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Process Safety: Uniandes vision from the Latin-American context

Jaime E. Cadena Chemical Engineering Department, Universidad de los Andes Cra 1 Este No 19A 40, Bogot, Colombia je.cadena21@uniandes.edu.co German E. Gmez, Felipe Muoz Giraldo Chemical Engineering Department, Universidad de los Andes Cra 1 Este No 19A 40, Bogot, Colombia ge.gomez59@uniandes.edu.co, fmunoz@uniandes.edu.co

Prepared for Presentation at American Institute of Chemical Engineers 2013 Spring Meeting 9th Global Congress on Process Safety San Antonio, Texas April 28 May 1, 2013 UNPUBLISHED

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AIChE shall not be responsible for statements or opinions contained in papers or printed in its publications

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Process Safety: Uniandes vision from the Latin-American context

Jaime E. Cadena Chemical Engineering Department, Universidad de los Andes Cra 1 Este No 19A 40, Bogot, Colombia je.cadena21@uniandes.edu.co German E. Gmez, Felipe Muoz Giraldo Chemical Engineering Department, Universidad de los Andes Keywords: process safety in Latin America, lack of safety development

Abstract
When performing a search about process safety incidents in Latin-America the results are not exactly what a user from a developed country might expect, they are quite scarce. This relates directly to the lack of clearly defined concepts and the understanding of process safety as an element of its own in the process industries safety. The lack of record keeping and concepts weakens the performance of safety management systems as reflected by the 30 million of workrelated accidents per year and 240 thousand work-related fatalities per year (as reported by the American Syndical Confederation - CSA). Also, the region has had process safety incidents such as the explosion and fire at a refinery in Amuay (~41 fatalities, ~80 injured, under investigation), Venzuela on August 25 2012, the explosion in Burgos fields natural gas reception in Mexico D.F. (30 fatalities, 46 injured), Mexico on September 20 2012, and the pipeline failure and subsequent explosion at Dosquebradas (38 fatalities, ~70 injured), Colombia on December 23 2011. These and the Latin American projection of energy demand growth by 2040 of ~73%, and particular cases such as the Colombian with ~20% growth in 4 years, makes it necessary to have a clearly defined vision of process safety. This is a presentation of the vision constructed at Universidad de los Andes in Bogot, Colombia, approaching solutions to the regions challenges at a decisive moment.

1. Introduction
When searching the internet for industrial accidents at Latin America, the results can be ambiguous, since the results present accidents which have a high toll on social structures. This leads to a general confusion between industrial safety, process safety and industrial hygiene concepts. This concept ambiguity reduced the opportunity to identify and control hazard flows, avoiding undesired consequences on specific targets such as people or critical infrastructure. This creates issues in every area of process safety, beginning with metrics, having no unified data base and existing data bases focused strictly on industrial safety (HSE), reporting 30 million of work-related accidents per year and 240 thousand work-related fatalities per year on 2012 (as reported by the American Syndical Confederation - CSA) [1].

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This high rate of accidents and fatalities in Latin America represent significant issues several levels of safety as a general concept, but this is not a new fact in the region. The regions antecedents can be traced back to reports of 1998, showing that the averaged fatal rates for the region represented almost 2700% of USAs with a value of 0.005, concluding that public Occupational Health and Safety (OHS) policies were insufficient to decrease the high fatality and accidental rate [2]. This was later reinforced on 2002 when revising the occupational risks in the region, finding a fatalities rate between 27270 and 73500, representing a level of uncertainty which is usually unacceptable for engineering applications but fits the already mention ambiguity in safety concepts and lack of policy and enforcement resources [3]. However, the regions socio-economical risk on a large portion of the population also relates directly to the safety performance and the fact that accidents impact it directly. This is also presented by the relationship between competitiveness and fatal accidents index in which an inversely proportional relation is found in 2002 [4]. Nonetheless, the presented picture of the safety performance during the beginning of the past decade is only partial and there is two key pieces of information that allow understanding the current state of safety performance and the need for a clear vision of process safety, its development and its implementation at a local and regional level: industrial boosted economic development and its impact on fatal rates. The economic development in the region has been significant as presented by future energy demand reports [5], in which the Latin American projection of energy demand growth by 2040 is expected to be around 73%, and in particular cases such as the Colombian, a ~20% growth in 4 years is also expected. This demand is supported by hydroelectric energy development given by high-capital projects such as the Maua hydroelectric plant in Brazil, which produces 361 MW and had a cost of US$675 M [6]. Such figures and development relate directly to the Oil & Gas boom shown in the past 5 years by most of the region and particularly by Brazil and Colombia [7, 8]. This situation has boosted the industrial development and specially de intensification of industrial processes, which modifies previous risks and generates a new set of risks. This has been reflected by some of the worst process incidents of the region as shown in Table 1. Table 1. Relevant process incidents
Date 25/02/1984 Location Cubatao, Brazil [9] Las Tejeras, Venezuela [10] Orn, Argentina [11] Barrancabermeja, Colombia [12] SalamancaCelaya, Mxico [13] Event Gasoline spill due to a pipeline failure generated a 10 hours fire A pipeline section located under a freeway failed and generated an UVCE and a fire Explosion on the Norandino gas duct During a maintenance work at a refinery, a gas leak resulted in an undetermined type of explosion Undetermined causes led to gas leaks from the Guanajuato-Guadalajara gas duct, resulting in multiple explosions Related loss ~500 fatalities ~7000 injured Total destruction of 75% of the village 36 fatalities Environmental damage 3 fatalities ~8 injured 5000 evacuated

