Identifying hazards is fundamental for ensuring the safe design and operation of a system in process plants and other facilities. Several techniques are available to identify hazardous situations, all of which require their rigorous, thorough, and systematic application by a multi-disciplinary team of experts. Success rests upon first identifying and subsequently analyzing possible scenarios that can cause accidents with different degrees of severity. While hazard identification may be the most important stage for risk management, it depends on subjectivity issues (e.g., human observation, good judgment and intuition, creativity, expertise, knowledge) which introduce bias. Without a structured identification system, hazards can be overlooked, thus entailing incomplete risk-evaluations and potential loss. The present Thesis is focused on developing both managerial and technical aspects intended to standardize one of the most used techniques for hazard identification; viz. HAZard & Operability (HAZOP) study. These criteria have been carefully implemented not only to ensure that most of the hazardous scenarios will be identified, but also that US OSHA PSM Rule, EPA RMP, and Seveso Directive requirements will be accomplished. Chapter I pioneers the main research topic; from introducing the process safety concept up to the evidence of more detailed information is required from related regulations. A review of regulations (i.e., US, Europe legislation) focused on Hazard Identification has been conducted, highlighting, there is an absence of specific criteria for performing techniques intended to identify what can go wrong. Chapter II introduces the risk management system required to analyze the risk from chemical process facilities, and justifies that hazard identification stage is the Process Safety foundation. Hereafter, an overview of the key Process Hazard Analyzes (PHA) has been conducted, and the specific HAZOP weaknesses and strengths have been highlighted to establish the first steps to focus on. Chapter III establishes the scope, the purpose and the specific objectives that the research covers. It answers the following questions on the spot: why the present research is performed, which elements are included, and what has been considered for acquiring the final conclusions of the manuscript. Chapter IV gathers HAZOP-related literature from books, guidelines, standards, major journals, and conference proceedings with the purpose of classifying the research conducted over the years and finally define the HAZOP state-of-the-art. Additionally, and according to the information collected, the current HAZOP limitations have been emphasized, and thus, the research needs that should be considered for the HAZOP improvement and advance. Chapter V analyzes the data collected while preparing, organizing, executing and writing HAZOPs in five petroleum-refining processes. A statistical analysis has been performed to extract guidance and conclusions to support the established criteria to conduct effectively HAZOP studies. Chapter VI establishes the whole set of actions that have to be taken into account for ensuring a wellplanned and executed HAZOP study. Both technical and management issues are addressed, criteria supported after considering the previous chapters of the manuscript. Chapter VI itself is the result of the present research, and could be used as a guideline not only for team leaders, but also for any related party interested on performing HAZOPs in continuous chemical processes. Chapter VII states the final conclusions of the research. The interested parties should be released about the hazard identification related-gaps present in current process safety regulations; which are the key limitations of the HAZOP study, and finally, which are the criteria to cover the research needs that have been found Annex I proposes the key tools (tables, figures and checklists "ready-to use'') to be used for conducting HAZOPs in continuous chemical processes. The information layout is structured according to the proposed HAZOP Management System. This information is intended to provide concise and structured documentation to be used as a reference book when conducting HAZOPs. Annex II is intended to overview the most relevant petroleum refining processes by highlighting key factors to take into account in the point of view of process safety and hazard identification, i.e. HAZOP. In this sense, key health and safety information of specific petroleum refining units is provided as a valuable guidance during brainstorming sessions. Annex III illustrates