Hazardous Production Facilities Research Articles

Возможности мер административного принуждения для обеспечения национальной безопасности Российской Федерации

The article shows the role of administrative coercion measures that are used to prevent such threats to national security as the consequences of emergencies at hazardous production facilities and non-compliance with the requirements for their anti-terrorist protection. The measures of administrative warning, suppression and punishment, which are used by authorized entities to neutralize these threats, are disclosed.

Impact Assessment of the Industrial Site at Former Battery Plant "Vostsibelement" in Irkutsk Region on Environmental Compartment

It was brought to light that soils, benthal deposits and vegetation at the industrial site were loaded with a lot of heavy metals and arsenic. It was concluded about an extreme social and ecological danger of the industrial site at the former battery plant "Vostsibelement". It is a potential threat for the entire upper Bratsk reservoir, all the necessary criteria for its inclusion in the State register of hazardous production facilities are met, and it is to be reclaimed.

К вопросу о структуре цифровых двойников опасных производственных объектов

The structure of the digital twin of a hazardous production facility is considered, the construction of which is based on the concept approved by the Coordinating Committee for Integrated Automation of Production and Technological Processes, Metrological Support and Communications of PJSC Gazprom. Overview is given concerning the innovative developments in the field of fire and industrial safety reflecting the process of digital transformation of safety technologies. Among them: remote monitoring systems at hazardous production facilities designed to carry out permanent state supervision; robotic complexes for fire extinguishing; software systems for scenario modeling of accidents, fires and evacuation of people, risk assessment, calculation of parameters of the affecting factors; virtual training complexes for interactive training of the personnel; digital twins of oil fields, gas turbines, nuclear power plants. Based on the reviewed scientific papers and federal legislation in the field of industrial safety, the concept of a digital twin of a hazardous production facility is formulated, and the principal structure of its technical equipment is considered. The function of each element of the digital twin structure of a hazardous production facility is established. Typical tasks solved by means of digital twins of hazardous production facilities and the effects of their implementation are identified. SWOT-analysis was conducted related to the advantages, disadvantages, opportunities, and negative factors in the digital transformation of hazardous production facilities. The image of future industrial systems with the use of digital twins in the field of industrial safety was formed.

Применение процессного подхода при разработке документационного обеспечения системы управления промышленной безопасностью в организации

Information is provided on the legislative documents of the Russian Federation that regulate the activities of organizations in the field of industrial safety in the operation of hazardous production facilities. Relevance and expediency are substantiated related to the application of the process approach at the stage of development and implementation of the documentary support for the industrial safety management system based on the Decree of the Government of the Russian Federation of August 17, 2020 № 1243 On approval of the requirements for documentary support of industrial safety management systems. The methodological justification is provided concerning the process approach to the development of documentation support of the industrial safety management system in the organization. It is based on the system approach with the use of the well-known principle of PDCA the basic issues of its applicability are considered. Model was developed related to the documentation support system for industrial safety management system based on the process approach, structural analysis, and design technology SADT, as well as the functional modeling methodology IDEF0. The main context diagram was developed related to the process of creation of the documentation support system for industrial safety management system in the IDEF0 notation. Decomposition of the processes of the second and third level is presented, and all their functional relations are described. It is demonstrated that the process approach used in the design of the documentation support system of the industrial safety management system allows structuring the composition of processes, clearly defining the input and output parameters of processes, process participants, resources, ensuring control and adjustment of processes.

Characteristics of the role of the human factor in the analysis of the causes of accidents at hazardous production facilities

Characteristics of the role of the human factor in the analysis of the causes of accidents at hazardous production facilities

Structure, Magnetic Characteristics and Stress-Strain State of Structural Steel Welded Pipelines

