Hazardous Production Facilities Research Articles

Методические подходы к расчету показателей риска аварий при обосновании безопасности размещения магистральных газопроводов в пределах пятой подзоны приаэродромной территории

The issues of safe allocation of hazardous production facilities, particularly trunk gas pipelines and gas supply facilities, as well as the application of a risk-oriented approach with the substantiation of such allocation, are currently at the top of the agenda. The article continues the earlier published studies dedicated to the review of quantitative and qualitative approaches to the risk analysis of the field, the determination of acceptable risk criteria with the substantiation of safe allocation of trunk gas pipelines and gas supply facilities within the fifth subzone of the aerodrome environs. The study provides general relations for the calculation of risk indices; the final calculated indices are the individual risks of fatalities among passengers and crewmembers as well as the annual number of fatalities on aircraft as a result of accidents at hazardous production facilities per 1 million persons of passenger traffic. The suggested approach takes into account several aviation-specific factors; i.e., aircraft flights at variable heights, complex configuration of take-off and landing, several available routes of approach to the airport (departure from the airport), and random allocation of hazardous production facilities adjacent to the aerodrome. A methodology and algorithm to use the introduced general relations have been provided, for which lists of input data and basic assumptions have been composed. The assumptions enable the conversion of general relations into simple algebraic expressions. Safety criteria and methodological approaches to determine their actual values, as suggested by the authors, enable linking the field of industrial safety and the field of aircraft flight safety and primarily aim at the reduction of uncertainties associated with problems of risk-oriented approach with the substantiation of allocation of trunk gas pipelines within the fifth subzone of the aerodrome environs. The vectors of further improvement of the methodology have been proposed.

Қызметкерлерді ынталандыру арқылы қауіпсіз еңбек жағдайын жасау

The main idea of the article is the creation of safe working conditions at the enterprise with the help of labor motivation. In the modern system of occupational risk management in production, the importance of encouraging the safe behavior of an employee is increasing. The article studies the problems of labor motivation among employees working in hazardous production facilities. The reasons for non-compliance with the basics of safety regulations are considered. The result of this article is the development of recommendations for improving safe working conditions at especially hazardous production facilities.

ИСПОЛЬЗОВАНИЕ ПОКАЗАТЕЛЯ УЯЗВИМОСТИ КРИТИЧЕСКОГО ЭЛЕМЕНТА ДЛЯ ОЦЕНКИ СНИЖЕНИЯ ПОЖАРНОГО РИСКА

Рассмотрено использование интегрального показателя уязвимости критического элемента (ПУКЭ) для оценки снижения пожароопасности и разработки соответствующих мер безопасности. Представлен методический подход к определению ПУКЭ и оценке пожарного риска на основе этого показателя. ПУКЭ представляет собой комбинацию вероятности возникновения пожара и последствий, которые он может вызвать. Чем выше значение ПУКЭ, тем более уязвим критический элемент и, следовательно, выше риск возникновения пожара. Отмечена важность данного подхода и приведены примеры его применения в различных сферах деятельности. In accordance with the requirements of the Federal Law 256-FZ “On the safety of fuel and energy complex facilities” dated 21 July 2011 it is necessary to analyze the vulnerability of critical elements of the facility from an act of unlawful interference. The facilities associated with the processing of oil and petroleum products are the ones with the largest fires among all critical infrastructure facilities. Thus, it is most important to calculate and reduce the fire risk at such facilities. According to Federal Law 123-FZ “Technical Regulations on Fire Safety Requirements” dated 22 July 2008, fire risk is a measure of the possibility of implementing a fire hazard situation and its consequences for both humans and material values. However, the methodology for calculating the fire risk at industrial facilities stated in the Order of EMERCOM of Russia No. 404 dated 10 July 2009 “On approval of the methodology for determining calculated values of fire risk at production facilities”, takes into account only the consequences for humans. So there is introduced a new concept – “integral normalized index of fire vulnerability” (hereinafter referred to as “fire vulnerability index”). Goals and objectives. Calculate the fire risk value, as well as the value of the “fire vulnerability index”. Elaborate the measures to reduce fire risk. Analyze the effectiveness of elabirated measures. Methods. To calculate the fire risk value, there were used the data obtained during the categorisation of the hazardous production facility. On the basis of these data, a "vulnerability analysis" was carried out with respect to critical elements of the facility. For the discovered "vulnerable critical element" the value of fire risk and "value of fire vulnerability" was calculated. The compensating measures were developed in accordance with Federal Law 123 and also fire risk and "value of fire vulnerability" were recalculated. Results and their discussion. The fire risk calculations show that there is an exceedance of the permissible value at the object under study. According to the results of categorisation, the facility was assigned an "medium" hazard category. The reduction of the fire risk value after the developed measures was 97 %. And the reduction of the "fire vulnerability index" was 69.8%. Conclusion. The developed measures allowed significantly reducing the fire risk value, which indicates a strict necessity for their installation and presence at the studied facility. Based on a reduction in “fire vulnerability”, the financial department of the enterprise can more objectively form a financial reserve. And based on “fire vulnerability”, it is possible to more accurately form insurance payments for facilities with a “high” potential hazard category.

