Accident Analysis Techniques in the Industries: A Review
Accident Analysis Techniques in the Industries
Keywords:
Accident causation analyses, Systemic analysis, Sequential analysis, Human information models, Structural equation modelling, Manufacturing industries, Industrial safetyAbstract
Since the industrial revolutions, accidents have become more common and frequent in all the industries. To find out the causes of these accidents, plenty of techniques have been used until now. A review of the existing techniques of accident causation has been done in this study which highlights the strengths and weaknesses of all these techniques that have been used to find out the contributory factors of these incidents. In addition, the industries where these techniques have been used, have been identified and it is emphasized that these techniques should be applied in the textile industry in Pakistan which is the most accident prone industry in recent times. This study also leads to the realization that there is a need for newer techniques such as structural equation modelling that address the complex nature of accidents and deal with the interactions of contributory factors of accidents in large scale industries. It is also emphasized that the government should take the initiative of making an institution that gathers the accidents data so that the exact causes can be known and dealt with accordingly.
References
Katsakiori, P., G. Sakellaropoulos, & E. Manatakis, Towards an evaluation of accident investigation methods in terms of their alignment with accident causation models. Safety Science, 47(7): 1007-1015(2009).
Garrick, B.J., The approach to risk analysis in three industries: nuclear power, space systems, and chemical process. Reliability Engineering & System Safety, 23(3): 195-205 (1988).
Li, Y.-H., Y.-D. Wang, & W.-Z. Zhao. Bogie failure mode analysis for railway freight car based on FMECA. in Reliability, Maintainability and Safety. ICRMS 2009. 8th International Conference on. IEEE (2009).
Brown, D.B., M.D. Ironside, & S.M. Shaw, Safety Notables: Information from the Literature (2016).
Yi, L., S. Zhang, & L. Xueqing, A hazard analysis-based approach to improve the landing safety of a BWB remotely piloted vehicle. Chinese Journal of Aeronautics, 25(6) 846-853 (2012).
Kim, T.-e., S. Nazir, & K.I. Øvergård, A STAMP-based causal analysis of the Korean Sewol ferry accident. Safety science, 83: 93-101 (2016).
Dunjó, J., et al., Hazard and operability (HAZOP) analysis. A literature review. Journal of hazardous materials, 173(1) 19-32 (2010).
Li, W.-C., D. Harris, & C.-S. Yu, Routes to failure:Analysis of 41 civil aviation accidents from the Republic of China using the human factors analysis and classification system. Accident Analysis & Prevention, 40(2) 426-434 (2008).
Lee, S., et al., Applying the AcciMap methodology to investigate the tragic Sewol Ferry accident in South Korea. Applied ergonomics, 59: 517-525 (2017).
De Carvalho, P.V.R., The use of Functional Resonance Analysis Method (FRAM) in a mid-air collision to understand some characteristics of the air traffic management system resilience. Reliability Engineering & System Safety, 96(11) 1482-1498 (2011).
Willey, R.J., Layer of Protection Analysis. Procedia Engineering, 84: 12-22 (2014).
Debrincat, J., C. Bil, & G. Clark, Assessing organisational factors in aircraft accidents using a hybrid Reason and AcciMap model. Engineering Failure Analysis, 27: p. 52-60 (2013).
Khan, F.I. & S. Abbasi, Major accidents in process industries and an analysis of causes and consequences. Journal of Loss Prevention in the process Industries, 12(5) 361-378 (1999).
Ericson, C.A., Event tree analysis. Hazard Analysis Techniques for System Safety, 2005: p. 223-234.
Khan, F.I. & S. Abbasi, An assessment of the likelihood of occurrence, and the damage potential of domino effect (chain of accidents) in a typical cluster of industries. Journal of Loss Prevention in the Process Industries, 14(4): 283-306 (2001).
Pula, R., et al., A grid based approach for fire and explosion consequence analysis. Process Safety and Environmental Protection, 84(2) 79-91 (2006).
