Chemical Accidents Research Articles

Accidents in Chemical & Process Industries of Bangladesh: Awareness Among People Working in Chemical & Process Plants

Chemical usage has steadily expanded in tandem with economic expansion, resulting in an increase in chemical accidents. Chemical incidents endanger lives and can cause a slew of health issues for those who live near chemical factories. The purpose of this study was to evaluate the knowledge of chemical accidents in chemical sector and awareness about the risk they pose among those working in chemical facilities and process plants. The research was conducted through survey which was composed of questionnaire regarding chemical safety and chemical accident in different chemical sectors participated by 120 people working in different chemical plants. Although the process safety has not mentioned in any kind of safety rules and regulations or acts the employee should have received the safety training to mitigate hazardous situation. The study shows that there was a lack of awareness and negligence of using PPE in most of the employees. A large number of respondents were doubtful of their plants following safety rules and regulations and also there was a negligence of following rules and regulations among the employees. Though there is eagerness to take safety training but most of the plants didn’t provide proper training to their employees. Journal of Engineering Science 14(1), 2023, 53-63

Study on statistical indicators of economic loss of major chemical accidents

AbstractThis paper summarizes the economic loss caused by chemical accidents in China, as well as the outstanding problems that need to be urgently solved. The affected parties of a major chemical accident are personnel, property, resources, the environment, and the social economy from the perspective of an accident target and emergency management. Economic losses of each type of accidental target include property losses, emergency disposal costs, and recovery/reconstruction costs. Based on this idea, a statistical system composed of 12 indicators for economic losses of major chemical accidents is established. The new statistical indicator of economic loss of major chemical accidents is more reasonable than the current statistical method of China's GB 6721‐86 “Standard,” and can fully reflect the harm due to major chemical accidents.

Evaluating the Efficiency of the Process Safety Management System through Analysis of Major Industrial Accidents in South Korea

The process safety management (PSM) system was introduced in South Korea in 1996, wherein a company voluntarily organizes and manages a chemical accident prevention system, which contributes to reducing chemical accidents. However, large- and small-scale chemical accidents occur frequently. This trend necessitates analysis and improvement of the PSM systems. This study aimed to analyze the correlation between major industrial accidents, their main causes, the status of accidents by company size and industry, and the PSM evaluation grade through an analysis of 130 accidents that occurred in the past 17 years (2005–2021). The results showed that small- and medium-sized enterprises (SMEs) with fewer than 100 employees accounted for 36% of all accidents, indicating a higher occurrence rate than large companies. Additionally, the proportion of companies with inadequate PSM levels, rated as M-grade (M+, and M−), were 67.0%, suggesting a high probability of major industrial accidents. The results of this study show that a company’s voluntary safety management can be induced by an improved PSM system and management plan, which is expected to prevent major industrial accidents.

Environmental forensics using stable and radioactive isotopes in naturally attenuated soil after phenol-leakage accidents

Phenol is a carcinogenic and hazardous chemical used in multiple industries and poses a high risk of chemical spills into the environment. To date, environmental forensic research has not focused on chemically remediated soils. In this study, an advanced environmental forensic analysis was performed on microbial communities and breakdown products of phenol, carbon stable isotopes, and radioactive isotopes in phenol-contaminated soil. As indicators of phenol-spill accidents after natural attenuation, higher δ13C levels and lower 14C/12C ratios were observed in phenol-contaminated soil compared with uncontaminated soil. In addition, 16s rRNA gene analysis revealed that phenol-breakdown products identified by gas chromatography-mass spectrometry and the presence of soil bacteria, such as Nocardioides, Faecalibacterium, and Bacteroides, were indicators of phenol-leakage accidents. Therefore, the proposed environmental forensic strategy is a valuable tool for identifying the location of previously occurring chemical accidents and estimating the ecological impact after the natural attenuation of contaminated soils.

Failure factor analysis of China hazardous chemicals safety regulation system based on FMEA

AbstractIn order to strengthen research on the identification and classification of the failure factors at the level of government safety regulation, comprehensively and systematically understand the failure of China's hazardous chemical safety regulation system, strengthen the prevention of hazardous chemical accidents, and construct China's hazardous chemical safety regulation system according to the principle of “Safety II”, the three subsystems of the regulation subject, regulatory object, and third‐party institution and their seven functional blocks are determined. Second, taking 26 dangerous chemical accidents as analysis materials, the failure mode and effect analysis method (FMEA) is used to analyze China's dangerous chemical safety regulation system. Nineteen failure modes of China's dangerous chemical safety regulation system are identified and the distribution of failure modes is analyzed and discussed. The results show that personnel failure is the main factor in the failure of the safety regulation system. Good institutional tools help to improve law enforcement work. The coordination between the regulatory agencies has an essential impact on the role of the regulatory body. It is necessary to strengthen the regulation of third‐party institutions.

