安全、健康和环境

针对海外高腐蚀、高振动工况下往复式压缩机气缸泄漏事故致因不清、防控依据不足的问题，收集某石化公司近10年间的69起海外项目事故案例，提出并验证一种HAZOP-FMEA(危险与可操作性分析-故障模式与影响分析)定向融合分析策略；结合领结图(Bow-tie)与层次分析法(AHP),构建“定性识别-路径构建-定量评估”的系统风险分析模型。通过HAZOP-FMEA融合分析共识别出10项底层致因因素，事故多集中于气缸体与气缸盖；定量分析确定腐蚀环境、超载操作与振动是3个关键致因，其中腐蚀环境的权重最高(0.225 0)。基于分析结果，从材料选型、状态监测、操作规范与人员管理等维度提出了分级量化防控措施，为海外高腐蚀、高振动工况下压缩机的安全运行与风险防控提供了方案。

To address the issues of unclear causes and insufficient prevention and control basis for cylinder leakage accidents of reciprocating compressors under overseas high-corrosion and high-vibration operating conditions, this study collected 69 accident cases from overseas projects of a petrochemical company over the past 10 years. A HAZOP-FMEA integrated analysis strategy was proposed and validated, centered on using process parameter deviations as a guide to trace component failure modes and causes directionally, thereby overcoming potential analysis gaps in traditional methods. Furthermore, by integrating the Bow-tie diagram and the analytic hierarchy process(AHP), a systematic risk analysis model of “qualitative identification-path construction-quantitative assessment” was constructed and systematically applied to the risk identification and assessment of reciprocating compressor cylinder leakage. The results showed that through the HAZOP-FMEA integrated analysis, 10 underlying causes were identified, with accidents mainly occurring in the cylinder body and cylinder head, and design defects being common triggers. Quantitative analysis further determined that corrosive environment, overload operation, and vibration were three key causes, with corrosive environment having the highest weight(0.225 0), making it the primary risk under overseas high-corrosion conditions. Based on this, graded quantitative prevention and control measures were proposed from the dimensions of material selection, condition monitoring, operational procedures, and personnel management, providing actionable solutions for targeted safe operation and risk prevention of compressors under overseas high-corrosion and high-vibration conditions.