the device and performs priority high-level inspection and maintenance of the critical safety facilities.

[0030] The above-mentioned chemical industry key safety facility assessment system, the above-mentioned post-release protection includes leakage interception and collection, fire protection and explosion suppression systems.

[0031] Another object of the present invention is to provide a memory including a software program, wherein the software program includes steps suitable for being executed by a processor for the above-mentioned method for assessing critical safety facilities in the chemical industry.

[0032] A key safety facility assessment device for the chemical industry comprises the above-mentioned memory, wherein the above-mentioned memory is connected to a processor via a bus, and the instruction set in the above-mentioned memory is executed by the above-mentioned processor.

[0033] Compared with the prior art, the present invention brings the following beneficial technical effects:

[0034] The critical safety facility assessment method for the chemical industry of the present invention comprises a risk analysis module, a risk level screening module, an accident scenario protection measure layering module, a critical safety facility document module and a critical safety facility analysis module. Through the cooperation of each module, the following functions can be achieved:

[0035] Conduct risk analysis on the company's equipment and determine the risk level of equipment risk events; screen the risk level of equipment risk events and determine equipment risk events that will cause major safety accidents that may result in death or serious injury; manage the equipment's independent protection layers in layers based on the equipment risk event occurrence chain process; for risk events that may result in major safety accidents, determine the last line of defense for the accident scenario based on the event occurrence chain process and obtain a list of the equipment's key safety facilities; determine targeted key safety activities for each key safety facility to ensure that the last line of defense for the accident scenario functions as required, effectively curbing the occurrence of major safety accidents or reducing the severity of accident consequences. High-priority maintenance of equipment key safety facilities based on key safety activities can improve the reliability of the equipment's key safety facilities.

[0036] In summary, the method of the present invention can determine the key safety facilities of the device, improve the protection level of the key safety facilities, and avoid the occurrence of major safety accidents. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Figure 1 This is a schematic diagram of the independent protection layers of the accident scene of the present invention;

[0038] Figure 2 The risk matrix diagram used in the present invention;

[0039] Figure 3 This is a flow chart of the critical safety facility assessment in the chemical industry according to the present invention. DETAILED DESCRIPTION

[0040] The present invention proposes a method, storage device and system for evaluating key safety facilities in the chemical industry. In order to make the advantages and technical solutions of the present invention clearer and more specific, the present invention is described in detail below with reference to the accompanying drawings.

[0041] Unless explicitly stated otherwise, throughout the specification and claims, the term “comprise” or variations such as “comprising” and the like will be understood to include stated elements or components but not to exclude other elements or components.

[0042] The "obtaining the risk events of the device, and determining the risk level value of the risk events of the device according to the risk matrix" mentioned in the present invention, wherein the acquisition of the risk matrix can be achieved by referring to the existing technology, such as the quantitative assessment method of the safety risk level of petrochemical enterprises disclosed in CN110020760A, which has detailed how to obtain the risk matrix, and the steps for obtaining the risk matrix in the present invention are the same. The main technical improvement of the present invention is: for risk events that can cause major and above safety accidents, the last layer of protection measures of the risk events are identified, and they are given priority for high-level maintenance and repair, ensuring that the last layer of protection measures play a role when required, effectively curbing the occurrence of risk events or reducing the severity of the consequences of the events.

[0043] The key safety facility assessment system for the chemical industry of the present invention comprises a risk analysis module, a risk level screening module, an accident scenario protection measure layering module, a key safety facility document module, and a key safety facility analysis module.

[0044] In the above risk analysis module, professional risk analysts identify potential danger sources of the device, analyze the potential risks existing in the device, and determine the risk level of the device. The device risk analysis is that professional risk analysts use the HALOPA method to analyze the device risk and obtain the risk level of the device risk event.

[0045] The above-mentioned risk level screening module extracts risk events with risk levels of D and above based on the latest version of the risk matrix of Sinopec for the device risk events obtained by the risk analysis module.

[0046] The above-mentioned accident scenario protection measures stratification module, different device risk scenarios may have different types of protection measures. According to the event chain process of the risk event, the protection measures that may exist in the accident scenario are classified and layered.

[0047] The independent protection layers of the above-mentioned accident scenarios include: intrinsic safety design, basic process control system-safety control loop, key alarm and personnel response, basic process control system-safety interlock, SIS interlock, physical protection, other independent protection layers-prevention, post-release protection and other independent protection layers-mitigation. The above independent protection layers are set in sequence as the first to ninth layers of protection for the accident scenarios.