The analysis of factors affecting the state of the metal of pipelines of heating networks on the territory of hazardous production facilities is carried out, of which the effect of mechanical loads should be especially distinguished. The necessity of carrying out additional types of control along with visual and measuring control during routine inspections and after repairs of pipelines of heating networks has been substantiated. The method for measuring the coercive force and its measurement methods are considered, and a decision is made to develop a technique for studying pipelines of a heating network using this method. Samples for laboratory research have been prepared, namely, a fragment of a heating network pipeline, which has worked for over 10 years, and a fragment of a new pipeline with a similar steel grade. A plan for conducting experimental studies of the prepared samples has been prepared, including the developed methods of experimental studies of samples in accordance with the regulatory documentation, including: a method for studying samples of pipelines of heating networks by measuring the coercive force; method for determining the chemical composition of metals and alloys; methodology for carrying out metallographic studies. Measurements of the coercive force were carried out during the loading of the samples. A change in the coercive force with loading was recorded, mainly towards large values. In this case, the values of the coercive force on the sample, which worked in the territory of hazardous production facilities, are higher than those of the sample of the new pipeline. The complex of the studies carried out indicates that it is advisable at enterprises to measure the coercive force of the metal of pipelines of heating networks on the territory of a hazardous production facility during a routine inspection along with visual and measuring, as well as after repair and restoration work.

Опыт проведения аудита промышленной безопасности на примере ООО «ЗапСибНефтехим»

The results of the industrial safety audit of hazardous production facilities of ZapSibNeftekhim LLC with the involvement of an independent specialized organization — CJSC Scientific technical center of industrial safety problems research are presented. Brief information about ZapSibNeftekhim LLC is given, where the main emphasis is placed on the technological features of hazardous production facilities subject to audit. The audit planning procedure is described, including the formation of a group of direct executors and their distribution among the visited objects. The principles of formation of criteria for compliance with which it was carried out are outlined. The description of the course of the audit, including its preliminary and cameral parts, is presented. Attention is focused on the tools for conducting an audit. The obtained results are analyzed. All the identified results of observations are related to the specific hazardous production facilities, recommendations were developed for each of them. The formulated recommendations are divided into two main groups: actions aimed at eliminating the identified observations, and actions aimed at eliminating the causes of their occurrence. The parallel is drawn between the obtained results and modern views on management in the field of ensuring industrial safety. The involvement is noted concerning the wide range of technical specialists of ZapSibNeftekhim LLC in the process of analyzing the results of observations and developing follow-up actions. In conclusion, the evidence of effective implementation of the requirements for conducting an industrial safety audit of hazardous production facilities with the involvement of an independent specialized organization is presented. Parallels are drawn between the methodology underlying the work done and the basics of industrial safety audit, laid down in the draft law On Industrial Safety. The problems that need to be solved for the successful implementation of a new element of industrial safety regulation are outlined.

An empirical approach to quality assurance of materials, products and structures in industrial safety

The quality of the finished product determines its suitability in the consumer market. Experimental studies are necessary to decide on the applicability of materials and structures in the construction industry. The results of experimental studies require subsequent analysis with the use of information and knowledge base. The purpose of the experimental research presented in this paper is to generate new knowledge about the quality of concrete specimens under the conditions of a new information field. The information field contains the results of full-scale tests and video streams obtained during laboratory experiments. Experimental tests were carried out using conventional testing methodology of concrete specimens in central compression. This technique was accompanied by continuous monitoring and video streaming of each specimen. A distinctive feature of the formation research is the information field of experiments that contains three levels: the level of the initial data, the level of the initial data analysis and the level of new knowledge generation. The level of source data analysis using video stream enables to obtain data that cannot be captured in real-time mode after the experiment is over. Examples of crack development on a specimen surface in dynamics are given in this work. Time intervals with different rates of defect development have been obtained for the investigated specimens. It is proved that the possibility of using filtering algorithms and Kenny’s algorithm for processing images of concrete specimens during the process from the beginning of loading until failure. The obtained results allowed to reveal new possibilities of information field forming during traditional experimental researches of concrete samples quality and, on the basis of obtained information, to reveal regularities of damage development of surface continuity in dynamics, which cannot be found out by organoleptic methods of control. New formation possibilities of an information field allow receiving and processing the information on a condition of concrete and ferro-concrete structures of building objects on indicators of quality in a mode of real time. The results can be used to predict the risk of accidents, including at hazardous production facilities.

