Construction of emergency response assistant system based on risk analysis for petrochemical unit

Petrochemical hydrogenation unit has often been operated under high-temperature, high-pressure or critical hydrogen condition, probably resulting in severe accident such as leaking, fire and explosion. The reasonable emergency response program is an important guarantee for controlling the spread of risk and reducing the consequence of accident. There are a lot of database files in petrochemical units, and it is urgent to put forward a method of data classification and fast positioning for effective management. When the abnormal condition occurs, it can respond in time to find the data document needed to deal with the problems. The lacks of emergency response plans, difficulties in rescue information location and improper rescue measures have severe impact on the promptness and validity of the emergency response. The construction method of emergency response assistant system based on risk analysis was proposed and applied on residual oil hydrogenation unit. First, Hazard and Operability Analysis (HAZOP) was applied on qualitatively analyze the potential risks of the entire process. The probability of events of risk spread path was quantitatively calculated through establishing a Bayesian network model for the whole process. The consequence effect and the damage area could be acquired by conducting PHAST simulation. Secondly, equipment technical data was classified by using process safety document management (PSM) method, and established a knowledge database of emergency response information. Units risk analysis result can be matched up with emergency response document and emergency response information integrated management and knowledge remote network share could be achieved due to this database. Finally, the emergency response assistant system based on risk analysis was established. When the unit worked under an abnormal condition, the required technical information for risk event or accident treatment could be obtained at first time. According to clear emergency response step description and reasonable evacuation route and distance, emergency workers could deal with accidental problem efficiently and orderly.