A gas detector planning method that considers the area and zone based on the range of influence of chemicals with high vapor pressure

AbstractIn some countries with high population densities including Korea, chemical plants are densely distributed, and strict regulations are imposed. According to the Chemical Control Act, one gas detector must be installed every 10 m indoors and 20 m outdoors around a facility. However, the diffusion of chemicals should be evaluated based on area rather than perimeter. In the US and EU, gas detector locations are selected through chemical accident modeling. Here, we evaluated the feasibility of gas detector installation standards in the Chemicals Control Act by comparing highly volatile and toxic chemicals with sulfuric acid (relatively low volatility). Consequently, we suggested an appropriate installation location and number of gas detectors for initial countermeasures. For nitric acid, hydrochloric acid, and hydrofluoric acid, there was a difference in the number of detectors recommended via modeling and the number of detectors legally required. For the mezzanine design, four gas detectors should be installed on each floor in a 5‐story building; however, the modeling results showed that installing one was sufficient. For sulfuric acid with low vapor pressure, it is equitable to install a leak detector rather than a gas detector. Overall, regulations should be continuously evaluated for the response and prevention of chemical accidents.

Formal and Legal Requirements for Rescue Entities for the Identification of Chemical Hazards in Poland

Aim: The article presents issues related to selected aspects of chemical and environmental rescue, their location in the legal norms in relation to the performed tasks and taking into account the needs of the society. In this respect, the legal acts relating to the operation of the system of identifying chemical and environmental rescue hazard, its transformation, and its impact on the safety and execution of tasks by the rescue entities were reviewed. Moreover the meaning of records relating to the identification of chemical hazards was analysed and clarified. The topics were based on new legal regulations on the detailed organization of the national rescue and firefighting system and guidelines covering the organization of chemical and ecological rescue in Poland. The reviewed area in this analysis relates to the identification of hazardous materials, the designation of danger zones, the ability of emergency responders to identify hazards in formal and legal conditions, and their identification by the functioning cooperating entities. The dependencies that exist in the identification system and the future directions of its development are indicated. Introduction: In today’s world, the expectations of the society for emergency services focus on the quick and efficient execution of an organized rescue operation. In chemical rescue, the primary factor affecting the course and success of the operation is the identification of the chemical threat. Conducting reconnaissance activities under conditions of changing threats requires skills and the fulfilment of a number of conditions that will affect the functioning of the rescue entities in the reconnaissance system. Experience from ongoing rescue operations shows that reconnaissance tasks are carried out to varying degrees. On the one hand, they depend on regulations, and on the other, on the capabilities of emergency responders and the difficulties arising from the resulting disasters and chemical accidents. Therefore, it is reasonable to review selected legal elements relating to the identification of hazardous materials – in particular, those that condition the efficient and effective operation of the rescue entities in terms of the existing risks. Methodology: The article was developed using analyses of legal acts and literature on improving the system of threat identification. Consideration was given to the existing threats, the current international situation, the possibility of uncontrolled action and the release of hazardous substances with chemical, biological or radiological properties, especially in the border area. In analysing the conducted research, publications on rescue law, legal norms of the national rescue and firefighting system, emergency management, guidelines from chemical and ecological rescue, articles from the area of reconnaissance and conference materials were used. Conclusions: The emergence of new regulations in the Principles of Chemical and Environmental Rescue has led to the need for a unified course of action in the area of identifying the chemical agent. Ongoing monitoring of the area for the presence of a hazardous substance – due to the frequently changing weather conditions at the scene – should be a permanent part of the competence tasks of the rescue units. In addition, continuous and effective analysis of the samples taken at the site of the hazardous substance would allow detection and identification of the hazard relatively early – so that further appropriate action could then be taken. Such a solution would allow the emergency manager to conduct a chemical rescue operation continuously and make accurate decisions at every stage of the operation, despite a possible sudden change in the weather conditions. The inclusion in the regulations of all possible elements of identification in terms of the existing hazards will affect the effectiveness of the rescue entities in the elimination of chemical, biological, radiological hazards. Keywords: hazardous substance, danger zone, chemical and environmental rescue, chemical reconnaissance