the complete set of data collected during the field work of the present research, and also analyzed in Chapter V of the manuscript. Additionally, it depicts a statistical summary of the key variables treated during the analysis. Finally, the Nomenclature, References, and Abbreviations & Acronyms used and cited during the manuscript have been listed. Additionally, a Glossary of key terms related to the Process Safety field has been illustrated. / La present Tesis doctoral té com a objectiu estandarditzar l'aplicació d'una de les tècniques més utilitzades a la industria de procés per a la identificació de perills; l'anomenat HAZard & OPerability (HAZOP) study, específicament a processos complexes, com per exemple, unitat de refineria del petroli.El capítol I defineix el concepte de Seguretat de Processos, i progressivament analitza les diferents regulacions relacionades amb la temàtica, detallant específicament les mancances i buits d'informació que actualment hi ha presents a la primera etapa de la gestió del risc en industries de procés: la identificació de perills.El capítol II defineix el sistema de gestió del risc tecnològic que aplica a les industries de procés, i es justifica que l'etapa d'identificació de perills és el pilar de tot el sistema. Finalment, es mencionen algunes de les tècniques d'identificació més utilitzades, els anomenats Process Hazard Analysis (PHA), i es detallen les seves mancances i fortaleses, característiques que han acabat definint la temàtica específica de la Tesis. Concretament, es dóna èmfasis a la tècnica anomenada HAZard & OPerability (HAZOP) study, objecte principal de la recerca.El capítol III defineix l'abast, el propòsit i els objectius específics de la recerca. La intenció d'aquest capítol és donar resposta a les següents qüestions: el perquè de la recerca, quins elements han estat inclosos i què s'ha considerat per tal d'assolir les conclusions de la Tesis.El capítol IV descriu l'estat de l'art de la literatura relacionada amb el HAZOP. Aquesta revisió no només permet classificar les diferents línies de recerca relacionades amb el HAZOP, sinó que també permet assolir un coneixement profund de les diferents particularitats de la pròpia tècnica. El capítol finalitza amb un conjunt de mancances tant de gestió com tècniques, així com les necessitats de recerca que poden millorar l'organització i execució dels HAZOPs.El capítol V analitza la informació que ha estat recopilada durant la fase experimental de la tesis. Les dades procedeixen de la participació en cinc estudis HAZOP aplicats a la industria de refineria del petroli.En aquest sentit, el capítol V desenvolupa una anàlisi estadística d'aquestes dades per extreure'n conclusions quant a la preparació, organització i execució dels HAZOPs.El capítol VI estableix el conjunt d'accions que s'ha de tenir en compte per tal d'assegurar que un estudi HAZOP estigui ben organitzat i executat (la metodologia). Es defineix un Sistema de Gestió del HAZOP, i a partir de les seves fases, es desenvolupa una metodologia que pretén donar suport a tots aquells punts febles que han estat identificats en els capítols anteriors. Aquesta metodologia té la intenció de donar suport i guia no només als líders del HAZOP, sinó també a qualsevol part interessada en aquesta temàtica.El capítol VII descriu les conclusions de la recerca. En primera instància s'enumeren les mancances quant a la definició de criteris a seguir de diferents regulacions que apliquen a la Seguretat de Processos.Seguidament, es mencionen les limitacions de la pròpia tècnica HAZOP, i finalment, es descriuen quins són els criteris establerts per donar solució a totes aquestes febleses que han estat identificades.L'Annex I és una recopilació de diferents criteris que han estat desenvolupats al llarg de l'escrit en forma de taules i figures. Aquestes han estat ordenades cronològicament d'acord amb les diferents fases que defineixen el Sistema de Gestió HAZOP. L'annex I es pot utilitzar com a una referència concisa i pràctica, preparada i pensada per ésser utilitzada directament a camp, amb la intenció de donar suport a les parts interessades en liderar estudis HAZOP.L'annex II recopila informació relacionada amb aspectes clau de seguretat i medi ambient en diferents unitats de refineria. Aquest informació és un suport per tal de motivar el "brainstorming" dels diferents membres que conformen l'equip HAZOP.L'Annex III recopila les dades de les diferents variables que han estat considerades a la fase experimental de la recerca, juntament amb un conjunt de figures que mostren la seva estadística bàsica.