ВНЕДРЕНИЕ ПРОАКТИВНЫХ ПОКАЗАТЕЛЕЙ КАК СПОСОБ ПОВЫШЕНИЯ ЭФФЕКТИВНОСТИ МЕРОПРИЯТИЙ В ОБЛАСТИ ПРОИЗВОДСТВЕННОЙ БЕЗОПАСНОСТИ

Currently, the economy of the Republic of Kazakhstan is developing at a rapid pace. Of great importance in the economy of the Republic of Kazakhstan are industries that are associated with the extraction and processing of natural resources, especially oil and gas, which the Republic of Kazakhstan is rich in. Oil production is a multi-stage production process that includes exploration, drilling and construction of wells, their repair, purification of produced oil from water, sulfur and paraffin and impurities. Oil production facilities in the world, including in Kazakhstan, are classified as hazardous production facilities that require strict compliance with production safety requirements. At the same time, the extraction and processing of natural resources is associated with difficult and harmful working conditions, hazardous production factors, which, if safety requirements are not observed, can lead to industrial injuries, occupational diseases and other undesirable consequences. The international organization OPEC+ exists to develop a common production policy, maintain stable oil prices, ensure stable supply to consumers, and increase efficiency through investment in the oil industry. OPEC+ represents a community of participating countries, coordinating actions and strategies for exporting oil around the world. Today, OPEC countries have a total of about 80% of oil reserves. The value in the field of production reaches 40%, while global oil exports consist of OPEC + supplies for half. At a meeting of the government of the Republic of Kazakhstan, the results of oil production in 2021 were reported, which amounted to 85.7 million tons and 67.6 million tons for export. In 2021, the volume of reduction in oil production in oil exporting countries (OPEC +) was reviewed monthly. The Republic of Kazakhstan planed to maintain the volume of oil production in 2022 at the level of 87 million tons [1].

РИСКИ ЭКСПЛУАТАЦИИ НЕФТЕГАЗОВОГО ОБОРУДОВАНИЯ С ИСТЕКШИМ НОРМАТИВНЫМ СРОКОМ СЛУЖБЫ

A large number of oil and gas facilities and equipment parts around the world are approaching or have exceeded their original design life. Misuse of oil and gas equipment can easily lead to accidents, production failures or supply disruptions. This not only poses an immediate risk, but can also lead to wider economic losses as well as damage to the environment and human lives. While routine inspection can reduce some risks, it cannot identify all potential hazards. With obsolete equipment, possible safety problems cannot be predicted in advance. Taken together, all these factors can pose a potential threat to the safety of oil and gas complexes. When assessing the state of industrial safety, not only quantitative indicators of hazards must be taken into account, but also factors that can significantly increase the number of accidents and the severity of their consequences. These factors include the factor of almost constant retirement of main production assets due to depreciation and obsolescence of equipment. Having analyzed the main causes of accidents and incidents that occurred between 2016 and 2020, it was found that the cumulative share of accidents related to the operation of equipment with an expired standard service life was 64 %. The purpose of this article is to discuss guidelines for assessing life extension to ensure the technical and operational integrity of oil and gas equipment. Some threats to integrity from physical degradation mechanisms are considered. The aim is to highlight those mechanisms by which an installation deteriorates physically and functionally, including human factors and organizational problems. To make suggestions and recommendations for extending the service life without deteriorating the safe operation of the hazardous production facility.

Разрушения резервуаров и способы минимизации негативных последствий

Introduction. The most widely used for the storage of oil and petroleum products at industrial enterprises both in Russia and abroad, were vertical steel cylindrical tanks). However, despite the significant world experience in the design, construction and operation of vertical steel cylindrical tanks, from time to time their failures (destruction) occur, leading to negative consequences. Interacting with normative earthen landslides or enclosing walls, the resulting powerful hydrodynamic flow of liquid flows through them, spilling over a large area, involving in the incident nearby tanks, buildings, structures, pipelines, which leads to the cascading development of the accident, significant material damage, often to injuries and loss of life. Thus, a more detailed consideration of the effectiveness of existing ways to minimize the negative consequences of tanks destruction, as well as problematic issues of some promising methods on the topic under consideration, seems relevant. Goals and objectives. Identify the most effective ways to minimize the negative consequences of possible destruction of vertical steel cylindrical tanks. Analyze the consequences of characteristic accidents of vertical steel cylindrical tanks at production facilities. To propose a classification of methods on the basis of preventing or localizing the breakthrough wave formed during the destruction of vertical steel cylindrical tanks. To consider the problematic issues of promising ways to localize flammable liquid. Methods. In the process of developing a number of ways to minimize the negative consequences of accidents on vertical steel cylindrical tanks, methods of similarity theory and laboratory modeling, physical experiment, observation, comparison, finding empirical dependencies based on mathematical processing of experimental data, description, generalization were used. Results and their discussion. It has been established that the most effective way is to eliminate the dangerous factor (breakthrough wave) through the use of underground or horizontal tanks. Effective ways to localize the flow of liquid include the arrangement of an enclosing wall with a wave reflective visor or a protective wall additional to the normative fence. A promising method includes the construction of tanks of the "glass in a glass" type. Conclusion. The effectiveness of the considered methods should be taken into account, first of all, by the owners of hazardous production facilities, specialists of design organizations and supervisory authorities to find optimal solutions for the safe operation of tanks, including, if necessary, their placement in settlements, near water areas and federal highways. Keywords: tank, destruction, breakthrough wave, earthen collapse, enclosing wall, enclosing wall with a wave reflective visor, additional protective wall, "glass in a glass" tank.

