Abstract: Raw oil delivered by booster pumps in a residue hydrogenation unit is often under high-temperature and high-pressure, resulting in fire hazard when leaking. Hazard and Operability Analysis(HAZOP), a multi-parameter coupling quantitative risk calculation was applied to qualitatively analyze the failures of the booster pump and the failure impacts on the entire process. It was concluded that the leakage accidents could happen frequently resulting in serious consequence. This method identified the coupling relationship among the internal factors of the process node that contains the booster pump, established a Bayesian network model for the whole process, and calculated the failure probabilities of mechanical seal, packing seal and shell caused by multiple factors. According to the statistical results of local annual average wind speed and solar irradiance, common and extreme atmospheric stability and wind speed, the consequences severity of jet fire caused by leakage of high temperature raw oil under different leak diameters could be acquired by conducting process hazard analysis software tool(PHAST) simulation. Based on the probability and consequence severity calculation, risk assessment rules and risk matrix were established, and the risk levels of leakage accidents caused by different causes were evaluated. The risk levels of reason accidents can be used to risk prevention measures and proposing of emergency plans for accidents.

Key words: safety, pump, simulation, process hazard analysis software tool(PHAST), risk assessment

摘要： 渣油加氢装置中原料油增压泵输送的介质具有高温、高压和易燃的特点,泄漏后会直接导致着火事故。本文应用危险与可操作性分析(hazard and operability analysis,HAZOP)方法对原料油增压泵自身故障及故障后对整个装置造成的影响进行了定性风险分析得出,泄漏事故发生频率高且后果严重。为了定量计算原料油增压泵泄漏的风险,本文提出了原料油增压泵多参数耦合定量风险计算方法:辨识原料油增压泵所在节点内部因素间的耦合关系,建立贝叶斯网络,对多因素导致机械密封失效、填料密封失效、壳体破裂等事件的可能性概率进行定量计算;调研当地全年平均风速和太阳辐射等级统计结果,针对常见和极端的大气稳定度、风速条件影响,利用过程危害分析软件工具(process hazard analysis software tool,PHAST)模拟定量计算了不同泄漏孔直径情况下,高温原料油泄漏导致的喷射火后果严重程度;基于可能性概率和后果严重度计算结果,制定可能性和严重度等级判定标准,构建风险矩阵,针对不同原因导致的泄漏事故进行了风险评级。分析得到原因事件风险等级,用于确定风险预防措施和建立应急计划。

关键词: 安全, 泵, 模拟, 过程危害分析软件工具, 风险等级评价