起爆劑製程本質較安全設計與風險評估管理-以糊精疊氮化鉛製程為例

Abstract

起爆劑是在火藥鏈最前端的炸藥，最為敏感，亦最容易因非預期之能量引發而造成意外事故。如何妥善設計規劃與管理，以辨識、評估及控制此諸危害因子，防範意外事故發生，實為極其重要的課題。 本文選定以國內某研究機構起爆劑工廠之糊精疊氮化鉛製程為例，審視其運用本質較安全設計以消除及降低危害之情況，另以風險評估HAZOP分析方法，對製程各階段之危害因素進行鑑認與評估。所得結果本製程在本質較安全設計上歸納有10項運用，而以HAZOP評估，發現乾燥道次以離子化空氣吹乾成品無法即時監控離子化程度而具較高風險，文中提出改善方案，其餘顯示較大潛在危險還是在於安全管理上，必須相關管理作為能落實執行，方能確保已設之安全設備發揮應有效能，尤其應逐一依據評估表，重新審查現有SOP及JSA，對欠缺及內容有所疏漏者予以補強，並以此對操作人員實施教育訓練，以及訂定完整之自動檢查、維護保養及校驗計畫落實執行最為重要。

Primary explosive is acting as an initiator of the explosive chain reaction. With the sentitive nature, it is easily to cause an accident by unexpected energy. It is critical topic to indentify, assessment and control all of hazard factors through a well designed, planned and managed process in order to prevent an accident. In this work, the process of dextrinated lead azide in the plant of primary explosives of a research institute in Taiwan, was chosen as an example to review the application of inherently safer design, and through the HAZOP methodology, the hazard factors in the processes were identified and assessmented. There are 10 applications concluded from inherently safer design of the process in this work. As HAZOP is used for this work, it showed that ionizing of air can’t be detected real time when drying take a higher risk, it could cause explosion by electrostatic. So, it’s needed to change the dryig design. In others, no major hazards were found at the safety design of the process. However, the major potential risks were found at the safety management, and the safety management measures required to be followed in order to ensure safety equipments acting efficiently. With a checklist of the assessment, all of existing SOPs and JSAs were reviewed accordingly, and the insufficient part in the documents was enforced. The training courses were given to the operators. It is important to execute the well-defined plans of self-checking, maintenance, and calibration.