GORANA MILINČIĆ RISK ASSESSMENT AND SAFETY
UDC: 662.767.2:620.92:331.45:519.8DOI: 0.7562/SE2019.9.02.08Original / Review articleGORANA MILINČIĆSTANČIĆ1SNEŽANA ŽIVKOVIĆ21University of Novi Sad,Faculty of Technical Sciences, NoviSad2University of Niš,Faculty of occupational safety in .ac.rs2RISK ASSESSMENT AND SAFETYCONCEPTS FOR COGENERATIONBIOGAS PLANTSAbstract: The topic of this paper is risk assessment and protectionconcepts for cogeneration biogas plants using functional HAZOP andFMEA methods with 5x5 AS / NZS 4360: 2004 matrix. The assessmentwas based on the ISO 31010 Risk Assessment Standard, Guidelines forthe Safe use of Biogas Technology issued by the German BiogasAssociation (FNR), and Overall survey of engineering insurers forpotential hazards at biogas installations issued by the GermanInsurance Association (GDV). The paper analyses all potentialhazards that can occur during the regular operation of a biogas plant,how hazards can affect the occurrence of a harmful event, as well ashow harmful events can affect all vulnerable resources. According torisk assessment and hazard analyses, a unique protection concept wasproposed through a set of different measures. The final part of thepaper is concerned with the development of the biogas industry and theoccurrence of harmful events across Europe.Keywords: Cogeneration biogas plant, Risk assessment, HAZOP andFMEA method, matrix 5x5 AS / NZS 4360: 2004, Safety concepts.INTRODUCTIONThe production and use of biogas have been growing anddeveloping rapidly around the world for the past twentyyears. In our country, biogas production has been on theincrease for the past ten years. The main aim ofproducing electricity from renewable resources is toreduce the dependence on the import of fossil fuels andto protect the environment.Building a plant, obtaining the use permit, acquiring thestatus of the privileged producer of electricity andsigning the power purchase agreement is only one stagein the business. Real challenges begin later.The payback period for cogenerative biogas plants is atleast eight years. During that period plants should beable to operate efficiently with 8200 h a year in order toearn sufficient income for regular servicing and furtherdevelopment. The investors are aware of the fact that thisaim is not easily achieved because there are numerousproblems on the way.The production process inevitably entails hazards andtheir consequences. Therefore, it is extremely importantto identify all risks and establish a proper protectionconcept that will comprise technical, organizational,financial and personal measures so that biogas plantscould function safely.COGENERATIVE BIOGAS PLANTSBiogas is produced by anaerobic digestion(decomposition of organic matter in the absence ofoxygen) of different kinds of biomass. Biogas is amixture of gases containing methane CH4 (50%-70%),carbon dioxide CO2 (20%-50%), hydrogen sulfide H2S(0.01% to 0.04%), ammonia NH3, hydrogen H, nitrogenN and carbon monoxide CO.A cogenerative biogas plant, i.e., a plant for combinedsimultaneous production of heat and power (CHP)converts the chemical energy of biogas into electricaland heat energy using an engine connected to thegenerator [1].The biogas industry, as a combination of the chemicaland energy industry, is prone to numerous harmfulevents. Managing the production process in thesecircumstances is an enormous challenge. Therefore, it iscrucial that the plants are protected from all noneconomic damage.RISK ASSESSMENTRisk can be managed after it has been identified,analyzed and evaluated i.e. assessed [2]. Only then canit be said whether that risk is acceptable or somethingneeds to be changed to make it acceptable.Theoretically, a risk assessment would be more accurateif it involved more parameters [3]. On the other hand, itmakes the assessment more complex and more difficultto implement, very often having a nonlinear relationbetween those parameters [3].The most widely accepted theory is that risk is theprobability of harmful consequences or losses resultingfrom a given hazard over a specified time period [2, 48]. A better definition could be the one which says thatrisk can be viewed as a function of several components:hazard, vulnerability, exposure, and resilience [3, 9].Hazard frequency and magnitude indicate that we are97 Safety Engineering