Актуальные проблемы правового регулирования промышленной безопасности опасных производственных объектов нефтепромышленного комплекса

The article discusses the identification of hazardous production facilities and the legal regulation of permanent government supervision in the field of industrial safety. The author emphasizes that establishing the specific attributes and procedures for identifying and classifying the corresponding facilities, as well as determining the individuals responsible for providing relevant information or having the authority to identify them are of great importance for the categorization of production facilities. This article provides a systematic analysis of the current laws’ requirements in relation to judicial practice. It identifies problems in law enforcement practice and formulates conclusions on how to eliminate them.

Актуальные проблемы правового регулирования промышленной безопасности опасных производственных объектов нефтепромышленного комплекса

The article discusses the identification of hazardous production facilities and the legal regulation of permanent government supervision in the field of industrial safety. The author emphasizes that establishing the specific attributes and procedures for identifying and classifying the corresponding facilities, as well as determining the individuals responsible for providing relevant information or having the authority to identify them are of great importance for the categorization of production facilities. This article provides a systematic analysis of the current laws’ requirements in relation to judicial practice. It identifies problems in law enforcement practice and formulates conclusions on how to eliminate them.

INVESTIGATION OF OIL PIPELINE EQUIPMENT FAILURE-FREE PERFORMANCE DEPENDING ON INTRODUCED QUALITY MANAGEMENT MECHANISMS

The industry system for assessing the conformity of the main types of products used by Transneft has been operating since 2004 and is implemented on the basis of the Research Institute of Pipeline Transport of Transneft Research Institute. Conformity assessment shall be carried out for products of producers ensuring the technological processes of oil and petroleum products transportation and safety of facilities of oil trunk pipelines and petroleum product pipelines, including products operated under excess pressure of oil and petroleum products.As part of the implementation of this area of activity, the institute solves the following tasks:— expert examination of technical documentation of products;— participation in factory tests of products;— conducting tests of products on their own at the Research and Development Center of NII Transneft LLC (Ufa);— participation in the inspection of the production of products. In turn, Transneft has defined a list of the main types of products that are subject to mandatory conformity assessment and inclusion in the ORP Register, after which they are allowed to be used at Transneft’s hazardous production facilities, as well as developed its own industry regulatory documents of the type general technical requirements that take into account the uniqueness of the operating conditions of the equipment. Management of equipment reliability at different stages of the life cycle in an oil transportation enterprise represents a complex multilevel system of interrelated scientific, methodological and organizational and technical measures that directly or indirectly affect the reliability of equipment.Within the framework of the studies carried out by the specialists of Transneft Research Institute, more than thirty such measures were analyzed for direct or indirect impact on the reliability of equipment, including incoming control of equipment, factory, bench, resource, laboratory tests, production inspections, technical supervision of manufacturing, construction control of installation, diagnostics, maintenance, repairs, development of industry standards and other procedures. The variety of such processes makes up the system reliability of hazardous production facilities for pipeline transport of oil and petroleum products. The heterogeneity and sometimes redundancy of such processes negatively affect both operating organizations and equipment manufacturers.