Hazard communication is an essential part of a comprehensive safety plan, especially for those facilities that contain reactive chemicals. There are a variety of means of communicating a chemical hazard, but one of the most prevalent in the United States is the Instability Rating found in the NFPA 704 standard. While the NFPA 704 identifies hazards associated with exothermically decomposing compounds, it neglects compounds that decompose endothermicly to form large quantities of gas. Such compounds have been known to cause accidents due to pressure buildup, such as in the BP Amoco Polymers explosion in 2001. In this work, twenty-five compounds were examined via an APTAC to determine their pressure and temperature profiles. These profiles were then used to determine the amount of gas generated, the gas generation rate, the gas generation product, the onset temperature, and the instantaneous power density. These properties were analyzed to determine those that best represented the instability hazard of the chemical. Ultimately, the molar gas generation rate and onset temperature were chosen to rate the selected chemicals, and new cut-offs were established to divide the chemicals into revised instability groupings. Compounds that did not decompose in the temperature range examined were given the rating of zero. Compounds with low onset temperatures and high gas generation rates were assigned the rating of 4, while chemicals with high T_onset and low dn/dt_maxn were assigned a value of 1. Chemicals with high onset temperatures and high gas generation rates were grouped into rating 3. Group 2 included low onset temperature compounds with low gas generation rates. The cut-offs used to define these regions were 130 degrees C for the onset temperature and 0.01 (1/min) for the gas generation rate. The ratings were found to be comparable to the current NFPA system, but improved upon it by providing a valid rating (group 1) for the chemicals that endothermically generated gas. Detailed plots of the data are provided as well as suggestions for future work.

Submitted by Joana Azevedo (joanad@id.uff.br) on 2017-12-11T13:15:24Z No. of bitstreams: 1 Dissert Alinne S Moreira.pdf: 2603904 bytes, checksum: d32d6697689a376a5eb10cd73052d2b2 (MD5) / Approved for entry into archive by Biblioteca da Escola de Engenharia (bee@ndc.uff.br) on 2018-01-10T15:41:28Z (GMT) No. of bitstreams: 1 Dissert Alinne S Moreira.pdf: 2603904 bytes, checksum: d32d6697689a376a5eb10cd73052d2b2 (MD5) / Made available in DSpace on 2018-01-10T15:41:28Z (GMT). No. of bitstreams: 1 Dissert Alinne S Moreira.pdf: 2603904 bytes, checksum: d32d6697689a376a5eb10cd73052d2b2 (MD5) Previous issue date: 2017-01-11 / Em função da ocorrência de acidentes industriais catastróficos, observados nas últimas décadas, a segurança de processos emergiu como um tema de grande relevância, sobretudo para as organizações classificadas como de alto risco. Tal fato deveu-se aos impactos ambientais, materiais, humanos e aos ativos intangíveis, decorrentes destes eventos. Na indústria do petróleo, a maior representação deste tipo de acidente é o ocorrido durante a perfuração do poço de petróleo Macondo, no Golfo do México, em 2010. Este evento demonstrou que havia, àquela época, fragilidades na indústria de óleo e gás em todo o mundo, além de dúvidas quanto à capacidade de governos e agências reguladoras para prevenir e contingenciar ocorrências dessa magnitude. Por este motivo, tal acidente demandou mudanças imediatas e impactantes na regulamentação vigente e na gestão da segurança de processos das empresas deste ramo. Neste contexto, o presente trabalho tem por objetivo propor práticas para a melhoria da gestão da segurança de processos, na atividade de construção de poços marítimos de uma empresa petrolífera brasileira, de modo a evitar a ocorrência de acidentes de grande magnitude, como o ocorrido no Golfo do México. Para atender ao objetivo proposto, foram analisados casos de sucesso na indústria e foi conduzido um estudo de caso na empresa onde se pretende implementar o modelo de gestão. Este último foi realizado na área de transporte aéreo de pessoas, que também possui operações de alto risco, tal como a atividade de construção de poços de petróleo. Desta forma, além de ter grande contribuição científica, esta pesquisa pode ser inspiradora para as empresas que estejam diante do desafio de gerir a segurança dos seus processos, em cenários de grande complexidade, onde a combinação de diferentes variáveis podem causar acidentes de grandes proporções. / Due to occurrences of major accidents, observed in recent decades, process safety emerged as a very important issue for high risk organizations. This is because such accidents are characterized by the environmental, material, human and intangible assets impacts. In the oil and gas industry, the main representation of major accident is Macondo, a well drilled in the Gulf of Mexico in 2010. This event had shown the oil and gas industry’s weakness and had created doubts about the ability of governments and regulatory agencies to prevent and to manage occurrences of this magnitude. At that time, Macondo required immediate and impactful changes in the current regulations and in process safety management of oil and gas companies. In this context, this present study aims to suggest some practices, focusing on process safety, for drilling and completion activities of a Brazilian oil company, in order to prevent the occurrence of major accidents, as occurred in Gulf of Mexico. Industry successful cases were analyzed and it was performed a case study at air transport sector, whose operations are considered as high risk, as the drilling well activity. In this way, besides the great scientific contribution, this research can inspire companies that have the challenge of manage their process safety, in high complexity scenario, where interaction of multiple variables can cause serious accidents.