SAFETY ENGINEERING - INŽENJERSTVO ZAŠTITEtalking about risk [5]. Therefore, to assess riskadequately, data about the underlying hazardous eventshould be collected first [3,10].Hazard is a potentially damaging physical event,phenomenon or human activity that may cause the lossof life or injury, property damage, social and economicdisruption or environmental degradation [2].In industrial systems, hazardous events include therelease of chemicals and toxic substances, radioactivity,the release of energy in the form of fires and explosions,spillage and leakage of waste. These events are the resultof failures in the industrial system, that is, a technical orhuman error, or are the result of events in nature such asearthquakes, landslides, floods, atmospheric discharges.The redundancies are most often sudden and intensewith extensive damage that is not only limited toproperty but also to injuries to employees, often withfatalities, as well as to disruption of their regularoperations.Risk assessment in cogenerative biogas plantsFor the assessment of risk in cogenerative biogas plants,according to ISO 31010 recommendations, it isnecessary to choose proper methods of risk assessment.For that purpose, the combination of functional methodsHAZOP and FMEA with 5x5 AS/NZS 4360:2004matrix was used.HAZOP is an acronym for HAZard and OPerabilitymethod of structured and systematic evaluation of aplanned or an existing product, process, procedure orsystem. It is a technique for detecting risks that people,equipment, property, environment or organisationalgoals are exposed to. Failure mode and effects analysis(FMEA) is a technique used for detecting cases wherecomponents, systems or processes cannot fulfill theirpurpose [11]. The assessment was performed using a5x5 matrix with the 5x5 AS/NZS 4360:2004 matrix inwhich consequences for people, environment andproperties, and frequencies of an event were categorised.Based on the assessed values of consequences C andfrequency of exposure F, the level of risk is calculatedas the product of these two parameters:R CxFcategories of the vulnerable resources or individualcategories of the vulnerable resources: Formation of an explosive atmosphere as a result ofputting the plant into operation, maintenance,regular release of biogas by means of overpressurevalves, ruptures of the gas membrane, increasedconcentration of methane in the exhaust of thecogeneration or sudden failure of the burner.Coming into contact with an ignition source (spark),all these lead to explosions and fires which have adevastating effect; Self-ignition of the raw material as a result ofimproper storage conditions leading to fires, as wellas fires resulting from ignition of other flammablematerials in the plant; Release of hydrogen sulphide H2S as a componentof biogas from the mixing pit and pre-digestion pits,small concentrations of which can be fatal; Leakage of various biological substances.Injuries caused by traffic accidents, by working withequipment that carries high voltage or with faultyequipment, and those caused by maintenance. Injurieshappen when procedures are not followed and whenprotective equipment is not used or is used carelessly.Analysis of events which cause firesCogenerative biogas plants store different flammablematerials and explosive gases. In biogas plants, fires canoccur both inside and outside the plant. Depending onthe place of occurrence, fires can be medium or big. In acogeneration biogas plant, depending on the kind andamount of combustible materials, the following classesof fire can be expected: Class A fire is related to solid combustiblematerials such as corn silage, straw, wood(furniture and stationery in the administrationbuilding with the pumping station), paper andcardboard in the administration building. Thesefires are extinguished with water, sand, foam, halonand some kinds of powder; Class B fires are fires in flammable liquids such asdifferent greases for technological equipment andcogeneration unit, oils in the substation, variouspaints, plant oils, thinners, etc. The mainextinguishers here are powder, carbon dioxide andfoam; Class C fires are fires of flammable gases such asmethane CH4, hydrogen sulphide H2S andammonia NH3. These gases are generated in theproduction process. The main extinguishers arepowder and carbon monoxide, whereas the bestway to extinguish fire in gas installations is to shutoff the inflow of gas.(1)The levels of risk in the matrix were qualitativelydetermined as very high (VH), high (H), medium (M)and low (L).The purpose of this kind of assessment is an observationof all risks, identification of the most significant risksand elimination of the less significant ones from theanalysis. However, low risks with a high frequency ofoccurrence and significant cumulative effect should notbe eliminated.Depending on the characteristics of the technologicalprocess, facilities and equipment, a total of 49hazards/failures were identified. The following eventsentail very high risk and cause extreme damage to allClass E fires are fires in electric equipment andinstallations (machines, electric motors, substations).The main extinguishers are powder and carbon dioxide.98 Safety Engineering