DYNAMIC SIMULATION BASED SAFETY CONSEQUENCE ANALYSIS OF CHEMICAL PROCESSES

Consequence analysis can timely predict the occurrence of potential chemical safety accidents, but is time-consuming and inaccurate when using a manual and qualitative mode. A safety con-sequence analysis method based on dynamic simulation is proposed for chemical processes in this paper. The dynamic simulation system of chemical process is composed of complete thermodynamic model and general unit model to quantitatively describe the dynamic change of chemical process parameters. Combined with fault tree analysis, the accident model is designed prior to forecasting safety consequences by computational fluid dynamics. This method was applied to acetylene production process. A dynamic simulation system was designed to calculate the pressure and concentration of acetylene leakage gas and analyze the parameters affecting the diffusion of acetylene gas. The results show that this method can obtain the quantitative change of acetylene concentration with time at different locations around acetylene generator, which is convenient for accurate and dynamic analysis of process safety consequence.

The property value impacts of industrial chemical accidents

Using hedonic methods, we examine how chemical accidents at industrial facilities impact home values. The study focuses on facilities regulated by the U.S. Environmental Protection Agency’s Risk Management Plan (RMP) program, which is in place to reduce the risk of harm to offsite populations from accidental chemical fires, explosions, and releases of toxic vapors. RMP facility and accident data were linked to residential transactions in Michigan, Ohio, and Pennsylvania. To facilitate causal inference, alternative difference-in-differences and triple differences models are estimated, where we compare homes near and far, and before and after, an accident; as well as homes near facilities where an accident did and did not occur. We find that the typical accident does not generally affect home values, but accidents resulting in offsite injuries, property damage, evacuations, or shelter-in-place orders lead to a 5% to 8% decrease in the value of homes within five kilometers; suggesting an average loss of $12,000 to $20,000. The benefits of policies that help avoid these impacts are particularly relevant from an environmental justice standpoint. Proximity to an RMP facility, irrespective of any incidents, is associated with significantly lower home values. Existing inequities are exacerbated by chemical accidents that impact offsite populations.

Inherent Hazards Assessment and Classification Method for University Chemical Laboratories in China

In recent years, chemical laboratory accidents have frequently occurred in Chinese universities. A three-year safety inspection by the Ministry of Education of China discovered many issues in university chemical laboratories, including inadequate hazards identification, limited risk awareness, and insufficient safety management. In view of these problems, this study established the inherent hazards assessment and classification (IHAC) method for university chemical laboratories. We quantitatively evaluated the materials, equipment, and processes of chemical laboratories for inherent hazards. To differentiate levels of supervision over inherent hazards, we separated chemical laboratories into four tiers: A, B, C, and D. We used IHAC in a Chinese university’s chemical laboratory to show that it can effectively identify and evaluate laboratory dangers. Simultaneously, splitting laboratories into multiple levels can result in more targeted laboratory safety management and accident prevention.

Why do major chemical accidents still happen in China: Analysis from a process safety management perspective

As an important consideration in the chemical industry, chemical process safety has received notable attention in China. However, catastrophic chemical accidents still occur. To better understand why accidents continue to occur, this paper presented a diagnostic analysis of 14 major chemical accidents in China from 2012 to 2022 based on VOSviewer software. The authors analysed the correlation between the accident causation and their relationship with the safety management elements. The study observed that inferior process safety culture, intentional violation (rule-breaking) of procedure, inadequate safety training, and illegal operations were the most frequent causes of accidents. These causes highlighted the prominent gaps in PSM in China in the process safety culture, compliance with standards, the conduct of operations, process safety competency, and training & performance assurance. The results based on co-occurrence analysis indicated a strong correlation between these gaps in PSM. Enterprises should pay attention to collaborative management among them. These deficiencies in the enterprise’s PSM system showed that the essential defects in China’s chemical industry are a poor safety culture, inadequate accident investigation, inadequate training, and a lack of chemical safety personnel. The study recommended that the chemical industry establish superior process safety culture and competency for all personnel, monitor leading and lagging process safety indicators, apply inherent safety, and practice advanced safety management concepts. We hope that the findings can provide China’s perspectives and strengths for global chemical safety.