Submitted by Marcia Silva (marcia@latec.uff.br) on 2016-07-19T19:28:45Z No. of bitstreams: 1 Dissertacao_MSG_Marcio_Muniz_Final.pdf: 2620890 bytes, checksum: b3ca9261af59621b5f9407cc5ee2bb4c (MD5) / Made available in DSpace on 2016-07-19T19:28:45Z (GMT). No. of bitstreams: 1 Dissertacao_MSG_Marcio_Muniz_Final.pdf: 2620890 bytes, checksum: b3ca9261af59621b5f9407cc5ee2bb4c (MD5) Previous issue date: 2016-03-18 / O objetivo da presente dissertação é desenvolver uma análise crítica da contribuição da metodologia LOPA para a gestão de segurança de processo na indústria e perpetuar sua aplicação. Como modelo metodológico, utilizou-se a pesquisa bibliográfica e a pesquisa exploratória, através de um questionário aplicado. Utilizaram-se os resultados do questionário para avaliar o perfil dos respondentes, testou-se a confiabilidade interna das escalas do questionário através da utilização do alfa de Cronbach e executou-se um modelo de triangulação a luz do referencial teórico, dos resultados do questionário e da experiência e dos conhecimentos teóricos do pesquisador. Como resultados, detectou-se a baixa disponibilidade de estudos guiados pela comunidade científica internacional que efetivamente relacionem a utilização da metodologia LOPA com a gestão de segurança de processos, confirmou-se o baixo nível de difusão do conhecimento e de utilização da metodologia LOPA e detectou-se a alta relevância de inclusão da metodologia em um sistema de gestão de segurança de processos. As confiabilidades internas calculadas para os clusters do questionário obtiveram classificação alta e muito alta. / The main goal of this Dissertation is develop a critical analysis of the LOPA methodology contribution to the Process Safety Management in the Industry and to disseminate the LOPA. The Dissertation methodological model included a Bibliographical Research and an Exploratory Research (Through a survey applied, mainly, to the process safety professionals. The Dissertation tested the internal reliability of the survey scales (Through the Cronbach alfa tool), evaluated the survey participants profile and used a triangulation model considering the theoretical framework, the survey results and the experience and theoretical knowledge of the researcher. The Results detected the low availability of studies guided by international scientific community that effectively connect the methodology LOPA with Process Safety Management, the low level of dissemination of knowledge and the low utilization frequency of methodology LOPA and detected the high significance of LOPA inclusion in a Process Safety Management System. The internal reliability values calculated to the survey clusters obtained high and very high classification.