G. Milinčić Stančić, S. Živković, Vol 9, No2 (2019) 97-102Analysis of events which cause explosionsAn explosion is a sudden chemical reaction of anexplosive, flammable matter with oxygen, during whichan enormous amount of energy is released and dispersedin different ways [12], through the creation of thepressure wave, bursting of vessels, thermal radiation,physical displacement of equipment and secondary fires.An explosion occurs in an explosive atmosphere (withparticular concentration and under particular pressure)in the presence of oxygen and an ignition source. Thereis a danger of explosion when the concentration ofbiogas is in the range between 6% and 22%. Anexplosive atmosphere is formed when gas leaks from thetechnological equipment or due to incomplete gascombustion which happens as the result of faultymachines or different problems with buildings wherebiogas is processed and stored.Analysis of events which cause release ofpollutants, dangerous and toxic substances intothe environmentActivities which take place in cogenerative biogas plantscan affect the environment through the release ofsubstances into the soil, water and air. These activitiesinclude disposal of drainage water from trench silos anddisposal of the biological substrate from pre-digestionpits, mixing pits and digesters.Analysis of events which cause failures anddifferent hazards connected to the use oftechnological and electrical equipmentA cogenerative biogas plant uses various kinds ofequipment in the process of producing heat and power.The most frequent failures are breakdowns of mixers,pumps and CHP unit and are induced by the quality ofthe substrate, chemical compounds in the process andthe quality of biogas - all of them damage and corrodethe material of which the equipment is made. Thedangers related to the technical and electrical equipmentare dangers of explosion, electric arc and staticelectricity. These dangers occur if the equipment is notperiodically controlled or maintained, or if safetyprocedures are not adhered to. Within the technologicalprocess, injuries occur while manipulating the rawmaterials all the way from trench silos to hoppers, duringwork at height and as a consequence of non-compliancewith safety procedures.CONCEPTS OF PROTECTIONCogenerative biogas plants are complex systems. Inorder to produce biogas and convert mechanical energyinto electrical energy, they need to have appropriatefacilities and equipment. All facilities must have a usepermit and proper equipment. Different procedures haveto be followed and different protective measuresconsidered. In order to reduce risk, it is necessary toestablish a system of protection through technical,organisational, financial and personal measures and tomonitor the work of the whole plant using appropriatedocumentation.Risk reduction by means of technical protectivemeasuresRisk prevention tends to reduce the number of damagesor completely eliminate them [12, 13] and primarilydepends on the specific risk with which an organizationmay be encountered. The causes of damage, and inparticular damage from fires, explosions and otheraccidents, fall into the categories of damage that scienceand the profession can predict and which can beprevented, i.e. managed.In parts of a biogas plant in which gas is stored andtransported, Ex zones must be classified. The facilitiesare protected using: a hydrant network with aboveground fire hydrants(which have a specific reservoir volume and apressure booster) aimed at fighting primary fires; portable and transportable fire extinguishers, typeS-6, S-9, S-50; warning boards.The equipment used for storing and transporting biogasmust be checked for possible leakages and the formationof an explosive atmosphere. Devices used for thispurpose are cameras and laser methane detectors. If theelectricity supply goes