شناسایی خطر و تجزیه و تحلیل ریسک¬ با رویکرد مدیریت ایمنی فرآیند در مجتمع فولاد مبارکه (مطالعه موردی: واحد اکسیژن و هیدروژن)
محورهای موضوعی : آلودگی خاک
هانیه نیکومرام
1
(استادیار، دانشکده منابع طبيعي و محيط¬زيست، واحد علوم و تحقیقات، دانشگاه آزاد اسلامی، تهران، ایران.)
حسین مدرسی فر
2
(مدیر بهداشت، ایمنی و محیط¬زیست، شرکت فولاد مبارکه، اصفهان، ایران. )
جواد کیانی
3
(رئیس ایمنی، بهداشت حرفه¬ای و آتش¬نشانی، شرکت فولاد مبارکه، اصفهان، ایران.)
محمد ده بزرگی
4
(همکار پژوهشی، دانشکده منابع طبیعی و محیط¬زیست، واحد علوم و تحقیقات، دانشگاه آزاد اسلامی، تهران، ایران. *(مسوول مکاتبات))
کلید واژه: تجزیه و تحلیل ریسک, رویداد ایمنی فرآیند, شناسایی خطر, مدیریت ایمنی فرآیند.,
چکیده مقاله :
زمینه و هدف: صنعت فولاد به دلیل ماهیت ذوب فلزات و حرارت بالا، گازها و مواد شیمیایی خطرناک یکی از پرمخاطره¬ترین صنایع فرآیندی به¬شمار می‌رود. پتانسیل بالای بروز رویدادهای فرآیندی با پیامدهایی نظیر آتش¬سوزی، انفجار و انتشار مواد سمی در صنعت مذکور بر اهمیت شناسایی مخاطرات به عنوان اولین مرحله در مدیریت ریسک¬هاي¬ ایمنی فرآیند تاکید دارد. در پژوهش حاضر به منظور فراهم¬سازی زیرساخت¬های لازم شامل متدولوژی مدون اجرای مطالعات شناسایی خطر و تجزیه و تحلیل ریسک¬ به عنوان یکی از مهم¬ترین الزامات مدیریت ایمنی فرآیند (PSM) و در راستای پیاده¬سازی سیستم مذکور در مجتمع فولاد مبارکه، روش اجرایی مربوطه تدوین و جهت اطمینان از عملیاتی بودن آن، مخاطرات و رویدادهای ایمنی فرآیند در یکی از پرمخاطره¬ترین واحدها (واحد اکسیژن و هیدروژن) با بهره¬گیری از روش اجرایی مذکور، شناسایی و تحلیل گردید. روش بررسی: روش اجرایی شناسایی مخاطرات و تجزیه و تحلیل ریسک¬های ایمنی فرآیند در انطباق با الزامات مدیریت ایمنی فرآیند راهنماهای مرجع PSM و سایر اسناد فنی مرتبط، مشتمل بر کاربرگ شناسایی مخاطرات (HAZID)، فهرست کلمات راهنما، سطوح احتمال وقوع و شدت پیامد، ماتریس ریسک، متدولوژی اجرا و غیره تدوین گردید. جهت انجام مطالعه HAZID در واحد اکسیژن و هیدروژن، کارگروهی شامل افراد متخصص و با تجربه در حوزه شغلی مربوطه تشکیل و پس از آماده¬سازی مقدمات لازم از قبیل بررسی مستندات واحد، جلسات شناسایی مخاطرات طبق متدولوژی تنظیمی برگزار، کاربرگ¬های مربوطه به تفکیک Node¬های¬ مطالعاتی تکمیل و تحلیل و اقدامات اصلاحی مربوطه نیز پیشنهاد گردید. یافته¬ها: از مجموع 40 رویداد ایمنی فرآیند شناسايي شده در واحد اکسیژن و هیدروژن، 5 درصد داراي سطح ریسک کم، 65 درصد داراي ریسک متوسط، 15 درصد داراي ریسک زیاد و 15 درصد داراي ریسک حاد مي¬باشند. بدین¬ترتیب، اکثر ریسک¬های ایمنی فرآیند شناسایی شده دارای سطح ریسک متوسط (قابل تحمل) بودند. رویدادهای فرآیندی عمده با سطوح ریسک زیاد (غیرقابل قبول) و حاد (غیرقابل تحمل) نیز 30 درصد از کل رویدادها را تشکیل می¬دهند. پلنت¬های واحد اکسیژن بیشترین رویدادهای فرآیندی را از منظر تعداد به خود اختصاص ¬داده و مخازن گاز و مایع داراي بالاترين سطح ریسک رویدادهای ایمنی فرآیند می¬باشند. در مجموع، 12 رویداد فرآیندی عمده با سطوح ریسک زياد و حاد شناسایی گردید. بحث و نتیجه¬گیری: از دستاوردهای کلیدی پژوهش، تدوین روش اجرايي "شناسایی مخاطرات و تجزیه و تحلیل ریسک¬های ایمنی فرآیند" در مجتمع فولاد مبارکه به منظور شناسایی و تجزیه و تحلیل رویدادهای ایمنی فرآیند و ساير ویژگی¬های مربوطه از قبیل علل و پیامدهای وقوع رویدادها، کنترل¬های پیشگیرانه و کاهشی، احتمال وقوع و شدت پیامدها، سطح ریسک و غیره می¬باشد. همچنین روش اجرایی مذکور موجبات ارائه متدولوژی منسجم ارزیابی ریسک¬های ایمنی فرآیند، فراهم¬سازی بستری مناسب جهت اتخاذ اقدامات اصلاحی ریسک¬های عمده، اجرای مطالعات تکمیلی و تدوین و پیاده¬سازی سایر سازوکارهای مورد نیاز برآورد الزامات PSM را تامین می¬نماید.