Ribeiro, A., et al., Human reliability analysis of the Tokai-Mura accident through a THERP–CREAM and expert opinion auditing approach. Safety science, 87: p. 269-279 (2016).
van de Merwe, K., S. Øie, and K. Gould. The application of the SPAR-H method in managed-pressure drilling operations. in Proceedings of the Human Factors and Ergonomics Society Annual Meeting. Sage Publications Sage CA: Los Angeles, CA (2012).
Panchal, D. and D. Kumar, Integrated framework for behaviour analysis in a process plant. Journal of Loss Prevention in the Process Industries,. 40: p. 147-161 (2016).
Sharma, R.K., D. Kumar, and P. Kumar, Predicting uncertain behavior of industrial system using FM—A practical case. Applied Soft Computing,8(1): p. 96-109 (2008).
Davison, I. and N. Fairburn. Practical experience of failure analysis on nuclear facility or how I learned to love a well-structured FMEA. in Safety and Reliability. Taylor & Francis (2016).
Kokosz, C. and R. Engle. Using Operational Failure Modes and Effects Analysis to Identify Project Top Risks. in Offshore Technology Conference. Offshore Technology Conference (2016).
Jun, L. and X. Huibin, Reliability analysis of aircraft equipment based on FMECA method. Physics Procedia, 25: p. 1816-1822 (2012).
Bertolini, M., M. Bevilacqua, and R. Massini, FMECA approach to product traceability in the food industry. Food Control, 17(2): p. 137-145 (2006).
Bevilacqua, M., M. Braglia, and R. Gabbrielli, Monte Carlo simulation approach for a modified FMECA in a power plant. Quality and Reliability Engineering International, 2000. 16(4): p. 313-324 (2000).
Rodríguez, M. & I. Díaz, System theory based hazard analysis applied to the process industry. International Journal of Reliability and Safety, 10(1): p. 72-86 (2016).
Rodríguez, M. & I. Díaz, A systematic and integral hazards analysis technique applied to the process industry. Journal of Loss Prevention in the Process Industries (2016).
Chiesi, S.S. STPA application for safety assessment of generic missile systems. in 2016 Annual Reliability and Maintainability Symposium (RAMS). IEEE(2016).
Schmittner, C., Z. Ma, & P. Puschner. Limitation and Improvement of STPA-Sec for Safety and Security Co-analysis. in International Conference on Computer Safety, Reliability, and Security. Springer2016.
Pérez-Marín, M. & M. Rodríguez-Toral, HAZOP–Local approach in the Mexican oil & gas industry. Journal of Loss Prevention in the Process Industries, 26(5): 936-940 (2013).
Wu, J., et al., An integrated qualitative and quantitative modeling framework for computer-assisted HAZOP studies. AIChE Journal, 60(12): p. 4150-4173 (2014).
Lenné, M.G., et al., A systems approach to accident causation in mining: An application of the HFACS method. Accident analysis & prevention, 48: 111-117 (2012).
Gong, Y. & Y. Fan, Applying HFACS Approach to Accident Analysis in Petro-Chemical Industry in China: Case Study of Explosion at Bi-Benzene Plant in Jilin, in Advances in Safety Management and Human Factors. Springer. 399-406 (2016).
Zhan, Q., W. Zheng, & B. Zhao, A hybrid human and organizational analysis method for railway accidents based on HFACS-Railway Accidents (HFACS-RAs). Safety science, 91: 232-250 (2017).
Johnson, C.W.& I.M. de Almeida, An investigation into the loss of the Brazilian space programme’s launch vehicle VLS-1 V03. Safety Science, 46(1): 38-53 (2008).
Tabibzadeh, M. & N. Meshkati. Applying the AcciMap Methodology to Investigate a Major Accident in Offshore Drilling: A Systematic Risk Management Framework for Oil and Gas Industry. in SPE Western Regional Meeting. Society of Petroleum Engineers (2015).
Lee, S., et al., Applying the AcciMap methodology to investigate the tragic Sewol Ferry accident in South Korea. Applied Ergonomics, (2016).
Tian, J., et al., FRAMA: a safety assessment approach based on Functional Resonance Analysis Method. Safety science, 85: 41-52 (2016).
Rosa, L.V., A.N. Haddad, & P.V.R. de Carvalho, Assessing risk in sustainable construction using the Functional Resonance Analysis Method (FRAM). Cognition, Technology & Work, 17(4): 559-573 (2015).