off, the unburnt gas must not bereleased into the atmosphere. It has to be burnt with theburner.Risk reduction by means of organisationaland personal protective measuresBefore putting the plant into operation, the operatorshould create a register of sources of danger andpollution that would contain information on types,amounts, way and place of entry, release and disposal ofpollutants in the gaseous, liquid and solid state, or on therelease of energy (noise, vibrations, heat, ionizing andnon-ionizing radiation) [14]. If the environment isharmed in the process of work of a cogenerative biogasplant, the legal entity is responsible for repair andremediation [14].It has been shown in practice that precautions againstfires improve when each operator is in regular contactwith the concerned fire brigade and when fire drills arepracticed so that the fire brigade can take proper actionin case of fire.It is necessary to wear adequate equipment while theplant is working. Personal protective equipmentincludes: safety glasses; masks with filter; protective helmets; earmuffs;99 Safety Engineering
SAFETY ENGINEERING - INŽENJERSTVO ZAŠTITE protective clothing and boots; protective gloves; safety harness for working at heights and in closedspaces.Documentation as a special measure of riskmanagementDocumenting for cogenerative biogas plants isperformed by writing: Project technical documentation, essentially areport on danger zones and the main fire safetyproject; Documentation on risk assessment;Financial resilience to hazards is a preventive financialmeasure that helps individuals or communities toquickly recover from financial shocks that hazardousevent brings [9]. Instructions on the safe use of equipment and workof the plant; Instructions on the maintenance of the equipmentand the plant;Insurance, as a financial instrument, ensures financialsecurity to the affected individuals and companies [15].By taking the risk within the insurance portfolio, theinsurance company takes responsibility for damages thatmight arise from the risk realization [15,16]. A plan for preventive and regular maintenance; Procedures in case of accidents, fires, explosions,power failures, injuries at work; Instructions on the training of all employees by thesupplier of technology before the plant are put intooperation; A record showing that putting the plant intooperation was done with the supplier of technology; Register of dangerous substances.Transfer of risk by means of financial protectivemeasuresGenerally, the transfer of risk to insurance companiescould mitigate the effects of natural disasters in twoways: first, the insured is motivated to take appropriatepreventive measures in order to be entitled to a moreacceptable insurance premium and second, the insured iscompensated for the damage by insurance companiesimmediately after the harmful event [17,18]. This way,financial liquidity of the affected individuals and firmsis achieved, contributing to the reduction ofvulnerability, i.e. to increased resilience [17].Cogenerative biogas plants are exposed to various risks:fire and explosion, gas or liquid leakages, stock selfignition, bad weather hazards, machine breakdowns andstaff injuries. Considering the above-mentioned, the bestsolution for these plants is the All risks insurancecontract. With all risks insurance, one policy is taken outfor a precisely defined number of risks where standardrisks can be expanded so that the property and businessactivities of a company are best protected. This policyhas to be carefully formulated. It has to be unambiguousso that specific property or risk would not beaccidentally excluded. All risks policy should cover thefollowing risks: physical damage to property; faults in electrical and mechanical parts ofequipment; lost profit (including the loss of feed-in tariffs); fire and explosion; accidents, illness and injuries of the employees; decay of raw materials; responsibility for pollution; responsibility of managers and operators; theft and deliberate destruction of property.DEVELOPMENT OF BIOGASINDUSTRY AND HARMFUL EVENTSWith the development of engineering and technology,the global demand for bioenergy has been on theincrease during the past ten years. The projections arethat the demand will be increasing until 2035, as a resultof strategies aimed at reducing air pollution.According to information and databases such as EMARS, INFOSYS and ARIA, an investigation [19] wascarried out in the