СОВЕРШЕНСТВОВАНИЕ СИСТЕМЫ ОБУЧЕНИЯ ДЛЯ АТТЕСТАЦИИ РАБОТНИКОВ ПО ПРОМЫШЛЕННОЙ БЕЗОПАСНОСТИ ООО ИК «СИБИНТЕК»

To date, when conducting certification, a large number of campaigns answer the question of compliance or non-compliance of an employee with his position, in this regard, the certification process needs to be modernized. In order to ensure greater effectiveness in solving the tasks set and achieving the intended goal, the management of the organization needs to periodically monitor the compliance of the competencies of a certain employee with the obligations and official functions assigned to him. One of the options for such certification is the evaluation of employees, which occupies a specific place in the employee management system, since it is periodic and formalized, and is able to dramatically increase the productivity of a certain employee, create conditions for the safety of his work. Not only the prospects of the employee at the enterprise depend on its results (that is, the probability of his advancement on the career ladder), but also the guarantee of uninterrupted performance of the production process. Compliance with established and modern requirements aimed at ensuring the necessary level of industrial safety is fully an integral part of almost any production process carried out in practice, especially high-risk. The problem of ensuring such security is most clearly manifested in such branches of modern industry as coal and oil. Enterprises of the extractive industry can be attributed to a greater extent to hazardous production facilities, whose industrial safety is regulated by a developed set of current legislative acts, regulations, standards and other existing regulations of both federal, regional and industry significance. These enterprises need a special attitude of the staff in order not to harm themselves and others. Therefore, each employee is obliged to comply with the established safety rules, reliably represent their behavior and modus operandi in emergency situations, and be psychologically prepared for such situations. The improvement of the training system for the certification of industrial safety workers at Sibintek IC LLC will increase the level of safety of employees working at this enterprise.

Оценка быстродействия системы противоаварийной автоматической защиты

Introduction. Emergency protection systems are an indispensable element of modern automated control systems for fire and explosion hazardous technological processes. The protection of personnel, process equipment and the environment depends on their timely operation. Therefore, the methodology for quantifying the performance of the Emergency Protection System in the design and analysis is of undoubted practical interest. Targets and goals. The goal is to develop an algorithm and methodology for quantifying the response time of the protection system in the pre-emergency mode of operation of a technological facility. The tasks include the formation of mathematical models for calculating the time parameters of the elements that make up the Emergency Protection System. Methods. Methods of mathematical analysis and modeling of emergency protection systems are used. Results and discussion. The functions of the Emergency Protection System and the regulatory requirements for their performance depending on their safety class of hazardous production facilities are considered. A generalized algorithm for the formation of the Emergency Protection System is considered, taking into account the requirements for its speed. Using the typical structure of the Emergency Protection System as an example, an expression was obtained for the delay time when it performs the functions of an alarm and the operation of automatic shut-off and shut-off devices. According to technical sources, the approximate time parameters of the elements of the Emergency Protection System are given. The method of quantitative assessment of the response time is considered using the example of an emergency protection system designed to detect gas contamination of a production facility due to depressurization of process equipment, the formation of control signals when the concentration of combustible gases reaches a pre-explosive level, the activation of an alarm, and the operation of valves that block the access of combustible gas to a process facility. Mathematical expressions for calculating the parameters are determined, which allow estimating the total response time of the Emergency Protection System and its compliance with the safety condition for the normatively set time. Conclusions. The considered technique can be used in practice for a preliminary assessment of the response speed of the Emergency Protection System, as well as in the educational process for carrying out practical and laboratory work in the study of industrial automation systems to prevent fire and explosion. Keywords: emergency protection system, protection response time, pre-emergency mode of operation, accident.