Background and Objective: The steel industry is one of the most hazardous process industries due to the nature of metal melting and high heat, gases and hazardous chemicals. The high potential of process incidents with consequences such as fire, explosion and release of toxic substances in the mentioned industry emphasizes the importance of hazard identification as the first step in process safety risk management. In the present research, to provide the necessary infrastructure, including a written methodology for hazard identification and risk analysis studies as one of the most vital requirements of Process Safety Management (PSM) and in line with PSM implementation in Mobarakeh Steel Company, the relevant procedure was developed and to ensure its applicability, process safety hazards and their associated incidents in one of the most hazardous units (oxygen and hydrogen unit) were identified and analyzed using the aforementioned procedure. Material and Methodology: The “hazard identification and process safety risk analysis” procedure was developed in accordance with the requirements of process safety management expatiated in PSM best practices and other relevant technical documents. The procedure includes hazard identification (HAZID) worksheet, guide words, levels of probability of occurrence and severity of consequences, risk matrix, implementation methodology, etc. In order to conduct the HAZID study in the oxygen and hydrogen unit, a team including experts and experienced engineers in their relevant job fields was formed, and after preparing the necessary arrangements such as reviewing the documents, HAZID meetings were held according to the developed methodology, the worksheets were completed and analyzed as per the study nodes and relevant corrective measures were also suggested. Findings: From the total of 40 process safety incidents identified in the oxygen and hydrogen unit, 5% had a low-risk level, 65% had a medium-risk level, 15% had a high-risk level and 15% had an extreme-risk level. Therefore, the majority of the identified process safety risks had a medium (tolerable) risk level. Major Process Incidents (MPIs) with high (unacceptable) and extreme (intolerable) risk levels also constitute 30% of all incidents. The plants of the oxygen unit had the most process incidents in terms of the number, and gas and liquid tanks had the highest risk level of process safety incidents. In total, 12 MPIs with high and extreme risk levels were identified. Discussion and Conclusion: One of the key achievements of the research is the development of the “hazard identification and process safety risk analysis” procedure in Mobarakeh Steel Company to identify and analyze the process safety incidents and other related characteristics such as the causes and consequences of incidents, prevention and mitigation controls, the probability of occurrence and severity of consequences, risk level, etc. Also, the aforesaid procedure would help deliver a coherent methodology for assessing process safety risks, provide a suitable platform for adopting corrective measures for major risks, conduct supplementary studies, and develop and implement other mechanisms required to meet PSM requirements.
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