period from 2006 to 2016, including208 harmful events in different European countries.The most frequent harmful events out of these were fires- 123 (59%) and then 45 explosions (22%), 23 eventsharmful to the environment (11%), 11 gas leakages(5.29%) and 6 poisonings of employees (2.88%) [19].Financial damage was recorded in 95 events and theaverage value of damage was 400,000 [19]. Theaverage financial damage caused by the fire was around250,000 , and the average financial damage caused bythe explosion amounted to 960,000 [19].Between 2006 and 2016, four harmful events resulted inthe loss of life [19]. There were 21 cases of accidentswith severe injuries, whereas major injuries occurred in16 cases (76%) as a result of biogas explosion [19].Analysing the reports on the recorded harmful eventsfrom the available databases of biogas plants, it can beconcluded that the data is incomplete and ofquestionable quality. The questionnaires were carelesslyor only partially completed and not supported byphotographs which captured the harmful event. Apartfrom this, not all harmful events were recorded in theMARS database. A considerable number of data can befound only in INFOSYS or only in the ARIA database.100 Safety Engineering
G. Milinčić Stančić, S. Živković, Vol 9, No2 (2019) 97-102CONCLUSIONAlthough today all risks in the process of converting andgenerating energy are known, and specific engineeringstandards adopted, harmful events continue to happen.This is due to inadequate technological solutions, noncompliance with rules, poor organisation of work, lackof safety procedures, lack of adequate standards for thetraining of operators, and lack of awareness of the riskson the part of managers of biogas plants.After twenty years of intensive development, it isnecessary to adopt specific technical standards and rulesfor this industry because the process of production andconversion of biogas is unjustifiably seen as safer thanclassical chemical processes.The analysis showed that it is necessary to update theinformation from reports on harmful events and liaisewith insurance companies in order to obtain informationabout real damage inflicted on vulnerable resources.Only comparable results in combination with a sufficientnumber of analysed plants will enable a betterunderstanding of harmful events from the whole sectorand the creation of a reliable database.Finally, the concept of safety can only be developedwhen both preventive engineering and a set of technical,organisational, personal and financial protectivemeasures are applied.REFERENCES[1] Fachverband Biogas e.V.: “Biogas-Safety first,Smernice za bezbednu upotrebu tehnologijebiogasa”, 2016, Freising, Germany.[2] T. Novaković, J. Simić, Lj. Popović, S. Popov, M.Velemir, Đ. Ćosić, D. Sakulski: “Subject „DisasterRisk Management - Spatial Context“, ITRO - ajournal for information technology, educationdevelopment and teaching methods of technicaland natural sciences, Vol. 3, No. 1, 2013, pp. 8188.[3] Đ. Ćosić, S. Popov, D. Sakulski, A. Frank: “GeoInformation Technology for Disaster RiskAssessment”, Acta Geotechnica Slovenica, Vol. 8,No. 1, 2011, pp. 65-74.[4] S. Schneiderbauer, D. Ehrlich: “Risk, hazard andpeople’s vulnerability to natural hazards. a reviewof definitions, concepts and data”, EuropeanCommission Joint Research Centre, 2004,Brussels.[5] S. Popov, Đ. Ćosić, T. Novaković, Lj. Popović, J.Bondžić, D, Sakulski:“Application ofGeoinformation Tehnologies in Assessment ofSocio-economical Vulnerability on Floods”,Proceedings of the 4. International ScientificConference on Sustainable business and ecologicalintegration and collaboration, University of NoviSad, Faculty of Technical Sciences, 2018, pp. 139154.[6] K. Thywissen: “Components of risk, A comparativeglossary”, United Nations University, Institute forEnvironment and Human Security, 2006, Bon,Germany.[7] T. Novaković, M. Jevtić, J. Bondžić, Lj. Popović,Đ. Ćosić, S. Popov, M. Laban, V. Radonjanin:“Insurance and disaster risk management:reduction vulnerability and risk”, Proceedings ofthe 1. S-FORCE: Knowledge FOr Resilient SocietyConference, University of Novi Sad, Faculty ofTechnical Sciences, Department of CivilEngineering and Geodesy, Novi Sad, 2018, pp. 7986.[8] T. Novaković, J. Bondžić, S. Popov, Đ. Ćosić:“Flood simulation for expected damagecalculation”, Proceedings of the 8. ITRO InternationalConferenceonInformationTechnology and Development of Education,University of Novi Sad, Technical faculty „MihajloPupin”, Zrenjanin, 2017, pp. 215-219.