Declaration of conformity in the field of metallurgical production

At present, the declaration of conformity in Russia is a priority form of confirmation of the conformity of products to the requirements of technical regulations. Technical regulations are documents containing mandatory requirements for products, methods and forms of assessment, approved by the decision of the Supreme Eurasian Economic Council, acting on the territory of the Eurasian Economic Union and being mandatory for execution and compliance. A list of technical regulations has been established, for compliance with which the declaration of conformity of products in the field of metallurgy is carried out. The sources of risk of the process of declaration of conformity have been identified and their causes have been established. Among these sources are selection of product samples; on-site testing of products, samples or their study as a representative of all subsequently manufactured products; assessment of test (research) results from the standpoint of visibility of product compliance with the requirements of technical regulations; production control; study of a sample for the planned production as a typical representative of a product used at hazardous production facilities; analysis of the technical documentation submitted by the applicant and its preliminary assessment; assessment of the risk of harm when applying the requirements proposed by the applicant; quality management system (QMS) certification. On the basis of risk management, conformity declaration schemes have been established, with the use of which the likelihood of products hazardous to the consumer appearing on the market is greatest - 1D, 3D. The content of the documentation on the applicant’s production control when declaring conformity is proposed - technological equipment, personnel, measuring instruments, documentation (design, technological, registration and accounting), infrastructure (territory, production facilities, transport, etc.), incoming control, special processes (operations), acceptance control and periodic testing, marking of finished products. A list of national standards of the Russian Federation is presented, which make it possible to implement all stages of the declaration of conformity by the applicant.

Determination the rational locations of territorial emergency response teams in the area of possible emergency situations of natural and technogenic nature

Due to frequent emergency cases at hazardous production facilities, which can lead to an environmental disaster, material and social damage, the issue of using the rational locations of territorial emergency response teams in the area of responsibility is the most relevant. The greatest weight if it is necessary to determine the rational place for the permanent deployment of territorial emergency rescue units created by the state authorities of the subject of the Russian Federation. Due to the lack of guidance documents and methodological recommendations for determining the permanent location of territorial emergency rescue units, this task was solved in each constituent entity of the Russian Federation in its own way and with a significant degree of subjectivity. It is proposed to use an algorithm for determining the permanent location of the rescue formation in the area of responsibility based on the probability of calling the formation to incidents, accidents and emergencies.

Results of experimental tests of building samples

The purpose of the experimental study presented in the work is to generate new knowledge about the quality of concrete samples in a new information field that consolidates information about the results of full-scale tests and video streams that were obtained during active laboratory experiments-studies. When conducting experimental studies, the traditional technology of testing concrete samples for central compression was used. This was accompanied by continuous monitoring and the formation of a video stream for each sample. A distinctive feature of the study is the formation of an information field of experiments, which contains three levels: the level of initial data, the level of analysis of initial data and the level of generation of new knowledge. The level of analysis of the source data using the video stream allows you to obtain information at the end of the experiment that cannot be recorded in real time. For the samples under study, time intervals with different rates of defect development were obtained. The results obtained made it possible to identify new possibilities for the formation of the information field during traditional experimental studies of the quality of concrete images and, based on the information obtained, to identify patterns of development of surface continuity disorders in dynamics. New opportunities for the formation of the information field allow in real time to obtain and process information on the state of concrete and reinforced concrete structures of construction projects by quality indicators and, on the basis of the data obtained, predicting the risk of accidents, including at hazardous production facilities.