[0048] The above-mentioned key safety facility document module, combined with the actual situation of petrochemical enterprises, directly identifies the equipment and facilities that play a key role in the risk events of the device as key safety facility documents.

[0049] The above-mentioned key safety facility analysis module analyzes the risk event protection measures one by one for the device risk events obtained by the risk level screening module, and determines the list of key safety facilities for the device. Based on the list of key safety facilities for the device, key safety activities are formulated, and priority high-level maintenance is performed on key safety facilities.

[0050] The specific analysis steps of the above-mentioned key safety facility analysis module are as follows:

[0051] In the risk analysis module, the risk events of the device are obtained, and the risk level of the device risk events is determined according to the latest version of the risk matrix of Sinopec;

[0052] In the risk level screening module, based on the risk events in the risk analysis module, risk events with risk levels of D and above are screened out;

[0053] For the risk events screened out by the risk level screening module, the following analysis is performed one by one:

[0054] For a risk event with a risk level of D or above, the independent protection layer of the risk event is determined, and the independent protection layer of the event is compared with the key safety facility document. If the independent protection layer belongs to the document, then this independent protection layer of the event is the key safety facility of the device.

[0055] For independent protection layers that do not belong to the key safety facility document, determine whether there is a sixth layer of protection - physical protection in the independent protection layer according to the accident scenario occurrence chain process. If so, the independent protection layer is a key safety facility of the device; for the remaining independent protection layers, determine whether they are independent protection layers that serve as the last line of defense to prevent / mitigate accident scenarios. The independent protection layers of the last line of defense are key safety facilities of the device; the remaining independent protection layers in the accident scenario do not belong to the key safety facilities of the device.

[0056] The risk events obtained by the risk level screening module are analyzed one by one to determine the list of key safety facilities of the device.

[0057] Based on the list of key safety facilities of the device, determine the key safety activities for the key safety facilities of the device, and carry out high-level inspection and maintenance on them with priority to ensure that the key safety facilities can function when required.

[0058] Combine the following Figure 1 The above-mentioned accident scenario protection measure layered module is explained in detail.

[0059] Accident scenario protection measures layering module: Based on the risk event chain process, the independent protection layers for preventing or mitigating risk events are managed in layers. The key safety facility analysis module judges the independent protection layers based on this layering and determines the last line of defense for the event, so as to form a list of key safety facilities for the device.

[0060] like Figure 1 As shown, the accident scenario protection measures are layered as follows:

[0061] Intrinsically safer design as the first layer of protection for incidents;

[0062] The Basic Process Control System (BPCS) includes safety control loops and safety interlocks. The safety control loop is the second layer of protection during normal process operation, and the safety interlock is the fourth layer of protection during normal process operation.

[0063] Critical alarms and personnel response are the third layer of protection during normal process operation;

[0064] The safety instrument function (SIF) is functionally independent of the BPCS. The safety instrument function (SIF) is usually used as an independent protection layer and is the fifth layer of protection for process operation.

[0065] Physical protection-release facilities as the sixth layer of protection in certain scenarios;

[0066] Post-release protection includes leak containment and collection, fire protection and explosion suppression systems, etc., and is the eighth level of protection for an event;

[0067] Other independent protection layers cannot be accurately classified into the above protection layer classification, but among other independent protection layers there are other independent protection layers of prevention type and other independent protection layers of mitigation type; here other independent protection layers-prevention are regarded as the seventh layer of protection, and other independent protection layers-mitigation are regarded as the ninth layer of protection.

[0068] Based on the hierarchical management of independent protection layers in accident scenarios, key safety facility analysis is performed for risk events that meet the requirements, such as the attached Figure 3 The details are as follows:

[0069] Log in to the risk assessment system, professional risk analysts select the device to be analyzed, identify the potential risk sources of the device, and use the HALOPA method to analyze the potential risk events of the device. Figure 2 The risk matrix in determines the risk level of each risk event in the device.

[0070] Reference Figure 2 The risk level in the risk matrix is ​​used to screen the device risk events obtained in the above process, and the screening standard is that the risk level of the risk event is D or above. If the standard is not met, the key safety facility screening will not be carried out; (The present invention mainly focuses on major and above safety accidents, the determination of key safety facilities and the priority high-level maintenance to ensure that the last line of defense in the accident scenario chain plays a role when required, and can effectively curb the occurrence of accidents or reduce the severity of their consequences, avoiding casualties and high property losses.) If the standard is met, refer to the attached Figure 3 Continue to the next step of the screening process.