Markowski, A.S. & M.S. Mannan, ExSys-LOPA for the chemical process industry. Journal of Loss Prevention in the Process Industries, 23(6): p. 688-696 (2010).
Khalil, M., et al., A cascaded fuzzy-LOPA risk assessment model applied in natural gas industry. Journal of Loss Prevention in the Process Industries,25(6): 877-882 (2012).
Sonnemans, P.J. & P.M. Körvers, Accidents in the chemical industry: are they foreseeable? Journal of Loss Prevention in the Process Industries, 19(1): 1-12 (2006).
Underwood, P. & P. Waterson, Systems thinking, the Swiss Cheese Model and accident analysis: a comparative systemic analysis of the Grayrigg train derailment using the ATSB, AcciMap and STAMP models. Accident Analysis & Prevention, 68:75-94 (2014).
Van Sciver, G.R., Quantitative risk analysis in the chemical process industry. Reliability Engineering & System Safety, 29(1): 55-68 (1990).
Sarkar, S., S. Vinay, & J. Maiti. Text mining based safety risk assessment and prediction of occupational accidents in a steel plant. in 2016 International Conference on Computational Techniques in Information and Communication Technologies (ICCTICT). IEEE (2016).
Kumar, R. & A.K. Ghosh, Mines systems safety improvement using an integrated event tree and fault tree analysis. Journal of The Institution of Engineers (India): Series D, 1-8 (2016).
Phimister, J.R., et al., Near-miss incident management in the chemical process industry. Risk Analysis, 23(3): 445-459 (2003).
Khan, F.I. & S. Abbasi, Estimation of probabilities and likely consequences of a chain of accidents (domino effect) in Manali Industrial Complex. Journal of cleaner production, 9(6): 493-508 (2001).
Arunraj, N. & J. Maiti, A methodology for overall consequence modeling in chemical industry. Journal of hazardous materials, 169(1): 556-574 (2009).
Bø, T.I., et al., Dynamic consequence analysis of marine electric power plant in dynamic positioning. Applied Ocean Research, 57: 30-39 (2016).
Taylor, D.W., The role of consequence modeling in LNG facility siting. Journal of hazardous materials, 142(3): 776-785 (2007).
Konstandinidou, M., et al., A fuzzy modeling application of CREAM methodology for human reliability analysis. Reliability Engineering & System Safety, 91(6): 706-716 (2006).
Gould, K.S., A.J. Ringstad, & K. van de Merwe. Human reliability analysis in major accident risk analyses in the Norwegian petroleum industry. in Proceedings of the Human Factors and Ergonomics Society Annual Meeting. Sage Publications Sage CA: Los Angeles, CA (2012).
Gertman, D., et al., The SPAR-H human reliability analysis method. US Nuclear Regulatory Commission, (2005).
Jahangiri, M., et al., Human error analysis in a permit to work system: a case study in a chemical plant. Safety and health at work, 7(1): 6-11 (2016).
Dvorak, J., M. Sasiadek, & S. Hosnedl, Innovation of Methodological Support of Risk Analyses of Technical Products in Their Life Cycle During Their Designing, in The Latest Methods of Construction Design. Springer.197-202 (2016).
Mechhoud, E.-A., M. Rouainia, & M. Rodriguez, A New tool for risk analysis and assessment in petrochemical plants. Alexandria Engineering Journal, 55(3): 2919-2931 (2016).
Underwood, P. & P. Waterson, A critical review of the STAMP, FRAM and AcciMap systemic accident analysis models. Advances in Human Aspects of Road and Rail Transportation. CRC Press, Boca Raton, 385-394 (2012).
Kang, J. & L. Guo, HAZOP analysis based on sensitivity evaluation. Safety science, 88: 26-32 (2016).
Salmon, P.M., M. Cornelissen, & M.J. Trotter, Systems-based accident analysis methods: A comparison of Accimap, HFACS, and STAMP. Safety science, 50(4): 1158-1170 (2012).
Torres-Echeverria, A.C., On the Use of LOPA and Risk Graphs for SIL determination. Journal of Loss Prevention in the Process Industries, 41: 333-343 (2016).
de Ruijter, A. & F. Guldenmund, The bowtie method: A review. Safety science, 88: 211-218 (2016).
