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安全审查简介Introduction of Safety Review拜耳医药保健有限公司北京工厂BHC Product Supply Beijing Site2012 年 3 月March, 2012
Introduction of Safety Review • Page 2 •March, 2012
内容Content
拜耳集团工艺与工厂安全规范 Bayer Group Process and Plant Safety Regulations
安全概念的建立 Development of Safety Concepts
安全审查的程序 Procedures of Safety Review
降低风险的基本原理 Basic Principles to Reduce Risk
Introduction of Safety Review • page 3 • March, 2012
拜耳集团工艺与工厂安全规范Bayer Group Process and Plant Safety Regulations
政策方针Policy
Bayer 集团工艺及工厂安全Process & Plant Safety in the Bayer Group
集团规定 No. 2020
Group Regulation No. 2020
生效日期 : 2010 年 4 月 1 日
Effective: April 1, 2010
指令Directive
工艺及工厂安全Process and Plant Safety
集团规定 No. 13-1
Group Regulation No. 13-1
生效日期 : 2004 年 10 月 1 日
Effective: October 01, 2004
导则Guideline
工艺及工厂安全纲要
Process and Plant Safety Compendium
集团规定 No. 1928
Group Regulation No. 1928
生效日期: 2007 年 7 月 1 日
Effective: July 01, 2007
操作规程
Procedure
厂房、设备及公用系统的安全状态回顾Safety Status Review for Facilities, Equipment and
Systems标准操作规程 S 25-046
SOP S 25-046
生效日期: 2010 年 3 月 29 日
Effective: March 29, 2010
Introduction of Safety Review • page 4 • March, 2012
工艺及工厂安全指令和标准操作规程Directive and SOP of Process and Plant Safety
Directive
Process & Plant Safety
– 安全概念 Safety concept
– 工作流程 ( 含各级证书 )
Work flow (with certificates) • 初步安全分析 (A1) Preliminary Safety Analysis (A1) • 基础安全审查 (A2) Basic Safety Review (A2)• 详细安全审查 (A3) Detailed Safety Review (A3) • 开车前安全审查 (A4) Pre Start-Up Safety Review (A4)
– 角色和职责 Roles and responsibilities
对于每个工艺和工厂,安全概念必须建立、存在。For every process and plant a safety concept must be developed and in place
For R
efer
ence
Introduction of Safety Review • page 5 • March, 2012
A4-R
A3-R
生 产 / 运 行 阶 段
Production / Operation-Phase
R = 重新评估R = Revalidation
A1, A2, A3
A4
安全概念的建立Development of Safety Concepts
实施Do
行动Act
计划Plan
检查Check
工 程 / 运 行 前 阶 段
Engineering / Start-up-Phase
计划Plan 实施
Do
行动Act
检查Check
Introduction of Safety Review • page 6 • March, 2012
安全审查的程序Procedures of Safety Review
A1 初步安全分析A1 Preliminary Safety Analysis
A2 基本安全审查A2 Basic Safety Review
A3 详细安全审查A3 Detailed Safety Review
A4 运行前的安全审查A4 Pre Start-Up Safety Review
重新评估Revalidation
随着项目的进展,对安全设计概念进行逐步的,细化的安全评估。Stepwise review of safety concepts with increasing detailed investigation during the developing of project phases.
Introduction of Safety Review • page 7 • March, 2012
工作步骤: A1 初步安全分析Work Stage: A1 Preliminary Safety Analysis
A1 审查阶段Review Stage A1
─ 安全数据的编辑和评估 compilation and evaluation of safety data
─ 检查,提出本质安全设计的建议
examination, proposals for inherent safer design
─ 检查可选的安全概念 check of alternative safety
concepts
初步安全分析证书:Preliminary Safety Analysis Certificate:
在项目投资预批准之前获得For projects prior to Invest Pre-Approval
Introduction of Safety Review • page 8 • March, 2012
工作步骤: A2 基础安全审查Work Stage: A2 Basic Safety Review
A2 审查阶段Review Stage A2
─ 建立基本的安全概念develop the basic safety concept─ 使用检查表 using checklists
基础安全审查证书:Basic Safety Review Certificate:
在提交许可申请或者拨款申请前获得Prior to the submission of permit application or appropriation request
Introduction of Safety Review • page 9 • March, 2012
工作步骤: A3 详细安全审查Work Stage: A3 Detailed Safety Review
A3 审查阶段Review Stage A3
─ 系统地辨识危害 systematic identification
of the hazards─ 风险评估risk assessment─ 确定适当的安全措施 definition of adequate
preventive and mitigating safety measures
详细安全审查证书Detailed Safety Review Certificate:
在采购之前获得Prior to the procurement of plant components
Introduction of Safety Review • page 10 • March, 2012
工作步骤: A4 运行前安全审查Work Stage: A4 Pre Start-Up Safety Review
A4 审查阶段Review Stage A 4
运行前安全审查证书Pre Start-Up Safety Review Certificate:在运行前获得Prior to start up of the plant
