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 Site
2012年3月
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 2 •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
指令
Policy
Directive
Bayer集团工艺及工厂安全
工艺及工厂安全
Process & Plant Safety in the Bayer Group
Process and Plant Safety
集团规定No. 2020
集团规定No. 13-1
Group Regulation No. 2020
Group Regulation No. 13-1
生效日期: 2010年4月1日
生效日期: 2004年10月1日
Effective: April 1, 2010
Effective: October 01, 2004
导则
Guideline
工艺及工厂安全纲要
操作规程
Procedure
厂房、设备及公用系统的安全状态回顾
Process and Plant Safety Compendium
Safety Status Review for Facilities, Equipment and
Systems
集团规定No. 1928
标准操作规程 S 25-046
Group Regulation No. 1928
SOP S 25-046
生效日期：2007年7月1日
生效日期：2010年3月29日
Effective: July 01, 2007
Effective: March 29, 2010
Introduction of Safety Review • page 3 • 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
– 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)
Directive
Process & Plant Safety
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
Introduction of Safety Review • page 4 • March, 2012
安全概念的建立
Development of Safety Concepts
工程 / 运行前阶段
Engineering / Start-up-Phase
计划
实施
Plan
Do
A1, A2, A3
生产 / 运行阶段
Production / Operation-Phase
计划
行动
检查
Act
Check
Plan
A3-R
实施
Do
A4
R =重新评估
R = Revalidation
Introduction of Safety Review • page 5 • March, 2012
行动
检查
Act
Check
A4-R
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
Introduction of Safety Review • page 6 • March, 2012
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.
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 7 • 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 8 • 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 9 • 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
─ 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
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
Introduction of Safety Review • page 10 • March, 2012
工作步骤：定期再评审
Work Stage: Periodic Review
生产 / 操作 Production / Operation
开车
Start Up
变更
Modifications
重大的
项目
Significant
Project
minor /simple
A1
小的 / 简单的
变更管理
MoC
A4
在最近一次A3评审的5年之内
within 5 years after last A3
A2
安全概念再评审
A3
Revalidation of Safety
concept
A4
当前的安全评审文件
A3-R
A4-R
Current Safety Review Document
Introduction of Safety Review • page 11 • March, 2012
MoC= 变更管理
R =重新评估的
MoC= Management of change
R = Revalidation
安全审查参与成员
Participants of Safety Reviews
团队核心
工厂/部门
工程人员
PLANT/UNIT
生产人员
维修人员
Plant
Engineering
Maintenance
过程控制工程
师
Production
Process Control
Engineering
法规事务
Regulatory
Affairs
Safety
Review
消防
项目工程师
安全评审
Fire Prevention
Process and
Plant Safety
环境保护
Environmental
Protection
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 12 • March, 2012
Project
Engineering
工艺安全工
程师
职业安全
Occupational
Plant Safety
Core-Team
技术检查
Technical
Inspection
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 13 • March, 2012
降低风险的基本原理
Basic Principles to Reduce Risk
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
风险= 结果的严重程度 x 事件发生的可能性
Risk = Consequence Severity x Event Frequency
Introduction of Safety Review • page 14 • March, 2012
降低风险-工作流程
Reduce Risk-Work Flow
风险降低
风险评估
Risk reduction
Risk assessment
详细的安全措施
后果的严重性
危险识别
Specification of safety measures
Severity of consequences
情景发生的频率
Hazard identification
Frequency of scenario
安全措施工具箱
Measure tool box
严重性表Severity Tables
可能的风险
频率表Frequency Tables
Scenarios
Equipment
用风险矩阵鉴定风险级别
Identification of risk class with risk
matrix
压力高/低
Pressure high/low
温度高/低
Temperature high/low
Introduction of Safety Review • page 15 • March, 2012
Severity
严重性
爆炸
…….
可靠性
例子
Reliability
Example
Risk
class
A
设备
Explosion
风险
级别
D
C
B
A
F
D
C
B
F
F
F
E
D
F
E
F
B
C
VH (非常高)
VH (very high)
SIL3,
PSV
H (高)
SIL2
H (high)
频率 Frequency
D
I (增强型)
I (increased)
BPCS
E
N (一般)
N (normal)
BPCS
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
Introduction of Safety Review • page 16 • March, 2012
谢谢！
Thank you!