[0071] For all the risk events of the device obtained after screening, each event will go through the following assessment process to identify the key safety facilities of each risk event and form a list of key safety facilities of the device. The process is as follows:

[0072] Embodiment 1:

[0073] Determine each independent protection layer of the risk event, and cross-compare and analyze each independent protection layer with the key safety facility document. If the independent protection layer belongs to the key safety facility document, then the independent protection layer is the key safety facility of the device; for other independent protection layers that do not belong to the document, determine whether they belong to the sixth layer of protection in the risk event occurrence chain. If the independent protection layer is judged as "yes", it will be included in the list of key safety facilities of the device; if it is judged as "no", the independent protection layer will continue to be judged.

[0074] The above-mentioned key safety facility documents mainly include six categories: safety release, emergency stop, emergency cut-off / venting, neutralization / termination, automatic fire fighting and others. The detailed subcategories of each category are shown in Table 1.

[0075] It is to be noted that the appendix is ​​an example table of small categories and should not be limited to Appendix 1. Appendix 1 will be updated later based on the implementation of the present invention and the actual situation of the enterprise.

[0076] Table 1 Example of key safety facility documents

[0077]

[0078] Embodiment 2:

[0079] Judge the independent protection layer. If it belongs to the first to seventh layers of protection in the event chain (except the sixth layer), determine whether the event independent protection layer has a seventh layer of protection, that is, other independent protection layers - prevention. If it exists, analysts are required to judge which independent protection layer is the last line of defense to prevent the occurrence of the incident. The independent protection layer of the last line of defense is the key safety facility of the device, and the rest do not belong to it. When there is no seventh layer of protection, according to the accident scenario protection measure layered module, if the independent protection layer is the last layer of the first to fifth layers of protection, it is the last line of defense for prevention and belongs to the list of key safety facilities, and the rest do not belong to this list.

[0080] Embodiment 3:

[0081] After judgment, if the independent protection layer belongs to the eighth and ninth layers of the event chain, and the risk event chain does not have the first to seventh layers of protection (except the sixth layer), the on-site personnel need to make a manual judgment, the eighth layer of protection (post-release protection) and the ninth layer of protection (other independent protection layers-mitigation), which layer of independent protection layer is the last line of defense to mitigate the severity of the accident consequences. This independent protection layer is a key safety facility of the device. If it is not the last line of defense of the event chain, it will not be included in the list of key safety facilities; if the risk event chain has the first to seventh layers of protection (except the sixth layer), the eighth and ninth layers of protection will not be included in the list of key safety facilities. Because when there is a last line of defense to prevent the occurrence of an event, it will play a role when required and effectively prevent the occurrence of the risk event.

[0082] After the risk events are screened by level, they are identified and determined one by one as in the above embodiment to form a list of key safety facilities of the device. Professional analysts and on-site enterprise personnel formulate key safety activities with high priority one by one based on the list. Based on the details of this activity, they inspect and maintain the key safety facilities to ensure that the key safety facilities play a role when required, which can effectively curb the occurrence of risk events or reduce the severity of the consequences of the events.

[0083] The preferred embodiments of the present invention are described in detail above with reference to the accompanying drawings; however, the present invention is not limited thereto.

[0084] Although this article uses more terms such as risk analysis module, risk level screening module, accident scenario protection measures layering module, key safety facility documentation module, etc., it does not exclude the possibility of using other terms. These terms are used only to more conveniently describe and explain the essence of the present invention; interpreting them as any additional limitations is contrary to the spirit of the present invention.

[0085] It should be further noted that the specific embodiments described herein are merely examples of the spirit of the present invention. A person skilled in the art of the present invention may make various modifications or additions to the specific embodiments described or replace them in a similar manner, but this will not deviate from the spirit of the present invention or exceed the scope defined by the appended claims.

Claims

1. A method for assessing key safety facilities in the chemical industry, characterized in that: The following steps are included in sequence: S1. Obtain risk events of the device and determine the risk level value of the device risk events according to the risk matrix; S2. Screening the risk level values ​​to screen out risk events whose risk level values ​​exceed preset values; S3. Analyze the risk events one by one to determine the list of key safety facilities of the device; S4. List of key safety facilities for the device and determine the key safety activities for the key safety facilities of the device; In step S2, the risk level values ​​are screened to screen out risk events with risk level values ​​of D or above; Analyze each of the risk events, including: For a risk event with a risk level value of D or above, determine the independent protection layer of the risk event, compare the independent protection layer with the key safety facility document, and analyze whether the independent protection layer belongs to the key safety facility document; If the independent protection layer belongs to the critical safety facility document, the independent protection layer of the risk event is the critical safety facility of the device; For independent protection layers that are not part of the key safety facility documents, determine whether there is a sixth layer of protection - physical protection in the independent protection layer according to the accident scenario chain process: If so, the independent protection layer is a key safety facility of the device; for the remaining independent protection layers, determine whether they are independent protection layers of the last line of defense to prevent / mitigate accident scenarios. The independent protection layer of the last line of defense is a key safety facility of the device; the remaining independent protection layers in the accident scenario do not belong to the key safety facilities of the device.

