Anti-corrosive coatings for steel structures with an alternative anti-corrosive pigment, polyaniline was prepared and anti-corrosive characteristics of the prepared coatings were investigated. The structure of the polyaniline was identified by using FT-IR, UV/Vis. and TGA analysis, and the anti-corrosive properties were analyzed from the results of the salt spray experiment. We found that the anti-corrosion properties of the prepared coatings varied in accordance with the types of primer coating resins as well as with the existence and nonexistence of the top coating. In this condition, the properties of adhesion, chemical resistance, and water resistance were found to be very satisfactory when using the single-packaged urethane resin as the primer coating resin and the urethane resin as the top coating resin.

The likelihood of failure by the corrosion of high temperature H2S/H2, which affect to a risk of facilities, was analyzed through the risk based-inspection using API-581 BRD. We found that the corrosion rate was increased as temperature and H2S concentration were increased. Also, the technical module subfactor(TMSF) was increased as an used you increased, material thickness decreased, inspection number decreased, and inspection effectiveness increased. In these conditions, the maximum value of TMSF was not varied, but the TMSF was sensitively varied at low temperature for high concentration of H2S.

본 연구는 한국산업안전공단에서 구축한 종합위험관리체제(IRMS)의 추진경과, 운영조직체계, IRMS 효과, 개선사항 및 향후 발전방향 등 IRMS 사업의 전 분야를 재검토하여 문제점에 대한 개선방안과 중 장기 발전방안을 제시하고자 하였다. 이를 위해 IRMS가 구축된 PSM 사업장에 대하여 설문조사를 실시하여 IRMS 효과를 분석하여 문제점을 도출하고, 이를 바탕으로 교육, 조직, 정보공유, 전산화, 기타 부문에서 개선방안을 제시하였다. 또한 선진국의 안전관리 실태를 전망하고, 이를 통하여 IRMS 중 장기 발전방안 수립을 위한 추진방향을 제시하였다.

한국형 위험기반검사 프로그램을 석유화학공장에 적용하여 사업장의 안전관리 이행수준, 공정 위험도 등급 및 분포 및 설비의 손상메카니즘 분포를 산출하였으며, 이를 바탕으로 검사주기 변경으로 설비검사를 수행함으로써 배관의 안전성을 향상시키고, 검사비용을 절감할 수 있었다.

The likelihood of failure for the thinning of high temperature sulfide and naphthenic acid corrosion, which affect to a risk of facilities, was analyzed through the risk based inspection using API-581 BRD. We found that the corrosion rate was increased with increasing temperature and total acid number(TAN). And maximum value of the technical module subfactor(TMSF) was not varied with operating condition, but the TMSF was sensitively changed at the range of low temperature, low flow rate, and high TAN. Also, the TMSF was increased as an used year and inspection effectiveness increased, but it was increased as thickness, inspection number, and over design decreased.

Likelihood of failure for the external corrosion of carbon and low alloy steels, which affect to a risk of facilities, was analyzed quantitatively through the risk based inspection using API-581 BRD. We found that the technical module subfactor (TMSF) decreased as the inspection number increased and it increased as the Inspection effectiveness and the used year increased. In this condition, the TMSF showed high value for the case of the marine/cooling tower drift area as a corrosion driver, poor quality of coating, no insulation, and low insulation condition.

Acrylic resins (HSCs : EA/EMA/2-HEMA/CLA) which contain 70% solid content were synthesized by the copolymerization of monomers (2-hydroxyethyl methacrylate, ethyl acrylate, and ethyl methacrylate) and functional monomer (caprolactone acrylate : CLA) which improves the crosslinking density and physical properties of films. The physical properties of the prepared acrylic resins (HSCs) containing CLA, are as follows : viscosity 245~515 cps ; Mn 2670~2840 ; and conversions, 83~91%, respectively. From the correlation of Tg values, viscosities, and Mn of the HSCs, it was found that viscosity and Mn increased with Tg value.

An emulsion of octadecamidoethylaminoethyl dodecate (which provides softness) and an emulsion silicone oil KF-96 (which provides lubricity) were separately synthesized. Then PP finishing softeners (SSA-7) was prepared by blending of the synthesized emulsions with beef tallow hardened oil (a softness improving agent). PP finishing treatment was carried out with the prepared SSA-7 and PP finishing resin by a one bath method, and several physical properties were tested. As a result, crease recovery, tear strength, softness, lubricity, and bending resistance were all good, indicating that the prepared SSA-7 is a good PP finishing softener.

Likelihood of failure (LOF) for the external corrosion of stainless steel, which affect to a risk of facilities, was analyzed quantitatively through the risk based inspection using API-581 BRD. We found that the technical module subfactor (TMSF) decreased as the inspection number increased and it increased as the inspection effectiveness and the used year increased, and that the TMSF showed high value for the case of the marine/cooling tower drift area as a corrosion driver, In this condition, the LOF for the external corrosion of stainless steel had lower than that for the carbon and low alloy steels

Industrial facilities are becoming more complex and various with rapidly developing technologies. A number of installations and equipments are increased to improve productivity, and they are operated under the condition of high temperature and pressure. They are continuously repaired, replaced or abolished because of the deterioration with time, but their repair and replacement are not easy for economical and environmental concerns. If possible, the deteriorating equipments should be inspected and repaired effectively considering the state of maintenance and preservation, economic efficiency, and safety. That's where RBI(Risk Based Inspection) fits in. Even if RBI technology has been known among specialists, there were no tools readily available and it was hard to practice and apply RBI in industrial inspection and safety management. In the development of the qualitative RBI, the overall algorithm adopted API-581 BRD. The qualitative RBI program was developed to search the appling process.