МЕТОДИКА БАЛЛЬНО-ФАКТОРНОЙ ОЦЕНКИ ЧАСТОТЫ ИНИЦИИРУЮЩИХ ПОЖАРООПАСНЫЕ СИТУАЦИИ СОБЫТИЙ ДЛЯ ПОДЗЕМНЫХ ЕМКОСТЕЙ АВТОМОБИЛЬНОЙ ГАЗОЗАПРАВОЧНОЙ СТАНЦИИ

The purpose of the article is to develop a system for scoring the contributions of various technical and organizational measures to the magnitude of the risk of an accident based on existing approaches to the fire risk assessment at hazardous production facilities. To achieve the goal of the study and the formation of a score in cooperation with the organization operating the storage tanks of substances under pressure, a number of influencing factors were obtained. The following methods were applied in the work: analysis of hierarchies, comparison, analogy, study of documents and results of activities. The result of the work is the developed scoring system with groups of factors influencing the probability of an emergency and the resulting weight coefficients of the groups and the factors themselves. A method for point-factor estimation of the frequency of events initiating fire hazardous situations for underground liquefied petroleum gas tanks operated at gas filling stations is proposed. The results obtained can be used in assessing the fire risk for facilities where accidents can occur associated with the formation of an explosive and fire hazardous situation.

РАЗРАБОТКА ОБОСНОВАНИЯ БЕЗОПАСНОСТИ ДЛЯ ОПАСНОГО ПРОИЗВОДСТВЕННОГО ОБЪЕКТА, ПЕРЕРАБАТЫВАЮЩЕГО СЫРЬЕ РАСТИТЕЛЬНОГО ПРОИСХОЖДЕНИЯ

The safety justification is considered on the example of a hazardous production facility specializing in the storage and processing of plant raw materials. Estimates of the probability of an explosion and overpressure for two accident scenarios at the production site located in the basement of the building were made. On the basis of calculations, compensating measures are proposed to reduce the individual emergency risk for personnel, thereby justifying the possibility of deviation from the requirements of federal norms and rules on industrial safety in the prohibition of placing a section of dedusting soft containers in the basement of a production building.

СТРАХОВАНИЕ РАСХОДОВ ПО ЛОКАЛИЗАЦИИ И ЛИКВИДАЦИИ ПОСЛЕДСТВИЙ ЧРЕЗВЫЧАЙНЫХ СИТУАЦИЙ: ПРОБЛЕМЫ И ПЕРСПЕКТИВЫ РАЗВИТИЯ

The article presents an analysis of the current situation with legislative requirements for the formation of financial reserves for localizing and eliminating the consequences of emergency situations. The main reasons for the low penetration of this type of insurance in organizations both related to the operation of hazardous production facilities and organizations of a public nature have been identified. The pros and cons of the main methods of forming financial reserves for localizing and eliminating the consequences of emergency situations are considered and analyzed. The economic feasibility of insurance as the most effective form of forming the necessary financial reserve is substantiated. The most complete list of risks covered by this type of insurance has been compiled. A set of measures has been proposed aimed at developing this type of insurance, ensuring maximum coverage of the risks of organizations and introducing a set of preventive measures that reduce the likelihood of emergency situations and/or reducing the severity of the consequences from them.

Обучение рабочих и специалистов для горнодобывающей отрасли в аспекте безопасности труда

Labor safety in the mining industry is a set of measures aimed at improving the production environment that affects the health and operability of a person at work and the continuous professional development of employees. The objective assessment of safety of all stages of the production process is a crucial aspect of the enterprise’s activities. It is based on compliance with the requirements of regulatory authorities in the field of labor protection and industrial safety, occupational standards as characteristics of labor conditions, qualifications and professional competence of an employee, as well as compliance with the federal state educational standards as a basis of training of a specialist or a worker who are the main participants of the technological process in mining. The formation of professional competencies of each employee that ensure safe operation at the site or enterprise, the in-depth knowledge, development of operational algorithms, and the skill to perform technological operations at the workplace primarily depend on the basic education of employees obtained under the programs of secondary vocational education. The Federal State Educational Standards existing since 2013 became outdated and were gradually updated in 2022–2023. The training terms were normatively determined within the framework of the federal project «Professionalism» which aimed to resume close cooperation between educational organizations and enterprises. Educational organizations were enabled to increase the time to practice. The qualification of graduates under skilled worker training programs has become universal and does not specify the type of activity, whereas a new type of professional activity, namely ensuring the functioning of the occupational health and industrial safety management system at the site (or enterprise), was introduced for midlevel specialists. All this should ensure the future training of new personnel in compliance with the requirements of Federal Law of July 21, 1997 № 116–FZ «On industrial safety of hazardous production facilities» and the Russian Federation Government Decree of August 17, 2016 № 806 «On application of the risk-oriented approach in the organization of certain types of state control (supervision) and introducing amendments to some acts of the Government of the Russian Federation».