2. A method for evaluating critical safety facilities in the chemical industry according to claim 1, characterized in that: After determining the key safety activities for the critical safety facilities of the device, they shall be given high priority for overhaul and maintenance.

3. A critical safety facility assessment system for the chemical industry, characterized in that: include: The assessment method adopted by the risk analysis module, risk level screening module, accident scenario protection measures layering module, key safety facility documentation module and key safety facility analysis module includes the following steps in sequence: S1. Obtain risk events of the device and determine the risk level value of the device risk events according to the risk matrix; S2. Screening the risk level values ​​to screen out risk events whose risk level values ​​exceed preset values; S3. Analyze the risk events one by one to determine the list of key safety facilities of the device; S4. List of key safety facilities for the device and determine the key safety activities for the key safety facilities of the device; In step S2, the risk level values ​​are screened to screen out risk events with risk level values ​​of D or above; Analyze each of the risk events, including: For a risk event with a risk level value of D or above, determine the independent protection layer of the risk event, compare the independent protection layer with the key safety facility document, and analyze whether the independent protection layer belongs to the key safety facility document; If the independent protection layer belongs to the critical safety facility document, the independent protection layer of the risk event is the critical safety facility of the device; For independent protection layers that are not part of the key safety facility documents, determine whether there is a sixth layer of protection - physical protection in the independent protection layer according to the accident scenario chain process: If so, the independent protection layer is a key safety facility of the device; for the remaining independent protection layers, determine whether they are independent protection layers of the last line of defense to prevent / mitigate accident scenarios. The independent protection layer of the last line of defense is a key safety facility of the device; the remaining independent protection layers in the accident scenario do not belong to the key safety facilities of the device.

4. A chemical industry key safety facility assessment system according to claim 3, characterized in that: The risk analysis module is used to analyze the potential risks of the device, determine the risk level of the device, and obtain the device risk events; The risk level screening module is used to extract risk events with risk levels of D and above based on the risk matrix for the device risk events obtained by the risk analysis module; The accident scenario protection measures stratification module categorizes and stratifies the possible protection measures in the accident scenario according to the event chain process of the risk event; The key safety facility document module is used to directly identify the equipment and facilities that play a key role in the risk events of the device as key safety facility documents in combination with the actual situation of the petrochemical enterprise. The critical safety facility analysis module is used to analyze the risk event protection measures one by one for the device risk events obtained by the risk level screening module, and determine the list of critical safety facilities for the device.

5. A chemical industry key safety facility assessment system according to claim 4, characterized in that: The analysis of potential risks existing in the device is that professional risk analysts use the HALOPA method to analyze the risks of the device and obtain the risk level of the device risk event.

6. A chemical industry key safety facility assessment system according to claim 4, characterized in that: The accident scenario protection measures layered module includes: intrinsic safety design, basic process control system-safety control loop, key alarm and personnel response, basic process control system-safety interlock, SIS interlock, physical protection, other independent protection layers-prevention, post-release protection and other independent protection layers-mitigation, and the independent protection layers are set in sequence as the first to ninth layers of protection for the accident scenario.

7. A chemical industry key safety facility assessment system according to claim 4, characterized in that: After determining the list of critical safety facilities for the device, formulate key safety activities based on the list of critical safety facilities for the device, and perform priority high-level inspection and maintenance of the critical safety facilities.

8. A chemical industry key safety facility assessment system according to claim 6, characterized in that: The post-release protection includes leakage containment and collection, fire protection and explosion suppression systems.

9. A memory, characterized in that: It comprises a software program, and the software program comprises steps suitable for being executed by a processor according to claim 1 or 2 for a method for assessing critical safety facilities in the chemical industry.

10. A critical safety facility assessment device for the chemical industry, characterized in that: It comprises a memory as claimed in claim 9, wherein the memory is connected to a processor via a bus, and the instruction set in the memory is executed by the processor.

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