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首页> 外文会议>The American Institute of Chemical Engineers 2002 Spring National Meeting, Mar 10-14, 2002, New Orleans, LA >Turning Tragedy into Triumph: How Process Accidents Can Benefit Companies, Employees, and Ultimately Customers
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Turning Tragedy into Triumph: How Process Accidents Can Benefit Companies, Employees, and Ultimately Customers

机译：将悲剧化为胜利：流程事故如何使公司，员工和最终客户受益

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摘要

In the mid-90's, FMC was challenged with a corporate goal of manufacturing the safest and highest quality persulfate product for our global customers. This directive stemmed from an industrial accident caused by a combination of several events simultaneously leading to the auto-accelerating decomposition of our persulfate product. This accident occurred in a warehouse at one of our chemical manufacturing plants and resulted in a fire with injuries and a fatality, environmental releases, infrastructure damage, and significant production downtime. The directive was, in essence, a command that this event never occur again. Successfully meeting this challenge required a systematic multi-team approach utilizing both novel methods and standard tools in innovative ways to uncover the root causes of the accident. A key part of this effort was the creation of state-of-the-art plant QC laboratory facilities. There are few, if any, other plant QC laboratories with these analytical tools and methods in the peroxygen chemicals business. These novel and/or improved QC methods subsequently allowed for the creation of new product and process internal specifications and for routine QC laboratory monitoring of critical final product safety and quality specifications or parameters. A combination of these methods led to the quantification of a product parameter called "thermal stability". It was discovered that this parameter was not only an excellent indicator of both product and process safety, but also of product quality as well as process quality and reliability. The use of this parameter as a predicator of product stability in storage, shipping, and handling was validated and benchmarked by full-scale SADT (Self-Accelerating Decomposition Temperature) tests. The FMC persulfate process and operating conditions were subsequently modified based on the lessons learned. In particular, the application of this new product safety specification combined with classical and innovative statistical tools was critical. As a result, the product safety and quality has improved and the packaged persulfate product has not undergone a decomposition in almost seven years. Based on our current process capabilities, product characteristics, and process/product safety modeling, it is well documented that this performance will continue with a high degree of certainty. FMC has such confidence in the persulfate product storage, shipping, and handling stability that an SADT value exceeding the UN DOT standards is incorporated as a specification on the product's Certificates of Analysis provided to FMC's customers. Product storage & handling safety training is available to all customers. Addressing product safety in turn automatically addressed process safety. Improvements in product / process safety have led to better product and process quality, which in turn were important factors that lead to better process reliability, increased capacity, reduced process downtime, reduced operating costs, and improved customer satisfaction. These improvements yielded improved return on capital employed (ROCE). Ultimately, this case study shows how safety pays!
机译：在90年代中期，FMC面临一个企业目标，即为我们的全球客户生产最安全，最优质的过硫酸盐产品的挑战。该指令源于一系列事故共同导致的工业事故，导致我们的过硫酸盐产品自动加速分解。该事故发生在我们一家化学制造工厂的一个仓库中，导致火灾，造成人员伤亡，环境释放，基础设施损坏以及大量生产停机。该指令实质上是一个命令，该事件不再发生。成功应对这一挑战，需要一种系统化的多团队方法，以创新的方式利用新颖的方法和标准工具来发现事故的根本原因。这项工作的关键部分是创建最先进的工厂QC实验室设施。在过氧化学品行业中，几乎没有其他工厂QC实验室使用这些分析工具和方法。这些新颖和/或改进的质量控制方法随后可用于创建新产品和过程内部规格，并允许对关键最终产品安全性和质量规格或参数进行常规质量控制实验室监控。这些方法的组合导致了称为“热稳定性”的产品参数的量化。发现该参数不仅是产品和过程安全的极好的指标，而且还是产品质量以及过程质量和可靠性的指标。通过全面SADT（自加速分解温度）测试验证并确定了此参数作为产品在存储，运输和处理中的稳定性的指标。 FMC过硫酸盐的工艺和操作条件随后根据吸取的经验教训进行了修改。特别是，此新产品安全规范与经典和创新的统计工具相结合的应用至关重要。结果，提高了产品安全性和质量，并且包装的过硫酸盐产品在近七年内都没有发生分解。根据我们当前的过程能力，产品特性和过程/产品安全模型，有充分的记录证明这种性能将高度确定地继续下去。 FMC对过硫酸盐产品的存储，运输和操作稳定性充满信心，以至于将超过UN DOT标准的SADT值纳入提供给FMC客户的产品分析证书的规范中。产品存储和搬运安全培训适用于所有客户。解决产品安全问题会自动解决过程安全问题。产品/过程安全性的提高带来了更好的产品和过程质量，这又是导致更好的过程可靠性，增加的产能，减少的过程停机时间，降低的运营成本以及提高的客户满意度的重要因素。这些改进带来了更高的使用资本回报率（ROCE）。最终，该案例研究显示了安全性如何付出！

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