28/09/1993 27/01/2002 18/18/2005

06/07/2007

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Date 10/09/2007 19/03/2008 Location Cuapiaxtla, Mxico [14] Barrancabermeja, Colombia [15] Buenos Aires, Argentina [16] San Martn Texmelucan, Mxico [17] Dosquebradas, Colombia [18] Papantla, Mxico [19] Event A natural gas leak at a gas pipeline resulted in a UVCE An undetermined incident at the main oilywater collector resulted in an undetermined type of explosion Undetermined causes led to chemical reactivity and fires at a chemical production plant A fire originated on fuel robbery from a pipeline led to multiple fires and explosions. Oil pipeline failure and posterior UVCE at a near-by village Fire at an agro-chemical production plant Related loss 3000 evacuated 4 injured Severe damage to oilywater collector 3 injured Evacuation of 3 blocks around the plant ~28 fatalities 52 injured 5000 evacuated 32 houses affected 31 fatalities 70 injured Envirnomental damage 18/09/2012 Reynosa, Mxico [21] Cuautitln Izcalli, Mxico [22] Explosions and fire at a gas plant Fire and explosions at a storage facility within a chemical production plant 48 fatalities Over 80 injured 33 families displaced Damage to around 200 residential buildings and 11 businesses Full stop of operations Domino effect leading to adjacent tank fires 26 fatalities 40 injured 12 injured 300 evacuated Damage to surrounding infrastructure

22/04/2009

19/12/2010

29/12/2011 11/07/2012

25/08/2012

Amuay, Venezuela [20]

Amuay refinery explosion and fire (currently under invetsigation)

16/10/2012

Table 1 not only is one of the very few process incidents summary of the last 15 years in Latin America, but it is also a source of information that reinforces previous statements regarding the lack of precise and official data and information. This of course also shows the lack of policies and enforcement issues regarding process safety, having almost no information or data bases from governmental entities across the region. Although the safety performance of the region improved during the 2006-2010 period in terms of Total recordable injury rate, Lost time injury frequency and Fatalities (TRIR, LTIF, FAR), the accidents severity (measured in averaged lost days per incident) increased in 2010 to more than the double 2005-2009 average [23]. However, the decreasing trend in FAR stopped in 2011, having a significant increase of 54%, along with a 15% increase in TRIR, 5% in LTIF and 55% in severity [24]. This along with the presented facts and analysis should help present a more complete picture of the actual safety performance at the region, making it necessary to have a clearly defined vision of Process Safety and the direction it should follow in Latin America in order to improve current performance. This work presents such vision based on a global research

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agenda and the past, on-going and future research at Universidad de los Andes, Bogot, Colombia.

2. Process Safety and Research Agenda

In order to define a process safety vision and due to the mentioned lack of clarity in concepts in Latin America, it is necessary to present a framework that allows differentiating among the different branches of safety. Such branches and a general view of their difference in scope is presented in Figure 1, and it should be noted that safety branches are not mutually exclusive but independent and have common grounds in which they have to interact. Figure 1: Safety branches framework

Distinguishing between occupational hazards and process risks is a fundamental step forward in understanding the differences between branches, their interaction and their scope. Process safety can be described as the area of engineering that deals with understanding the complex physicchemical processes that can turn the energy stored inside industrial processes and the hazardous material involved (HazMat), into undesired forms of energy such as fires, explosions and (toxic) dispersions. Nonetheless, for a region such as Latin America, there are no policies or legal frameworks in which this or similar definitions can be established and enforced on the operators of industrial processes. This lack of concepts as presented in the introduction- has a considerable consequence on the conception of safety, which in the region is usually understood only as personal safety, which means having safety management systems (SMS) focused on occupational hazards and including minor process risks considerations (usually enforced from within an organization). This can be shown by performing a simple or an exhausting search on safety metrics at different countries of Latin America or even through the references presented in this work. Therefore, a more specific framework is required, this time focusing on process safety and the management of process risks such as the one presented in Figure 2.