Orientador: Ana Maria Frattini Fileti / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Química / Made available in DSpace on 2018-08-27T02:40:23Z (GMT). No. of bitstreams: 1 Camargo_StellaForganesdeGodoy_M.pdf: 2742507 bytes, checksum: a2cd6bf18b9859966ac846d9d5939a21 (MD5) Previous issue date: 2015 / Resumo: O processo de polimerização em emulsão é um processo industrialmente importante para a produção de polímeros com diversos tipos de aplicações. Existe um grande interesse industrial para a obtenção de teor de sólidos mais altos, pois assim otimiza-se o volume do reator para o mesmo tempo de reação, reduz-se espaço de armazenagem do produto acabado bem como custos com transporte ao consumidor final. Porém, para obtenção de polímeros com alta concentração de sólidos, a dificuldade de estabilização da emulsão, viscosidade mais alta e formação de resíduos (coágulos) geram limitações no processo, interferindo na segurança da reação. Para este trabalho foi escolhida a copolimerização em emulsão de estireno-butadieno devido à sua importância industrial bem como às propriedades relevantes para aspectos de segurança industrial. O objetivo foi estudar as influências do aumento de teor de sólidos nas propriedades da emulsão estireno-butadieno em processo semi-contínuo que afetam a segurança da reação. Primeiramente foi encontrado na literatura um modelo já validado para a copolimerização em emulsão estireno-butadieno em processo semi-contínuo como base para realizar as simulações nos software Aspen Polymers® para as análises das propriedades e comportamento exotérmico da emulsão. O teor de sólidos na emulsão estireno-butadieno foi aumentado, reduzindo gradativamente a água da formulação e mantendo a proporcionalidade entre as demais matérias-primas variando dos originais 48,4 % para 65,1 % em que toda a água da pré-emulsão foi eliminada. As propriedades finais da emulsão apresentaram resultados esperados conforme embasamento teórico abordado: a massa específica, a viscosidade, massa molar média e diâmetro de partícula aumentaram com o aumento do teor de sólidos e a polidispersidade, a temperatura de transição vítrea, o calor específico e a condutividade térmica diminuíram. A taxa de remoção de calor da reação e a temperatura da reação sob condições adiabáticas em possíveis cenários de descontrole de reação foram consideradas para a segurança do processo aumentando significativamente com o aumento do teor de sólidos e indicando presença de monômeros não reagidos ao final do tempo de reação de 10 horas. A análise de sensibilidade do modelo foi realizada variando a temperatura do processo em diferentes concentrações de produto final com o intuito de aumentar o rendimento da reação. Para cada alteração realizada, as variações das propriedades do produto foram analisadas em detalhe para verificar modificações no produto final. O melhor ponto de trabalho encontrado no estudo foi à concentração de 60 % à temperatura de reação de 78°C em que os resultados demonstraram que pequenas alterações no processo podem ser suficientes para garantir a segurança do processo, a qualidade do produto final com altos rendimentos / Abstract: The emulsion polymerization process is a very important process to the industry in the production of polymers with a wide range of applications. There is a large industrial interest to obtain higher solid content polymers in order to optimize the reactor capacity with the same time of reaction, reducing the storage area and transportation to the final costumer. However, to obtain polymers with high solid contents, the difficulties with the stabilization of the emulsion, the higher viscosity and formation of residues (clots) generate limitations in the process, interfering in the safety of reaction. To this paperwork was chosen the styrene-butadiene emulsion copolymerization because of their industrial importance as well as the relevant properties for industrial safety aspects. The objective was to study the influences of the increased solids content in the properties of the styrene butadiene emulsion in a semi-continuous process that affect the safety of the emulsion copolymerization reaction. First of all, was found in the literature a model already validated to the styrene butadiene emulsion copolymerization in a semi-continuous process. This model was used as a base to perform simulations in the Aspen Polymers® software in order to examine the exothermic properties and the behavior of the emulsion. The solid content in the styrene-butadiene emulsion was increased gradually reducing the water of the formulation and maintaining proportionality between the other raw materials ranged from the original 48.4 % to 65.1 % where all water from the pre-emulsion was removed. The final properties of the emulsion had expected results as discussed on theoretical basis: the specific mass, viscosity, molecular weight and particle diameter enlarged with the increasing of solid content and polidispersity, the glass transition temperature, the specific heat and the thermal conductivity decreased. The reaction heat removal rate and the reaction temperature under adiabatic conditions in scenarios of possible runaway reaction were considered for the safety of the process, increasing significantly with the rise of solid content and indicating the presence of unreacted monomers at the end of the reaction time of 10 hours. The analysis of the sensitivity of the model was performed by changing the processing temperature of the final product in different concentrations in order to increase the reaction yield. For each change made, variations of product properties were analyzed in detail to verify changes in the final product. The best working point found in this study was 60 % of solids content at 78°C reaction temperature. The results demonstrated that small changes in process may be sufficient to ensure the safety of the process and the quality of the final product with high yields / Mestrado / Sistemas de Processos Quimicos e Informatica / Mestra em Engenharia Química