─ 检查在 A3 中提到的要求是否实现以及工厂是否按照之前讨论的结果来建设
checked whether all required defined measures which were specified in the detailed safety review (A3) have been realized and the plant is build as discussed
─ 检查,检查及功能性测试
plant inspections, checks and functional equipment
testing
Introduction of Safety Review • page 11 • March, 2012
工作步骤:定期再评审Work Stage: Periodic Review
开 车
Start Up
生 产 / 操 作 Production / Operation
A4
变更Modifications 在 最 近 一 次 A3 评 审 的 5 年 之 内
within 5 years after last A3
安全概念再评审Revalidation of Safety
concept
当 前 的 安 全 评 审 文 件Current Safety Review Document
A4-RA3-R
R = 重新评估的R = Revalidation
MoC= 变更管理MoC= Management of change
变更管理MoC
minor /simple
小的 / 简单的
项 目
Project
A3
A4
A2
重大的Significant
A1
Introduction of Safety Review • page 12 • March, 2012
安全审查参与成员Participants of Safety Reviews
技术检查Technical Inspection
Safety Review
安全评审消防
Fire Prevention
职业安全Occupational Plant Safety
生产人员Production
工艺安全工程师
Process and Plant Safety环境保护
Environmental Protection
项目工程师Project
Engineering
过程控制工程师
Process Control Engineering
维修人员Maintenance
工厂 / 部门PLANT/UNIT
团队核心Core-Team
法规事务Regulatory
Affairs
工程人员Plant
Engineering
同一人员也可能会同时担任多个角色Several functions may be assumed by a same person
Introduction of Safety Review • page 13 • March, 2012
安全审查文件的重要性Safety Review Documentation
安全审查的相关文件是工艺和工厂方面信息的最重要来源。它确保下列工作安全并且正确地执行:The safety review documentation is one of the most important sources of information for
a specific process or plant. It makes it possible to safely and correctly perform tasks such
as: – 预防性维护 Preventive maintenance– 故障应急维护 Emergency maintenance and breakdowns– 过程变更 Process changes – 员工培训 Employee training– 按照法律要求准备和更新安全报告 Preparation and updating of safety reports in compliance with legal requirements.
Introduction of Safety Review • page 14 • March, 2012
降低风险的基本原理Basic Principles to Reduce Risk
风险 = 结果的严重程度 x 事件发生的可能性Risk = Consequence Severity x Event Frequency
1. 消除危害或者将潜在的危害最小化 Eliminate or minimize potential hazard
2. 避免失误或者将潜在的失误降到最低 Avoid or Minimize potential failures
3. 把工艺或过程设计成失误 - 可接受 Design processes and plants to be fault-tolerant 4.减轻可能的事件的 影响 Mitigate the effects of potential incidents
Introduction of Safety Review • page 15 • March, 2012
降低风险 - 工作流程Reduce Risk-Work Flow
风险级别
Risk
class
可靠性
Reliability
例子
Example
A
B VH (非常高 )VH (very high)
SIL3,
PSV
C H ( 高 )H (high)
SIL2
D I (增强型 )I (increased)
BPCS
E N ( 一般 )N (normal)
BPCS
危险识别Hazard identification
用风险矩阵鉴定风险级别Identification of risk class with risk matrix
严重性表 Severity Tables
频率表 Frequency Tables
频率 Frequency
严重
性S
ever
ity
安全措施工具箱Measure tool box
风险评估Risk assessment后果的严重性
Severity of consequences情景发生的频率
Frequency of scenario
风险降低Risk reduction
详细的安全措施Specification of safety measures
可能的风险Scenarios
F
F D C B
F F E D
D C B A
F F E
设备Equipment
压力高 / 低Pressure high/low
温度高 / 低Temperature high/low
爆炸Explosion
…….
Introduction of Safety Review • page 16 • March, 2012
风险分析文件的结 构Hazard Analysis Document Structure• 工艺描述 DESCRIBE THE PROCESS
• 物质的描述和特性 DESCRIBE AND CHARACTERIZE THE SUBSTANCES
• 通过下面方法进行风险评估 EVALUATE THE RISK VIA
• HAZOP / FMEA = 评估可能性 HAZOP / FMEA = ESTIMATE THE PROBABILITY (P)
• 结果分析 = 评估严重程度 CONSEQUENCE ANALYSIS = ESTIMATE HOW BIG THE PROBLEM IS (E)
• RISK R = P x E
• 控制风险的措施 COUNTERMEASURES TO CONTROL THE RISK
• 确定剩余的风险 DEFINE THE RESIDUAL RISK
• 风险分析评估地点的分类 CLASSIFY THE PLACE WHERE THE RISK IS EVALUATED
• 爆炸环境 (燃烧 /爆炸) ATEX (FLAME/EXPLOSION)
• 噪声 NOISE
• 生物的 /致突变的 /致癌的 BIOLOGICAL/MUTAGENIC/CANCEROGENIC
• 机械的 MECHANICAL
• 建立系统来控制危险 SET UP A SYSTEM TO CONTROL THE DANGER
• 检查 WALKTHROUGH
• 提高意识 / 培训 AWARENESS / TRAININGS
谢谢! Thank you!