Predictive analysis of emergency fire risks for the boiler room

In the technosphere, ensuring fire safety of hazardous production facilities is a priority task for preserving human health, life, material values, and the environment. Therefore, it is important to predict emergency situations and minimize their risks. The purpose of the study is to assess fire risks and the degree of damage in an emergency situation in the boiler room. The study was based on statistical data on accidents at thermal power plants and regulated methods for determining fire risks and the degree of damage from an accident at coal boiler houses. A predictive assessment of fire risks was based on the example of two accident scenarios, the affected areas and the possible number of injured people are determined. The dimensions of the danger zones are shown – a fatal injury at a distance of 20 m from the epicenter of the explosion with a 97 percent probability of injury. The probability of weak destruction of buildings in a populated area of 17 percent was established. In case of a predicted accident in the form of an explosion of a steam boiler, damaging factors can affect industrial buildings and boiler room personnel

Модель мониторинга охраны опасных производственных объектов от лесных пожаров

The methodological analysis of the requirements for the prevention of forest fire onset and spread has demonstrated that at the design, development, and maintenance of forest sites, it is required to apply various proven methods enabling the assessment of risk of damage to hazardous production facilities protected from forest fires (upper and ground fires) via the selection of fire protection measures in forests, such as forest fire prevention, fire hazard and forest fire monitoring in forests, and forest fire extinguishing. The expert method, the system analysis methods, and the methods of management theory and decision-making were applied in order to solve the problems. The topicality of the study covered in the article is the analysis of fire safety requirements in forests and the development of informational and analytical support for the decision-making when evaluating the probability of the onset of forest fire and the risk of damage to the adjacent hazardous production facilities caused by a forest fire (upper fire, ground fire) in accordance with the calculation methodologies applied for specific situations, based on the expert method. The industrial safety management system and the industrial safety requirements must ensure the identification, analysis, and forecast of accident risk at hazardous production facilities, as well as the planning and implementation of fire safety measures and risk reduction. The scope of studies is industrial facilities, the Federal Forestry Agency, expert activities, activities of insurance companies, scientific activities, and individuals competent in forest fire safety (experts). To ensure the fire safety of hazardous production facilities, it is required to assess the risk of the onset and spread of a forest fire (upper fire, ground fire). In order to determine a safe allocation of forest stands and ensure the safe operation of firefighting subdivisions during forest fire extinguishing, it is required to apply the proposed expert method associated with the control of activities of the body responsible for the implementation of measures of planning, development and maintenance of forest stands at the exercise of official powers.

Remote behavior audit of hazardous activitiesand conditions in the oil and gas industry during video monitoring

The article discusses the problem of implementing a behavior safety audit, which is an effective tool for preventing industrial injuries and the basis for creating a behavioral model of workers. The article describes the behavior safety audit aimed to identify unsafe worker actions and hazardous work conditions at hazardous production facilities in the oil and gas industry. The possibility of conducting a behavioral safety audit is substantiated based on the analysis of video recordings of work at hazardous production facilities during drilling operations, underground and major well repairs. The study suggests conducting the remote behavior safety audit of “hazardous actions” and “hazardous conditions” in order to identify and prevent possible dangerous situations when performing standard and high-risk works. Flowcharts of the sequence of remote behavior safety audits of “hazardous actions” and “hazardous conditions” are presented.