A comprehensive process intensification analysis was performed for the integration of the Pd-based membrane reactor technology into IGCC power plants by designing effective process control strategies as well as identifying and optimally characterizing inherently safe operational conditions to achieve the most favorable economic outcomes. Experimental results indicated that Pd-based composite membranes supported on porous stainless steel tubes, fabricated with H2 permeance values as high as ~50 m3/[m2.h.atm0.5] at 450°C were capable of extra purity H2 production (≥99.99%). Two illustrative process control and performance monitoring cases namely, process regulation and servo mechanism, were considered and quite satisfactory process control was attained by maintaining CO conversion at levels higher than 95% so that the retentate stream could become suitable for high pressure CO2 sequestration. From a process safety standpoint, process parameters and operating conditions were identified and optimized to achieve the target performance level of 98% CO conversion and 95% H2 recovery and at the same time to prevent conditions which could potentially induce hazards and thus compromise process system safety. Furthermore, the average total product cost of a water-gas shift membrane reactor module including manufacturing costs and general expenses was carefully estimated by taking into account the full cost structure and found to be 1464 $/ft2. Moreover, a comprehensive economic assessment was performed for composite Pd/Alloy membrane reactor technology options integrated into IGCC power plants in the presence of market and regulatory uncertainty (possible regulatory action on CO2 emissions) as well as technology risks with the aid of Monte-Carlo simulation techniques. Within such a context, it was demonstrated that an IGCC plant with embedded Pd-based membrane reactors and a stream of revenues coming from electricity and H2 selling (IGCC co-production mode), represented an economically attractive and advantageous option when comparatively assessed against its main competitors namely, an IGCC plant with shift reactors and double stage Selexol units as well as the more traditional supercritical pulverized coal power plant option with an Econamine unit installed for CO2 capture purposes.

Este trabalho verificou o tema de segurança de processos no segmento de plataformas de produção de petróleo e gás no mar de forma a propor um modelo de indicadores globais a fim de facilitar a identificação de fragilidades no gerenciamento de riscos de processos da indústria de produção de petróleo e gás natural no mar. O resultado esperado é o fornecimento de dados para a otimização de recursos regulatórios na busca da melhoria da segurança operacional. Para tal, buscando conhecer a postura das empresas no cumprimento da necessidade regulamentar da implementação de um Sistema de Gestão de Segurança de Processos (SGSP), foram identificadas as principais práticas preventivas para a o gerenciamento de riscos. Por conseguinte, mensurou-se o esforço na implementação deste SGSP como correlação direta para a prevenção de acidentes (foco preventivo). Já a análise dos resultados deste gerenciamento de riscos (foco reativo) foi obtido através incidentes operacionais classificados de acordo com sua respectiva importância/impacto, dentro de linhas de corte pré-estabelecidas. Assim, o indicador Global preventivo (IGPRV) e o Indicador Global reativo (IGRTV) foram elaborados agregando diferentes indicadores específicos de cada segmento para simplificar a análise e incluir a articulação de conceitos de segurança de processos à atuação regulatória. Os indicadores globais propostos quantificam conceitos subjetivos e complexos para o estabelecimento de metas e permitem aferir o desempenho das ações e projetos da regulação da indústria. Também permitem a identificação e a disseminação das melhores práticas de gerenciamento de riscos, comparando-as em diferente níveis de gerenciamento. Na análise dos resultados, pôde-se perceber que a utilização dos indicadores globais propostos pode responder com sucesso às necessidades regulatórias identificadas

In this work, a source term model for estimating the rate of spreading and vaporization of LNG on land and sea is introduced. The model takes into account the composition changes of the boiling mixture, the varying thermodynamic properties due to preferential boiling within the mixture and the effect of boiling on conductive heat transfer. The heat, mass and momentum balance equations are derived for continuous and instantaneous spills and mixture thermodynamic effects are incorporated. A parameter sensitivity analysis was conducted to determine the effect of boiling heat transfer regimes, friction, thermal contact/roughness correction parameter and VLE/mixture thermodynamics on the pool spreading behavior. The aim was to provide a better understanding of these governing phenomena and their relative importance throughout the pool lifetime. The spread model was validated against available experimental data for pool spreading on concrete and sea. The model is solved using Matlab for two continuous and instantaneous spill scenarios and is validated against experimental data on cryogenic pool spreading found in literature.