본 연구에서는 계절별 기후인자를 고려하여 정성적 및 정량적 위험성 평가를 실시하여 사고 시나리오를 설정하였고, 비용-편익분석을 실시하여 사고 시나리오별 안전관리 비의 효율을 분석하였다. 그 결과, 최악의 시나리오는 비정상조업에서 유지보수 오류이었고, 가능성 있는 시나리오는 HAZOP 구간#4에서 발생되는 가스 누출사고이었으며, 각 사고 시나리오에서 전체 안전관리 투자비에 대한 편익/비용은 0.043과 0.13이었다. 이때 각 사고 시나리오에서 비용 효과적인 안전관리 항목을 평가할 수 있었다.

A copolymer 〈HSAs : EA/EMA/2-HEMA/AAEM) which is an acrylic resin containing 70% solid content was synthesized by the reaction of monomers, including ethyl acrylate, ethyl methacrylate, and 2-hydroxyethyl methacrylate with a functional monomer, such as acetoacetoxyethyl methacrylate, which may give improvements in cross-linking density and physical properties of films. The physical properties of prepared acrylic resins, HSA containing AAEM, are as follows : viscosity, 203~550cps ; Mn, 2590~2850 ; and conversion, 82~89%, respectively. It was found from the plotting of Tg versus viscosity and Tg versus molecular weight that viscosity increased with Tg while number averaged molecular weight decreased with increasing Tg.

An intermediate, tetramethylene bis (orthophosphate), was prepared by the esterification of pyrophosphoric acid and l,4-butanediol. Then pyrophosphoric-containing modified polyesters (ATTBs) were synthesized by polycondensation of tetramethylene bis(orthophosphate), trimethylolpropane, adipic acid, and l,4-butanediol. The content of l,4-butanediol was varied from 10 to 20wt% for the reaction. The increase of the amount of l,4-butanediol in the synthesis of ATTBs resulted in increase in average molecular weight and decrease in kinematic viscosity owing to the excellent flowability and reactivity of l,4-butanediol.

Fatty polyamide that gives softness, lubrication and bulky property and alkyl imidazoline that gives durable softness and antistatic property were synthesized. then, an O/W-type durable softener (DSN) was prepared by the emulsion of the synthesized fatty polyamide and alkyl imidazoline. Emulsion stability of the DSN was good, and the mixed HLB value was 11.2. From the measurement of softness, lubrication, antistatic property, bending resistance, and color fastness, it was proved that the prepared DSN was a good durable softener for nylon.

The quantitative evaluation method of the safety management cost was suggested to prevent a gas accident as a major industrial accident. In a gas governor station, process risk assessments such as the fault tree analysis(FTA) and the consequence analysis were performed. Based on process risk assessments, potential accident costs were estimated and the cost-benefit analysis(CBA) was performed. From the cost-benefit analysis for five classification items of safety management cost, the order of the cost/benefit ratio was estimated.

For the unconfined vapor cloud explosion accident by the continuous release of gas-liquid flow of various saturated liquids in a vessel at ground level, overpressures were estimated and analyzed with various release conditions and materials by TNT equivalency model with vapor dispersion. We found that at same release conditions, overpressure showed n-heptane > xylene > n-hexane > toluene > n-heptane > benzene, respectively and that overpressure was increased with increasing the hole diameter and the storage pressure, but it was increased with decreasing the wind speed, the interested distance, and the vessel thickness.

In this case study, results of the explosion accident at MEK-PO factory were analysed by using the consequence analysis of quantitative hazard assessment and the explosion energy, the burst pressure of vessel, and overpressures at the explosion center and at 300m distance from the explosion center were estimated, respectively. As a result, we found that a cause of accident was the runaway reaction of product(MEK-PO) because of the molecular expansion in vessel and that the possibility of the runaway reaction was classified the mechanical failure(the obstacle of refrigerator or the shutdown valve), design error, and operating error by lack of thermochemical knowledge. Also, the evasive action to prevent accident was suggested.

Cost-benefit analysis was investigated to propose the analysis method of the effect of investment and the optimum investment level of safety management cost for preventing gas accident in the B governor station. From five classifications of safety management costs consisting of cost items with similar characters and potential accident costs calculated by risk assessments(FMEA/HAZOP), we found that the order of the benefit(the reduction cost of the potential accident cost) was the instrument increase and repair cost > the safety checking and inspection cost > the labor and training cost > the safety equipment and corresponding cost > the research and development cost. As the benefit was increased with increasing the investment cost, the effect of investment was increased with decreasing the Investment cost. As a result, the optimum safety management cost was estimated and the investment level was analyzed by the model of optimum investment level.

An ACR/HMMM film was prepared by blending high-solid ACR with curing agent, hexamethoxymethyl melamine (HMMM). An active curing reaction was observed at 170℃. The dynamic viscoelastic Tg of the final film increased with the static viscoelastic Tg of the film. The log damp value, which means a viscoelastic ratio, decreased with the increase in the curing temperature of the film. Physical properties of the films were within a suitable range for films, and by an accelerated weathering resistance test the films were proved weather resistible ones.