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Figure 2: Process risk management framework. Based on the definitions presented in [25]

The risk management framework presented in Figure 2 allows a structured and logical sequence of steps in which the risk sources are identified and the components of risk (consequence and probability of occurrence) analyzed through quantitative or qualitative approaches. This provides a measurement of risk that must be compared to a scale in order to determine its location within a specific range, e.g. locating a risk value within a risk matrix. However, this is a gross risk which must be treated through elimination, optimization/minimization, by transferring it or retaining it. The latter process provides a net risk, which is to be accepted or not depending on the acceptance criteria of the organization performing the risk management or the legal framework that establishes acceptability limits, e.g. the Dutch approach. The final step consists of communicating the risks and risk treatment strategies to finally go back to the beginning of the process. The presented frameworks are a general representation of the most general elements constituting process safety. The implementation of such frameworks requires work beyond the application of handbooks or step-by-step procedures, implying the need for critical analysis and novel approaches to solve particular problems. These novel approaches to implement process safety are driven by research, and the latter is driven by specific needs. The current global needs have been outlined during a workshop of 36 of the most influencing researchers in the process safety area across the world, and it was published as a Process Safety Research Agenda for the XXI Century [26]. The mentioned research agenda constitutes a reference document for all researchers within the process safety area and it identifies five priority research areas (hazardous phenomena, inherently safer design, risk management, complex system failure, safety devices & technological improvements) and nineteen research subjects. This agenda can be interpreted as a

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diagnosis of the current knowledge on the different subjects that help implement the risk management structure and perform the processes involved e.g. risk analysis- through novel approaches and the most appropriate engineering tools available. The use of this agenda as guideline to determine subjects research priority and its current state of art, allows easily providing useful solutions to safety issues identified in an organization, a set of organizations, a country or a region.

3. Uniandes vision
The safety group within the Products and Processes Design Group (GDPP) of the Chemical Engineering department at Universidad de los Andes was created on the year 2008 and since then has devoted the work of undergraduate students, masters students and professors to the process safety research and development at Colombia and Latin America. Uniandes vision of process safety can be simply put as a systemic approach to risk assessment through several methodologies, including Quantitative Risk Assessment (QRA), the Decision Matrix riskassessment (DMRA) and qualitative techniques such as HazOP [27, 28]. The previous approaches have a scenario-based philosophy [29], focusing on the phenomenological and probabilistic analysis of accidental events such as fires, explosions and dispersions. Implementing such vision has required the understanding, use and development of cutting-edge engineering tools and models, allowing the estimation and increase in knowledge. The theoretical representation of the described vision is presented in Figure 3, taking into account the fundamental dimensions that compose Risk Analysis: Science, Design and Safety Systems. Figure 2: Representation of the Risk Analysis through its fundamental dimensions [26] (left) and its theoretical implementation at Uniandes (right)

The representation of the Risk Analysis process presented in Figure 3 constitutes a simple approach, allowing it to be applied in a wide range of applications for process safety issues.