Les risques sont inhérents à l’activité industrielle. Les prévoir et les maîtriser sont essentiels pour la conception et la conduite en sécurité des procédés. La réglementation des risques majeurs impose aux exploitants la réalisation d’études de sécurité quantitatives. La stratégie de maîtrise des risques repose sur la pertinence des analyses de risques. En marche dégradée, la dynamique des événements est déterminante pour quantifier les risques. Toutefois, de nos jours cette connaissance est difficilement accessible. Ce travail propose une méthodologie d’analyse de risques quantitative qui combine la méthode HAZOP, le retour d’expérience et la simulation dynamique de dérives de procédés. Elle repose sur quatre grandes étapes : La première étape est l’étude du fonctionnement normal du procédé. Pour cela, le procédé est décrit de façon détaillée. Des études complémentaires de caractérisation des produits et du milieu réactionnel sont menées si nécessaires. Ensuite, le procédé est simulé dynamiquement en fonctionnement normal. Lors de la seconde étape, parmi les dérives définies par l’HAZOP et le retour d’expérience, l’analyste discrimine celles dont les conséquences ne sont pas prévisibles et/ou nécessitent d’être quantifiées. La troisième phase fournit une quantification du risque sur la base de la simulation dynamique des scenarii retenus. Lors de la dernière étape, des mesures de maîtrise des risques sont définies et ajoutées au procédé lorsque le niveau de risque est supérieur au risque tolérable. Le risque résiduel est ensuite calculé jusqu’à l’atteinte de la cible sécurité. Le logiciel Aspen Plus Dynamics est sélectionné. Trois études de cas sont choisies pour démontrer d’une part, la faisabilité de la méthodologie et d’autre part, la diversité de son champ d’application : · la première étude de cas porte sur un réacteur semi-continu siège d’une réaction exothermique. L’oxydation du thiosulfate de sodium par le peroxyde d’hydrogène est choisie. Ce cas relativement simple permet d’illustrer la diversité des causes pouvant être simulées (erreur procédurale, défaut matériel, contamination de produits, …) et la possibilité d’étudier des dérives simultanées (perte de refroidissement du milieu et sous dimensionnement de la soupape de sécurité). · le deuxième cas concerne un réacteur semi-batch dans lequel une réaction exothermique de sulfonation est opérée. Elle est particulièrement difficile à mettre en œuvre car le risque d’emballement thermique est élevé. Cette étude montre l’intérêt de notre approche dans la définition des conditions opératoires pour la conduite en sécurité. · le troisième cas d’étude porte sur un procédé continu de fabrication du propylène glycol composé d’un réacteur et de deux colonnes de distillation en série. L’objectif est ici d’étudier la propagation de dérives le long du procédé. Sur la base du retour d’expérience, deux dérives au niveau du rebouilleur de la première colonne sont étudiées et illustrent les risques de pleurage et d’engorgement. La simulation dynamique illustre la propagation d’une dérive et ses conséquences sur la colonne suivante. / Risks are inherent to industrial activity. Predicting and controlling them is essential to the processes design and safe operation. Quantitative safety studies are imposed by the major hazard regulations. The risk management strategy relies on the relevance of risk analyzes. In degraded conditions, the dynamics of events are decisive for risks quantification. However, nowadays this knowledge is a real challenge. This work proposes a methodology of quantitative risk analysis, which combines the HAZOP method, the lessons learned from previous accidents and the dynamic simulation of process deviations. It is based on four main stages: The first stage is the study of the process normal operation. For this, the process is described in detail. Additional studies