Clemens, P. & R.J. Simmons, System Safety and Risk Management: NIOSH Instructional Module. US Department of Health and Human Services (1998).
Hollnagel, E., Cognitive reliability and error analysis method (CREAM). Elsevier (1998).
Kline, R.B., Principles and practice of structural equation modeling. Guilford publications(2015).
Lomax, R.G. & R.E. Schumacker, A beginner’s guide to structural equation modeling. Routledge Academic New York, NY (2012).
Zhang, Y., et al., Analysis 320 coal mine accidents using structural equation modeling with unsafe conditions of the rules and regulations as exogenous variables. Accident Analysis & Prevention, 92: p. 189-201 (2016).
Lahore factory collapse kills nine, traps dozens. Available from: http://www.dawn.com/news/693437 (2012).
Worker dies in Korangi cylinder explosion. Available from: https://www.dawn.com/news/720232 (2012).
At least 18 labourers killed, scores trapped in Lahore factory collapse. Available from: https://www.dawn.com/news/1217470 (2012).
At least 25 dead in Lahore shoe factory fire. Available from: https://www.dawn.com/news/748653 (2012).
Factory fire in Karachi injures two. Available from: https://www.dawn.com/news/754364 (2012).
Cylinder explosion: Three die as factory collapses. Available from: https://tribune.com.pk/story/490370/cylinder-explosion-three-die-as-factory-collapses/ (2013).
Hazardous work: One killed, 5 injured in factory boiler blast. Available from: https://tribune.com.pk/story/491184/hazardous-work-one-killed-5-injured-in-factory-boiler-blast/ (2013).
Eight workers injured in boiler leakage. Available from: https://www.dawn.com/news/778429/eight-workers-injured-in-boiler-leakage (2013).
Eight injured in Lahore factory fire. 2013; Available from: https://www.dawn.com/news/799007.
Factory fire revisits Lahore; millions gutted. Available from: http://nation.com.pk/lahore/24-Apr-2013/factory-fire-revisits-lahore-millions-gutted (2013).
Factory catches fire in Lahore; no casualties. Available from: https://www.dawn.com/news/1056532(2013).
Inexpert labour for industry boilers. Available from: https://www.dawn.com/news/1092182(2013).
iAvailable from: https://www.dawn.com/news/1093295 (2014).
Man dies in factory fire. Available from: https://www.dawn.com/news/1106577 (2014).
Short-circuit: Man suffocates to death in factory fire.; Available from: https://tribune.com.pk/story/709057/short-circuit-man-suffocates-to-death-in-factory-fire/ (2014).
Short circuit: Fire breaks out at a garment factory in Karachi. Available from: https://tribune.com.pk/story/722349/short-circuit-fire-breaks-out-at-garment-factor-in-karachi/ (2014).
Blaze in Karachi garment factory fire controlled. Available from: https://www.dawn.com/news/1120853 (2014).
Hundreds of workers lose jobs as fire destroys factory. Available from: https://tribune.com.pk/story/802934/hundreds-of-workers-lose-jobs-as-fire-destroys-factory/ (2014).
Six die after inhaling toxic gas in pickle factory. Available from: https://www.dawn.com/news/1175569 (2015).
13 workers caught in Karachi garment factory fire. Available from: https://tribune.com.pk/story/880600/8-workers-burnt-in-karachi-factory-fire/ (2015).
No injuries: Fire at dye factory in New Karachi causes significant damage. Available from: https://tribune.com.pk/story/894544/no-injuries-fire-at-dye-factory-in-new-karachi-causes-significant-damage/ (2015).
Ablaze: Towel factory gutted in fire. 2015; Available from: https://tribune.com.pk/story/924636/ablaze-towel-factory-gutted-in-fire/ (2015).
Shoddy construction: Four workers die, 14 injured in roof collapse. Available from: https://tribune.com.pk/story/950971/shoddy-construction-four-workers-die-14-injured-in-roof-collapse/ (2015).
Five die in Gujranwala flour mill boiler explosion. Available from: https://www.dawn.com/news/1205104 (2015).