Consideration of Temperature Factors when Designing Butterfly Check Valves for Hazardous Production Facilities

The safety of hazardous production facilities is directly related to the reliability of pipeline systems, which must be ensured regardless of environmental conditions. Accidents on pipeline sections can have catastrophic consequences associated with damage to human health and the environment. Damage to the metal of pipeline elements during operation due to internal corrosion occurring under the influence of the working fluid is one of the main reasons for failure. This study aims to develop an improved butterfly check valve (BCV), which is a pipeline element. For this purpose, various structural materials used in the production of check valves were analyzed, and the changes in their mechanical properties under the influence of temperature were also considered. Based on this material, a butterfly check valve was developed. The stress-strain state of the developed structure was assessed using the finite element method (FEM). Strains, stresses, and displacements were calculated to evaluate valve performance. These calculations are necessary to determine the most loaded elements of the BCV at the maximum and minimum ambient temperatures. The following conclusions were obtained: X6CrNiTi18-10 stainless steel grade is the most suitable material for piping systems transporting liquids in production facilities. On the basis of the simulation results, the values of equivalent stresses, maximum strains, and displacements were obtained. The research results confirmed the performance of the improved design, the unhindered motion of the working fluid in the working direction, and the convenient connection to horizontal and vertical sections of the pipeline. Doi: 10.28991/CEJ-SP2023-09-020 Full Text: PDF

Выбор технологии передачи данных для построения цифрового рудника

The main objective of systematic efforts of mining enterprises in securing the safety of mining operations is not an abstract reduction in the workplace injury rates, but prevention of dangerous incidents through specific measures. At the current technological state, such measures can be reliably ensured through building a unified digital environment of a hazardous production facility. Implementation of the mine digitalization projects requires application of multi-service networks as a unified data transmission environment. The article discusses the requirements for such networks, the challenges of selecting the core technology, as well as advantages and disadvantages of existing solutions. Using the case of a Russian technical solution, it is shown why in terms of efficiency and cost the optimal technology to create reliable high-load multi-functional security and communication systems at mining enterprises is the industrial Wi-Fi networks. Modern modifications of the Wi-Fi standard make it possible to cover more and more technological possibilities, e.g. location detection, monitoring of objects behind walls, motion and gesture capture and recognition. The channel bandwidth is also growing. Every 2-3 years, new modifications of standards and, accordingly, equipment with their support are released. In 2024, a new Wi-Fi 7 standard (IEEE802.11be) is planned to be released, which allows to provide data transmission speeds of up to 46 Gbps, as well as the ability to use several access points in parallel, which increases the flexibility of the network, its load capacity and stability of the radio signal for connected client devices.

CLUSTERING IN THE ANALYSIS OF COMPLEX SAFETY AND EFFECTIVENESS OF MANAGEMENT DECISIONS AT VARIOUS STAGES OF THE LIFE CYCLE OF PIPELINE TRANSPORT SYSTEMS

The work is devoted to the development of methodology for cluster analysis of indicators of the state of pipeline transport systems, taking into account the characteristics of technical systems and potential threats to management decision-making at various stages of the life cycle of a hazardous production facility for pipeline transport of oil and gas. The proposed methodology is based on the use of artificial intelligence and digitalization for the collection and analysis of databases. The possibilities of modern application software systems for performing cluster analysis and identifying potentially dangerous sections of the pipeline using 3D models are presented and analyzed.

Development of Mechanisms for Industrial Safety Culture Improvement Based on Employee Survey Analysis Results

Introduction. Ensuring industrial safety (IS) is one of the priority goals of any company. It is obvious that achieving its high level is impossible without the formation of a safety culture among employees, since their wrong actions can lead to emergencies and death of people at hazardous production facilities. The concept of industrial safety culture (ISC) is interpreted in different ways, but all definitions are united by the need for employees to realize that industrial safety should become their main goal and internal need. To date, there are many methods for determining the degree of ISC development. They are actively and successfully used at many enterprises. At the same time, it should be noted that the Russian legislation lacks, in particular, a methodology for quantifying the industrial safety culture specifically at the enterprises of the oil and gas complex, which have their own characteristics and specifics. Therefore, the introduction of a new quantitative approach to assessing the effectiveness of management of industrial safety culture has important scientific and practical significance on the industry agenda. The aim of this work in this regard was to develop mechanisms to increase the ISC level at one of the gas transportation enterprises of the country based on the results of the survey of its employees. Materials and Methods. For the analysis, the results of a three-level questionnaire conducted in 2021 and 2022 were used, which included socio-biographical characteristics of employees, their assessments on specially developed 16 components of industrial safety, as well as the interview of focus groups on six selected IS components. Results. During the analysis of the questionnaires, an increase in the level of industrial safety culture was established from the predicted (third level) to the proactive (fourth level) according to the five-level classification of the International Association of Oil and Gas Producers (IOGP). Discussion and Conclusions. The comparative analysis demonstrated positive dynamics of the results of the ISC level assessment by the employees of the gas transport enterprise. Its increase at this enterprise was achieved through the introduction and implementation of proactive measures, such as the development of personal obligations of employees in the field of safety, their maximum involvement in the development of competencies in the field of industrial safety, ensuring openness / transparency of communications on safety issues, and the formation of a positive attitude of employees to changes in this area.