[9] Đ. Ćosić, Lj. Popović, T. Novaković, A. Rizaj, E.Silo: “Microfinance products as a tool for financialresilience to hazards”, Proceedings of the 2. KFORCE: Knowledge for resilient societyConference, Epoka University, Faculty ofArchitecture and Engineering, Tirana, 2019, pp.59-64.[10] J. Bondžić, N. Medić, T. Novaković, Lj. Popović,Đ. Ćosić: “Aspects of petrol station accidentmodeling”, Proceedings of the iNDiS 2015,Departman za Građevinarstvo i Geodeziju,Fakultet tehničkih nauka Novi Sad, 2015, pp. 639646.[11] ISO: “Risk management - Risk assessmenttechniques“, Reference number Internationalstandard, IEC/FDIS 31010:2009 (E), 2009.[12] M. Laban, Đ. Ćosić, J, Bondžić, T. Novaković:“Osnove upravljanja rizikom od katastrofalnihdogađaja i požara”, Fakultet tehničkih nauka, FTNGrafički centar GRID 2017, Novi Sad.[13] D. Mrkšić, Đ. Ćosić: “Upravljanje rizikom iosiguranje”, Fakultet tehničkih nauka, FTNGrafički centar GRID, 2015, Novi Sad.[14] Zakon o zaštiti životne sredine: Sl. glasnik RS", br.135/2004, 36/2009, 36/2009 - dr. zakon, 72/2009 dr. zakon, 43/2011 - odluka US, 14/2016, 76/2018,95/2018 - dr. zakon i 95/2018 - dr. Zakon.[15] T. Novaković, J. Bondžić, Đ. Ćosić, M. Miškić:“Flood risk damage assessment”, Proceedings ofthe 17. International Scientific Conference onIndustrial Systems – IS17, University of Novi Sad,Faculty of Technical Sciences, Department forIndustrial Engineering and Management, NoviSad, 2017, pp. 410-413.[16] V. Njegomir, Đ. Ćosić: “Ekonomske implikacijeklimatskih promena na sektor osiguranja ireosiguranja”, Teme, Vol. 36, No. 2, 2012, pp. 679701.101 Safety Engineering
SAFETY ENGINEERING - INŽENJERSTVO ZAŠTITE[17] D. Cosic, S. Popov, T. Novakovic, Lj. Popovic:“Flood Damage Assessment Method: GIS-BasedApproach”, Fresenius Environmental Bulletin,Vol. 28, No. 3, 2019, pp. 1896-1904.[18] Lj. Popović, T. Novaković, J. Bondžić, Đ. Ćosić, S.Popov: “Impact of prevention measures on a zaštita od požara i eksplozija, Visokatehnička škola strukovnih studija u Novom Sadu,2012, str. 43-52.[19] P. Trávníček, L. Kotek, P. Junga, T. Vítěz, K.Drápela, J. Chovanec: “Quantitative analyses ofbiogas plant accidents in Europe”, Renewableenergy, Vol. 122(C), 2018, pp. 89-97.ACKNOWLEDGEMENTSThe published paper is the result of research funded bythe Ministry of Education, Science and TechnologicalDevelopment of the Republic of Serbia.BIOGRAPHYGorana Milinčić Stančić wasborn in Čurug in 1983.She defended her master'sthesis at the Faculty ofTechnicalSciences,Department of EngineeringManagement in June 2007.She has worked as an expertassistant in the SGScompany since October 2007. She has been anengineering expert witness in the field of mechanicaltechnology – the assessment of equipment,installations and vehicles since 2014. As anemployee of the SGS company, she has participatedin the process of supervision of building biogasplants. She is a member of the Serbian BiogasAssociation.PROCENA RIZIKA I KONCEPTI ZAŠTITE KOGENERATIVNIHBIOGAS POSTROJENJAGorana Milinčić Stančić, Snežana ŽivkovićRezime: Tema ovog rada je procena rizika i koncepti zaštite za kogenerativna biogas postrojenja primenomfunkcionalnih metoda HAZOP i FMEA sa matricom 5x5 AS/NZS 4360:2004.Procena je rađena na osnovuStandarda za procenu rizika ISO 31010, Smernica za bezbednu upotrebu tehnologije biogasa koje je izdaloNemačko biogas udruženje (FNR) i Istraživanja o biogas postrojenjima i potencijalu tehničkih opasnosti koje jeizdalo Nemačko udruženje za osiguranje (GDV). U radu su analizirane sve potencijalne opasnosti koje je javljajutokom redovnog rada kogenerativnog biogas postrojenja, kako one utiču na pojavu štetnog događaja, kao i kakoštetan događaj utiče na sve ranjive resurse. Po izvršenoj proceni rizika i analizi svih opasnosti dat je predlog zajedinstven koncept zaštite primenom seta različitih mera. Na kraju rada je sagledan razvoj industrije biogasa ipojava štetnih događaja na teritoriji Evrope.Ključne reči: Kogenerativna biogas postrojenja, procena rizika, HAZOP, FMEA, matrica AS/NZS 4360:2004,koncepti zaštite.102 Safety Engineering
Risk assessment in cogenerative biogas plants For the assessment of risk in cogenerative biogas plants, according to ISO 31010 recommendations, it is necessary to choose proper methods of risk assessment. For that purpose, the combination of functional methods HAZOP and FMEA with 5x5
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