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Taking into account the issues identified in the safety performance picture presented in the introduction, the safety group at Uniandes has made it a priority to address some of them. This has been carried out through the development of methodologies, (computational) tools, frameworks and the analysis of key case studies. Some of the most relevant work and the related subjects (classified as [26] presents) it addresses are briefly presented as follows: Societal and individual risk acceptance in pipeline design and operation (subject: Risk Management): The issue of lack of policies, legislation and enforcement elements in Latin America carries an absence of acceptance criteria for risk. This project and MSc thesis comprises the bibliographic research of the current available approaches to risk acceptance in HazMat transport through pipelines, in order to establish a first proposal of acceptance criteria for Colombia and along with the Brazilian approach, set an example for the region. Flexible framework for the study of dispersion scenarios in pipeline accidental events (subject: Consequence Analysis): Limited historical data concerning pipeline accidents in Latin America generates uncertainty and lack of information needed to establish frequencies and severities, taking into account failure types and conditions. Construction of fault and event trees allows determining critical analysis scenarios in the region, supporting risk analysis. Determining simulation parameters that can affect pool formation or vapor cloud dispersion will support the construction of a guide which facilitates pipeline accidental scenarios analysis, considering special characteristics, such as Colombian topography, leading to far field scenarios. Prediction of arrival times considering flow directions, the amount of infiltrated and evaporated material, using water quality models would help to establish faster response times. Implementation of the Lattice-Boltzmann method for liquid spills simulation, under turbulent and laminar regimes (subject: Hazardous Phenomena): this MSc thesis developed a userfriendly interface that allows performing simulation of one-phase liquid spills through its modeling with the Lattice-Boltzmann method. This allows the fast and accurate representation of accidental events in which spills have a key part without the need for a traditional Computational Fluid Dynamics (CFD) simulation. An original research paper is being developed based on this projects results and possible applications to the process industries. Re-design of an existing LPG storage tank under the Inherently Safer Design principles (subject Inherently Safer Design ISD): The project took a LPG tank from an existing facility in Colombia and performed a re-design maintaining its stored mass, but taking into account the inherently safer design principles established by Professor Kletz [30]. The results allowed obtaining a new design within prescriptive requirements given by ASME BPVC Section VIII for the design of pressurized vessels, but decreasing the operating pressure in 30%, hence decreasing the BLEVE risk and the Present Net Value of expected loss due to other accidental events such as leaks, jet fires and UVCE. The project was published as part of a tribute to Professor Kletz [31]. Compartment fires simulation and uncertainty analysis (subject: Hazardous Phenomena): Currently, fire scenarios in the process industries are treated as a merely prescriptive problem. However, modern fire safety engineering has shifted towards the Performancebased Design of systems such as high-rise buildings, and its application can also be found in the process industries. Past fire research at Uniandes regarding compartment fire simulations and fire protection systems has resulted in several user-friendly tools that allow calculating the consequences from box-compartment fires, tank farm fires, tank boilover and the

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calculation of minimum requirements for control-mitigation systems. A MSc thesis currently in development is focused on the analysis of compartment fire simulations using the Fire Dynamics Simulator (FDS.V5), in order to identify the variables and parameters that influence uncertainty of the CFD model. Further research is being addressed in order to find industry applicable computational tools for fire scenarios consequences and forecasting. Consequence calculation of accidental events in pipeline operations using uncertainty reduction methods (subject: Consequence Analysis): Pipelines transporting HazMat present risks that should be considered at its design stage, during the development of risk analysis. In this stage, risk scenarios are identified and among those the Unconfined Vapor Cloud Explosion (UVCE) present and interest case study. This work presents the application of the concepts of Probabilistic Risk Analysis (PRA), using Monte Carlo simulation for the consequences on structures and people. The selected case study presents the failure of a pipeline carrying gasoline in an urban area, providing a first estimate to the expected overpressures for a UVCE scenario. The code was written and run in MatLab, following a rather simple and flexible algorithm that takes into account the possible failure trees. Explosivity parameters determination for nano-metric powder dispersions through CFD (subject: Hazardous Phenomena): this MSc thesis carried out CFD simulations of disperse solids in a standard explosivity test device (Hartmann tube) using cutting edge turbulence models. This work allowed determining a descriptive model of the particle size distribution of a dispersed solid, aiding the determination of key explosivity parameters and the severity of a dust explosion.

The presented and future research has also been the result of international bilateral collaborations with recognized academic and research organizations aiming at achieving common goals together. Today the need for research has been boosted due to the some of the most recent incidents presented at Table 1, creating the need to fulfill the presented vision and enhance process safety performance in the region.

4. Conclusions
Process safety is still an engineering area with incipient development in Latin America, as presented by high occupational safety metrics and the lack of process incidents data bases and analysis. This along with the lack of governmental policies and legislative elements that enforce the process safety frameworks as in developed countries, constitute a huge lag between the safety performance of Latin America and the available frameworks, methodologies and tools available. Uniandes vision of process safety represents a part of a small group of Latin American initiatives to address the regions current safety performance and its issues. The presented research guided by the Process Safety Research Agenda is only one of the efforts at creating consciousness and transferring knowledge to the decision-making organizations in Colombia. Research and transference of knowledge constitute key elements in establishing process safety as a recognized and required engineering area in the region, therefore the main conclusion is that there is a long road ahead, but current results motivate the authors to keep going and achieve the desired goals.

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