双重预防机制在煤化工企业安全生产管理中的深化应用

Deepening Application of Dual Prevention Mechanism in Safety Production Management of Coal Chemical Enterprises

摘要

面向煤化工连续耦合与能量密集的工况场景，本文论证了双重预防机制“前置分级管控+反馈闭环治理”的理论适配性，提出以场景化风险识别为起点、处置闭环为终点的深化路径：构建HAZOP与LEC耦合的分级标准并对接LOPA，形成动态风险数据库；以物联网监测与事件关联驱动隐患闭环；通过OPC UA与语义模型融合MES、DCS、SIS，打通预警到工单的执行链；建立结果—过程—支撑三层指标与AHP权重评估体系。工程案例表明，事故发生率由0.8次/年降至0.1次/年，隐患整改完成率由85%升至98%，红橙级风险处置时效中位数由14 h缩短至6 h，DCS报警有效率由43%升至76%，无效告警抑制率由18%升至41%，SIS联锁健康度由0.92升至0.97，重大危险源稳定运行天数由180 d增至320 d，旁路合规率由88%升至99%。结果验证该机制可将重大危险源、剧毒介质与联锁失效纳入可分级、可核验、可追溯的治理路径。

Abstract

Addressing continuous coupling and energy-intensive operational scenarios in coal chemical plants, this study validates the theoretical applicability of a dual prevention mechanism combining “preliminary hierarchical control + feedback-based closed-loop governance.” It proposes an implementation pathway starting with scenario-based risk identification and ending with closed-loop remediation: Establishing hierarchical standards integrating HAZOP and LEC methodologies coupled with LOPA to form a dynamic risk database; Driving closed-loop hazard management through IoT monitoring and event correlation analysis; Connecting early warning systems to work order execution chains via OPC UA integration with semantic models for MES, DCS, and SIS systems; Developing a three-tiered evaluation framework comprising outcome-process-support metrics and AHP weight assessment. Engineering case studies demonstrate significant improvements: Accident rates decreased from 0.8 incidents/year to 0.1, hazard rectification completion rate increased from 85% to 98%, median response time for red-orange risk incidents reduced from 14 hours to 6 hours, DCS alarm effectiveness rose from 43% to 76%, invalid alarm suppression rate improved from 18% to 41%, SIS interlock health status enhanced from 0.92 to 0.97, stable operation days for major hazard sources extended from 180 to 320 days, and bypass compliance rate increased from 88% to 99%. These results validate the mechanism’s capability to incorporate major hazard sources, highly toxic media, and interlock failures into a hierarchical, verifiable, and traceable governance framework.

关键词

双重预防机制 / 煤化工 / 风险分级管控 / 隐患排查治理 / 一体化安全管理

Key words

dual prevention mechanism / coal chemical industry / risk classification and control / hidden danger investigation and management / integrated safety management

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