Обследование скрытых участков стальных труб малого диаметра с применением ультразвуковой дефектоскопии

According to the current regulatory documents, as the established service life of gas pipelines for various purposes expires, they must be inspected in order to assess the current technical condition, make a decision on the residual life and the possibility of further operation at hazardous production facilities, as well as other buildings and structures. The possibility is considered related to using ultrasonic testing for detecting damage of corrosion origin in the sections of such pipelines hidden from the direct observation in interfloor ceilings and passages through the walls of buildings at the facilities in various branches of industries, as well as in gas distribution and gas consumption systems, and water pipelines. In addition, the possibility of identifying layered deposits of various origins in the cavity of small-diameter steel pipes is considered. At energy facilities, as well as in water supply pipelines, such deposits can lead to a significant reduction in the flow area of the pipeline, up to its complete blocking. Deposits inside the pipelines form an anisotropic layered medium, and the passage of ultrasonic waves through it has a number of features that prevent the use of traditional ultrasonic echo testing. For small-diameter pipes, the criterion is given under which it is possible to perform «remote» (waveguide) ultrasonic testing of the hidden sections of pipes at a distance of up to 600 mm. It is illustrated how, from such a distance, it is possible to detect corrosion deposits in pipes by ultrasonic testing methods using phased array antennas. At the same time, it is possible to assess the thickness («power») of layered deposits and their structure even when the passage section of the pipeline is filled with such deposits up to 100 %. Use of the methods presented in the article allows to increase the accuracy of calculating the residual life of the pipeline and reduce the uncertainty in setting safety factors in such calculations.

О подходах к обеспечению герметичности оборудования высокого давления при его эксплуатации

The operation of high-pressure equipment requires special attention from the point of view of ensuring its safety. This problem is becoming increasingly relevant every year. According to various estimates, currently 60–80 % of high-pressure equipment at the industrial enterprises has already exhausted its standard service life. In this regard, there is a need to select and develop a promising method of operating production equipment that would consider the peculiarities of the state of modern domestic industry. The conducted analysis of the methods of operating high-pressure equipment showed that the strength criterion is used as the main criterion for assessing the technical condition of various devices and assemblies included in its composition. However, this approach contradicts the functional purpose of high-pressure equipment — its tightness. To increase the safety and tightness of such equipment when choosing a method of its operation, special schemes for sealing and monitoring of sealing units are proposed, allowing for conducting digitalization of their technical condition. Using this approach will allow to manage the process of ensuring the sealing of high-pressure equipment during its operation. Positive test results of the modernized sealing units in high-pressure equipment, subject to operating conditions, are a sufficient argument for its approval for use. The inclusion in the regulations on the system of maintenance and repair of enterprises operating hazardous production facilities, the requirements for ensuring the tightness of sealing units will allow: reduce the risk of depressurization of the sealing units; increase production profitability by reducing emissions; maintain the sustainability of the business using high pressure equipment. The feasibility of using this approach was repeatedly confirmed by the work of JSC IrkutskNIIkhimmash.

Практические советы по выбору манометров

The areas were determined reiated to the state regulation in the field of ensuring the uniformity of measurements when using pressure gauges installed on potentially hazardous industrial equipment of hazardous production facilities were determined. Including — in the field of defense and safety of the Russian Federation, in nuclear energy, in the field of competence of the Ministry of Emergency Situations, the Ministry of Internal Affairs, the Federal Service for Technical and Export Control and the National Guard troops. An analysis of the requirements for pressure gauges was carried out, and the forms of state control were determined. The technical (metrological) characteristics of pressure gauges are analyzed in accordance with the requirements of the international and national standards of the Russian Federation. Special features of measuring the pressure of various media and the need to use special technical devices and tools are considered. Significant criteria for the selection of pressure gauges were identified. A simple and understandable algorithm for their selection was developed.