An Integrated Risk Management Model for Transporting Explosive Remnants of War: A Case Study in the Republic of Serbia

Existing legal and by-law regulations prescribe risk management methodologies for various domains, such as the transportation of hazardous materials, fire and explosion protection, environmental protection, and protection against chemical accidents. However, there is a lack of comprehensive methodological guidance that unifies the management of all risks associated with the transportation of explosive remnants of war (ERW), which pose significant threats to human life, cultural assets, and the environment. Furthermore, the transportation of ERW often occurs along traffic corridors with compromised infrastructure, increasing the range of potential risks affecting the safety of people, their property, and critical infrastructure. This study presents an integrated risk management model for ERW transportation in the Republic of Serbia, developed based on current legal and by-law regulations, as well as modern criteria and risk assessment methodologies. By applying this model, the various risks associated with ERW transportation can be effectively mitigated, ensuring the safety and protection of people, assets, and the environment.

Runaway reaction investigation of di‑tert‑butyl peroxide using adiabatic calorimetry

Thermal safety assessment is an effective means to put an end to frequent chemical accidents. The conventional safety assessment generally uses differential scanning calorimetry (DSC) or accelerating rate calorimeter (ARC), while in this work the adiabatic calorimetry technique is applied to study the thermal runaway reaction for the first time. Adiabatic calorimeter (AC) has an excellent adiabatic and vacuum environment, and the process simulation of adiabatic runaway is more real in theory. The thermal decomposition reaction of 20% di‑tert‑butyl peroxide (DTBP) /toluene solution was measured, and the kinetic parameters and model of DTBP decomposition in the adiabatic reaction process were obtained by fitting the temperature rise rate-temperature data in the thermal runaway process. These research results not only show that the adiabatic calorimetry is competent for the determination and thermal risk assessment of adiabatic runaway reactions, but also provide an important reference for broadening the application of adiabatic calorimetry.

Research on the prediction model of hazardous chemical road transportation accidents

In recent years, hazardous chemicals road transport accidents have occurred frequently, causing huge casualties and property losses, and accident risk assessment has become the focus of researchers' research. To predict the risk probability value of hazardous chemical road transport accidents, first, we compiled data on road transportation accidents of hazardous chemicals in China in the past five years. And the nine nodes in the Bayesian network (BN) structure were defined in combination with relevant classification standards. The optimal Bayesian network structure for hazardous chemical road transport accidents was determined based on the K2 algorithm and the causalities between the nodes. Second, the node conditional probabilities were derived by parameter learning of the model using Netica, and the validity of the model was verified using the 5-fold cross-validation method. Last, the Bayesian network model of hazardous chemical road transport accidents is used to analyze accident examples, and the accident chain of “rear-end-leakage” is predicted, and the accident is most likely to be disposed of within 3–9 h. The study shows that the derived accident prediction model for hazardous chemical road transportation can reason reasonably about the evolution of accident scenarios and determine the probability values of accident risks under different parameter conditions.

ТЕХНИКО-ЭКОНОМИЧЕСКАЯ ЭФФЕКТИВНОСТЬ ПРИМЕНЕНИЯ РОБОТОТЕХНИЧЕСКОГО КОМПЛЕКСА МНОГОРЕЖИМНОГО ПОЖАРОТУШЕНИЯ В ЧС

The aim of the study is to evaluate the technical and economic efficiency of a robotic complex designedto eliminate man-made emergencies associated with the need to eliminate fires. These emergenciescan occur, first of all, in radiation and chemical accidents, as well as in accidents at fire and explosionhazardous facilities. The elimination of such emergencies, as a rule, is associated with an increased riskfor firefighters and rescuers and requires the use of heavy equipment. It is proposed to develop and use arobotic complex for multi-mode fire extinguishing (RTK-PM) in the following composition; six specializedrobotic means with the possibility of crew and remote control, including: barriers (RTS-RZ), fire (RTS-P),high-rise (RTS-VS), sleeve (RTS-RK), pumping (RTS-NS) and gas stations (RTS-ZV); mobile controlpoint; supply machines. At the same time, the actual problem is the development of approaches to assessing the technical and economic efficiency of robotic tools and complexes used to eliminate emergencysituations. A technique for conducting such studies is proposed on the basis of a two-level quantitativequalitativecomparative assessment in terms of technical and economic efficiency of the task. To assessthe technical efficiency, it is proposed to consider the deployment time, the time to extinguish the fire, thetime to complete the task, the amount of fire extinguishing agents as the main indicators. As criteria fortechnical efficiency, it is proposed to evaluate the coefficient of efficiency of the task, the coefficient ofdeployment mobility; coefficient of fire extinguishing efficiency; the degree of efficiency of RTCrobotization. Qualitative comparison consists in identifying the types of work available to one of the comparedcomplexes and inaccessible to another. The evaluation of the economic efficiency of the RTK iscarried out by the value of the annual economic effect from the production and use of a unit of the complex.Like the assessment of technical efficiency, the assessment under consideration is also comparative -it shows an advantage (or disadvantage) over the replaced (basic) complex. Also presented are the resultsof applying this technique when calculating the effectiveness of a promising robotic complex for multimodefire extinguishing, which show that the use of one robotic complex for multi-mode fire extinguishingwill provide an economic effect in the amount of 1.39 million rubles. in year.