to characterize the products and the reaction are carried out if necessary. Then, the process is dynamically simulated in normal operation conditions. During the second step, among all the deviations defined by the HAZOP and lessons learned, the analyst discriminates those whose consequences are not predictable and/or need to be quantified. The third phase provides a risk quantification based on the dynamic simulation of the selected scenarios. In the last step, safety barriers are defined and added to the process when the risk level is greater than the tolerable risk. The residual risk is then calculated until the safety target is reached. Aspen Plus Dynamics software is selected. Three case studies are chosen in order to demonstrate, on the one hand, the feasibility of the methodology and, on the other hand, the diversity of its scope: · the first case study is a semi-continuous reactor with an exothermic reaction study. The oxidation of sodium thiosulfate by hydrogen peroxide is selected. This relatively simple case illustrates the diversity of causes that can be simulated (procedural error, material defect, product contamination …) and the possibility of studying simultaneous deviations (loss of cooling and under sized safety valve for example). · the second case concerns a semi-batch reactor in which an exothermic reaction of sulphonation is carried out. This reaction is particularly difficult to conduct because of the thermal runaway high risk. This study shows our approach’s interest in the definition of the operating conditions for safe operation. · the third case study concerns a continuous process of propylene glycol production. It is composed of a reactor and two distillation columns in series. The objective is to study the propagation of deviations along the process. Based on lessons learned, two deviations in the first column reboiler are studied and illustrate the flooding and weeping risks. Dynamic simulation illustrates the propagation of a deviation and its consequences on the second column

Este trabalho verificou o tema de segurança de processos no segmento de plataformas de produção de petróleo e gás no mar de forma a propor um modelo de indicadores globais a fim de facilitar a identificação de fragilidades no gerenciamento de riscos de processos da indústria de produção de petróleo e gás natural no mar. O resultado esperado é o fornecimento de dados para a otimização de recursos regulatórios na busca da melhoria da segurança operacional. Para tal, buscando conhecer a postura das empresas no cumprimento da necessidade regulamentar da implementação de um Sistema de Gestão de Segurança de Processos (SGSP), foram identificadas as principais práticas preventivas para a o gerenciamento de riscos. Por conseguinte, mensurou-se o esforço na implementação deste SGSP como correlação direta para a prevenção de acidentes (foco preventivo). Já a análise dos resultados deste gerenciamento de riscos (foco reativo) foi obtido através incidentes operacionais classificados de acordo com sua respectiva importância/impacto, dentro de linhas de corte pré-estabelecidas. Assim, o indicador Global preventivo (IGPRV) e o Indicador Global reativo (IGRTV) foram elaborados agregando diferentes indicadores específicos de cada segmento para simplificar a análise e incluir a articulação de conceitos de segurança de processos à atuação regulatória. Os indicadores globais propostos quantificam conceitos subjetivos e complexos para o estabelecimento de metas e permitem aferir o desempenho das ações e projetos da regulação da indústria. Também permitem a identificação e a disseminação das melhores práticas de gerenciamento de riscos, comparando-as em diferente níveis de gerenciamento. Na análise dos resultados, pôde-se perceber que a utilização dos indicadores globais propostos pode responder com sucesso às necessidades regulatórias identificadas