流程生产风险防控的功能安全完整性

为提升流程生产安全管理水平,降低事故发生概率,本文提出生产过程中风险防控的功能安全完整性分析方法,并结合钢铁连铸场景进行验证。首先评估流程生产中主要事故类型的危险程度和确定其可接受频率标准；运用保护层分析法计算作业现场高危险性事故发生的真实频率,通过与可接受频率比较,判断是否需要新增防护措施；运用蒙特卡洛-马尔可夫模型验证新增防护措施的功能安全完整性等级。以大冶特钢炼钢转炉厂连铸作业区为例,结果表明:存在熔融物爆炸、火灾和中毒窒息3类高危险性事故隐患,且熔融物爆炸事故的人员伤亡后果为不可接受,需新增功能安全完整性等级为2级的防护措施；设计了防爆炸保护系统,其失效概率为4.37×10-3,满足功能安全完整性等级要求。

Research on Functional Safety Integrity of Process Production Risk Prevention and Control

This paper proposed a functional safety integrity analysis method for risk prevention and control in the production process combined with the steel continuous casting scenario, aiming to improve the safety management of process production and reduce the probability of accidents. Firstly, we evaluated the risk level of the main accident types in the process production and established acceptable risk frequency standard. Then we calculated the real frequency of high-risk accidents and judged whether it is necessary to add new protective measures by comparing with the acceptable frequency. Finally, we used the Monte Carlo-Markov model to verified the safety integrity level of the new protective measures. The continuous casting operation area of the converter plant of Daye Special Steel Co., Ltd. was selected as the verification scenario, the results show that there are three types of high-risk accident hidden dangers of molten explosion, fire and toxic asphyxiation. Moreover, the consequences of casualties in molten explosion accidents is unacceptable and it is necessary to implement additional protective measures with a safety integrity level 2. The failure probability of the designed anti-explosion protection system is 4.37 × 10-3, which meets the requirements of safety integrity level.