Smart chemical industry parks in China: Current status, challenges, and pathways for future sustainable development

The chemical industry has been pivotal to the rapid economic expansion and high standards of living in China. As an important carrier of the chemical industry, China has designated as many as 723 chemical industrial parks (CIPs). Unfortunately, safety concerns have become an obstacle to the sustainability of China's CIPs. Ever since the two devastating hazardous chemical accidents, namely “Tianjin Port 8·12 Explosion” and “Jiangsu 3·21 Explosion,” which occurred in 2015 and 2019 respectively, China has prioritized the safety of CIPs. The smart chemical industrial parks (SCIPs) are considered the optimal strategies toward the goal of sustainable development in China's CIPs. However, there has been a lack of research and subsequent discussion on the role of SCIPs in the forthcoming years. The period between 2020 and 2025 is considered a crucial period for the future development of CIPs and SCIPs in China mainly because the country has released a series of important government documents and national standards (such as “Fourteenth Five-Year (2020–2025) Plan for Hazardous Chemical Safety” and “Guidelines of SCIPs construction”) to promote hazardous chemical safety. With the aim of analyzing the future sustainable development for the construction of SCIPs in China, this paper proposes a systematic methodology in order to conduct an integrated and in-depth review on the standardization construction status (framework with Chinese characteristics, key events, spatial features, and national pilots), future tasks, problems, and sustainable development pathways of China's SCIPs. The method is implemented in accordance with the current scenarios of hazardous chemical safety in China and the latest government documents, regulations, and standards. Furthermore, this study provides basic data and a basis for future studies associated with the safety and sustainability of the SCIPs construction and chemical industry, both within China and in other countries.

Risk assessment of chemical release accident triggered by landslide using Bayesian network

This study evaluated the risk of 461,260,800 scenarios of chemical release accidents triggered by landslides. Several industrial accidents triggered by landslides have recently occurred in Japan; however, only a few studies have analyzed the impact of landslide-triggered chemical release accidents on the surrounding areas. Bayesian networks (BNs) have recently been used in the risk assessment of natural hazardtriggered technological accidents (Natech) to quantify uncertainties and develop methods applicable to multiple scenarios. However, the scope of BN-based quantitative risk assessment is limited to the risk assessment of explosions triggered by earthquakes and lightning. We aimed to extend the BN-based risk analysis methodology and evaluate the risk and the effectiveness of the countermeasures for specific facility. A methodology was developed to assess human health risk in the surrounding areas when n-hexane was released and dispersed into the atmosphere due to a landslide. Risk assessment results showed that the societal risk (representing the relationship between frequency and number of people suffering from a particular harm) of the storage tank closest to the slope exceeded the Netherlands' criteria, which are the safest among the criteria in the United Kingdom, Hong Kong, Denmark, and the Netherlands. Limiting the storage rate reduced the probability of one or more fatalities by up to about 40% compared with the no countermeasure case and was a more effective countermeasure than using oil fences and absorbents. Diagnostic analyses quantitatively showed that the distance between the tank and slope was the main contributing factor. The catch basin parameter contributed to the reduction in the variance of the results compared to the storage rate. This finding indicated that physical measures, such as strengthening or deepening the catch basin, are essential for risk reduction. Our methods can be applied to other natural disasters for multiple scenarios by combining it with other models.