Factory fire claims watchman’s life. Available from: https://www.thenews.com.pk/print/61259-factory-fire-claims-watchmans-life (2015).
At least 18 labourers killed, scores trapped in Lahore factory collapse. Available from: https://www.dawn.com/news/1217470 (2015).
Five workers killed in steel factory fire near Lahore. Available from: https://www.dawn.com/news/1218713 (2015).
Workplace Safety: 8 affected by gas leak at steel factory. Available from: https://tribune.com.pk/story/1022053/workplace-safety-8-affected-by-gas-leak-at-steel-factory/ (2016).
One dead, 30 injured as factory roof collapses in Gujranwala. Available from: https://tribune.com.pk/story/1022814/at-least-30-injured-as-factory-roof-collapses-in-gujranwala/ (2016).
Danger In Scrap: Worker dies in explosion at steel mill. Available from: https://tribune.com.pk/story/1023822/danger-in-scrap-worker-dies-in-explosion-at-steel-mill/ (2016).
Eight die in sugar mills boiler explosion. Available from: https://www.dawn.com/news/1234166 (2016).
Occupational hazard: Factory worker dies in loading accident. Available from: https://tribune.com.pk/story/1053700/occupational-hazard-factory-worker-dies-in-loading-accident/ (2016).
Accident: One killed in factory explosion. Available from: https://tribune.com.pk/story/1078236/accident-one-killed-in-factory-explosion/ (2016).
Fire breaks out in two factories. Available from: https://www.dawn.com/news/1252608 (2016).
5 workers die after inhaling toxic fumes at Korangi factory. Available from: https://www.pakistantoday.com.pk/2016/05/15/5-workers-die-after-inhaling-toxic-fumes-at-korangi-factory/ (2016).
Fauji Cement’s silo collapse sinks shares. Available from: https://www.dawn.com/news/1261735.
Warehouse of pharma factory catches fire. 2016; Available from: http://www.brecorder.com/2016/06/24/305816/ (2016).
Two workers die after falling into pulp tank. Available from: https://www.dawn.com/news/1268358 (2016).
At least six people dead as factory roof collapses in Karachi. Available from: https://www.dawn.com/news/1269036 (2016).
Workplace accident: Worker dies, four injured in factory cylinder blast. Available from: https://tribune.com.pk/story/1147322/workplace-accident-worker-dies-four-injured-factory-cylinder-blast/ (2016).
Work hazards: Three workers killed in boiler explosion. Available from: https://tribune.com.pk/story/1183495/work-hazards-three-workers-killed-boiler-explosion/ (2016).
Three workers die in Port Qasim factory accident. Available from: https://www.geo.tv/latest/116742-Three-workers-die-in-Port-Qasim-factory-accident (2016).
Three workers die while cleaning chemical tank. Available from: https://tribune.com.pk/story/1193507/three-workers-die-cleaning-chemical-tank/ (2016).
Factory owner booked after three workers die in boiler explosion. Available from: https://www.dawn.com/news/1291441 (2016).
Fire erupts in SITE textile factory. Available from: http://dailytimes.com.pk/sindh/25-Oct-16/fire-erupts-in-site-textile-factory(2016).
Deaths in factory fire: Owner arrested for violating building laws. Available from: https://www.dawn.com/news/1296044 (2016).
Boiler blast kills two sugar mills workers. Available from: https://www.dawn.com/news/1321229/boiler-blast-kills-two-sugar-mills-workers (2017).
Valuables burnt in shoe factory fire. Available from: https://www.thenews.com.pk/print/197460-Valuables-burnt-in-shoe-factory-fire (2017).
Material worth millions burnt in factory fire. Available from: http://nation.com.pk/national/28-Apr-2017/material-worth-millions-burnt-in-factory-fire (2017).
Kannan, P., et al., A web-based collection and analysis of process safety incidents. Journal of Loss Prevention in the Process Industries, 44:171-192 (2016).
Olivares, R.D.C., S.S. Rivera, & J.E.N. Mc Leod, Database for accidents and incidents in the biodiesel industry. Journal of Loss Prevention in the Process Industries, 29: 245-261 (2014).