Analysis of changes in the survivability of building structures reinforced after an emergency dynamic impact in the context of assessing the security of buildings in the oil and gas industry

The relevance of the subject matter is conditioned by the technical complexity of the oil and gas facilities due to the increase in the volume and rate of raw materials production, which may be affected by shock-wave loads in emergency situations. The causes of the impact can be explosions, heavy cargo falls, terrorist attacks, natural and anthropogenic disasters, etc. These situations are very likely to cause significant damage to the building structures of industrial facilities, which necessitates their reinforcement. For further safe operation of the facility, reinforced structures must have survivability under repeated impacts no less than before the reinforcement. Given the fact that the survivability of buildings is a complex characteristic influenced by many factors, and it itself is a component of the security of a hazardous production facility, research in this area is topical. The purpose of the study is to test the developed method for assessing the survivability of a building structure under short-term shock-wave load based on the energy parameter and to analyze the results obtained in the context of assessing the security of critical oil and gas facilities. Research methods: Measurement of accelerations, deflections, and loads by strain measurement methods, graphoanalytical method of study using the Microsoft Excel software. A method for assessing the level of survivability of a building structure under shock-wave loading for critical oil and gas facilities using the survivability coefficient is developed. Using specific tests of conventional and cage-reinforced bending concrete elements for short-term dynamic load, the values of the specified coefficient are obtained. The values are compared and conclusions are drawn.

Training systems and simulators in thermal power engineering

The article analyzes reasons of technogenic accidents in the RF. It mentions the key ‘internal’ and ‘external’ reasons of accidents at hazardous production facilities. The article deals with the requirements for ensuring reliable, economical and safe operating modes of the equipment. It sets forth a modern structure for personnel training. Certain scientific and technical requirements and recommendations are offered for simulation of ergatic distribution systems for trainers designed for operation personnel of power generation facilities. The article dwells upon the initial regulations of the power industry in the USSR that set forth the requirements for training and simulator systems.

Оценка распространения тепловой радиации в особых условиях

Increase of the requirements for the safety of hazardous production facilities stimulates the development and improvement of the methodological approaches to accidents consequences assessment on the main gas and other pipelines. Existing models for determining heat fluxes from radiating flame surfaces are focused on assessing damage under standard conditions when the epicenter of the accident is at the same altitude level with potential recipients and there are no barriers between them. In practice, special conditions are often implemented, in particular: fires on the pipelines located in the mountainous areas, safe passage of aircraft near the burning site, protection of objects from thermal radiation by installing impenetrable screens. Approaches are proposed related to assessing heat fluxes at the receiving sites located at different altitude levels with the fire source, as well as during accidents with ignition on the gas pipelines in the presence of screens protecting against thermal radiation. A parameter is introduced that describes the effect of the multilevel location of the source and the recipient on radiation — the coefficient of change in the thermal radiation flux from the side surface of a column-type fire in the absence of a wind, depending on the location height and distance in relation to the ground source of combustion of the site receiving the radiation. An expression is given for determining safe height of the flight of aircraft over a column-type fire in the range of flame heights from 50 to 850 m. Isolines of the fields of heat fluxes from the flame of a high-speed flat jet are calculated when the radiation is screened by a wall located at a normalized distance. The results obtained make it possible to predict the consequences of accidents on the main gas pipelines with gas ignition considering the relief, to assess the boundaries of safe corridors for flights of the aircraft near gas pipelines, and to efficiently develop means of protecting objects surrounding the main pipelines from thermal radiation from a flat torch.

Stress-strain state assessment capacitive apparatus taking into account impact piping for connectors

Capacitive equipment in oil refining and petrochemical processes belongs to one of the most significant and responsible groups of process equipment of hazardous production facilities. Having various purposes, an impressive part of the process vessels is operated at increased pressures and temperatures under conditions of corrosion-erosion wear. Therefore, capacitive equipment must meet all the necessary requirements in the field of reliability and industrial safety. Depending on the effect of various operational loads and other factors, the distribution of the stress-strain state of the equipment elements can vary according to various scenarios depending on the determining parameter of the technical state and the dominant damage mechanism. One such factor may be the loads on the nozzles from process pipelines. The geometry features and various operational parameters of the piping can have a significant effect on the formation of the stress-strain state of the vessel and the distribution of areas of concentration of increased stresses. In the future, defects of various levels may occur in these zones. In this regard, the work on the study of the stress-strain state of the vessel is relevant, taking into account the loads that pipelines from the process piping exert on the nozzles.