Management of decontamination in chemical accidents: a laboratory model

Rapid and efficient decontamination of the skin is a major task for emergency rescue services in the event of a chemical accident involving humans. While rinsing the skin with water (and soap) has been the standard procedure, some skepticism has developed in recent years regarding the situational suitability of this method. The efficacy of three different decontamination materials/techniques (Easyderm® cleaning cloth, water-soaked all-purpose sponge, rinsing with water) in removing Capsaicin, Bromadiolone, Paraquat and 2,2′-dichlorodiethylether (DCEE) from porcine skin was compared. Different cleaning motions (wiping, twisting, pressing) with the Easyderm® were evaluated for their effectiveness in removing Capsaicin from porcine skin. Finally, the impact of different exposure times of the skin to Capsaicin on the decontamination process were investigated. Contaminant recovery rates (CRRs) were analysed in the skin and in each decontamination material using high-performance-liquid-chromatography (HPLC; used for Capsaicin, Bromadiolone, Paraquat) or gas chromatography (GC; used for DCEE). Wiping the skin with the amphiphilic Easyderm® was most effective for decontamination of Capsaicin and DCEE, while the water rinsing method gave the best results for removing Paraquat and Bromadiolone. Both wiping with the Easyderm® and rotating the Easyderm® were significantly more effective in cleaning Capsaicin-contaminated skin than pressing the Easyderm® on the contamination area alone. Prolonged exposure times of the porcine skin to Capsaicin were associated with a decrease in efficacy of the following decontamination. Emergency rescue services should have materials available that can remove both hydrophilic and hydrophobic substances from skin. Since not all of our results for comparing different decontamination materials were as distinct as we expected, there are likely several other factors determining the efficacy of skin decontamination in some cases. Time is key; therefore, first responders should try to begin the decontamination process as soon as possible after arriving at the scene.

Human Factors Analysis by Classifying Chemical Accidents into Operations

In the chemical industry, organizational and operational human factors significantly contribute to accidents. Chemical accidents occur in various operations of the industry due to a range of factors. Understanding the relationship between these factors and the accidents that happen is crucial in preventing similar accidents from happening repeatedly and promoting sustainability. Therefore, this study was divided into five operations: maintenance repair, process, loading unloading, storage, and shutdown startup of the chemical industry, to provide a more concrete, intuitive explanation of the interplay between causes and illustrate the routes to failure. The data were collected from 251 accident reports from various online data. The study was analyzed using the Human Factors Analysis and Classification System (HFACS) method as a conceptual framework. Each level’s frequency variables were obtained to define nominal and ordinal data. The chi-square test and Fisher’s exact test were used in the difference analysis of data in the model. The results show that the high-frequency accidents caused under the HFACS framework were organizational processes in the process (63.73%), in the storage (70.58%), and in the shutdown startup (91.66%), and skill-based errors in the maintenance repair (81.81%) and in the loading unloading (66.03%). Furthermore, resource management, technological environment, and personal readiness were significantly correlated with the operations. Human factors have differences in different operations in the chemical industry.

A Risk-Data-Based Human Reliability Analysis for Chemical Experiments with Hazardous Processes

In recent years, chemical experiment accidents have frequently occurred, resulting in injuries and fatalities among researchers. It is crucial to address this issue to improve laboratory safety. Based on many publications, it is clear that human error makes a major contribution to many laboratory accidents which contain hazardous processes. However, there is limited research focusing on human error in laboratory safety, and there is also a lack of effective measures to assess Human Error Probability (HEP) for experimental process safety. Therefore, we propose an improved Cognitive Reliability and Error Analysis Method (CREAM) which is based on risk data to assess the HEP during hazardous processes in chemical experiments. The proposed method adjusts nine Common Performance Conditions (CPCs) in conventional CREAM to make them suitable to describe chemical experiments. Then, in contrast to the traditional approach, this study uses the definition of risk as the support to collect CPC data from the perspectives of possibility and severity, so as to improve the rationality of the data and decrease the subjectivity of expert judgment. Afterwards, the weight value of each CPC is calculated through Gray Relation Analysis (GRA) based on the collected risk data of each CPC. Meanwhile, the collected risk data are used to determine the fuzzy degrees of each CPC, the activated fuzzy If-Then rules, and the corresponding rule weights. Finally, the CPCs’ membership degrees, the CPCs’ weights, and If-Then rule weights are integrated together to acquire the HEP by defuzzification. In short, the proposed method changes the CPCs to ensure they are suitable, and then it innovatively uses risk data as the source to directly and indirectly determine the CPC’s fuzzy degree, the CPC’s importance weight, and the If-Then rule weight by fuzzy theory and GRA for collecting final HEP results. This method was tested on a selected chemical experiment, “preparation of active ferrous sulfide”, which contains hazardous processes. Through the proposed method, the HEP of each procedure in the selected risky chemical experiment could be determined, and among the procedures, the highest HEP was 1.51 × 10−3. In addition, with the HEP results, several subtasks with a high risk of human error could be identified. The results matched the real situations.