風險評估在PU泡綿製造廠之應用

Risk Assessment Applications in PU-Foam Manufacturing Plants

聚氨酯（Polyurethane，PU）泡綿製造業火災爆炸案件頻傳，本研究目的在降低PU泡綿製造業之火災爆炸事故發生。本研究訪視了10家廠商，將PU泡綿發泡製程概分為3種類型，包含手動製程、半自動製程及全自動製程，將工廠分為製程區、儲存區（成品或廢料），甲苯二異氰酸鹽（Toluene diisocyanate，TDI）儲存區及全廠考量，以危害及可操作性研究（Hazard and Operability Studies，Hazop）修正方法及工作安全分析法（Job Safety Analysis，JSA）分析，從8大面向考量可能存在的風險。並分析了動火作業標準作業流程（Standard Operation Procedure，SOP）及噴漆作業SOP潛藏之人為操作風險。除上述分析內容外，亦透過實地訪視所查核到之缺失一併加入查核表內容中。
所建立查核表內容包含：PU泡綿製程作業（單元）說明及標準作業流程、常見火災爆炸發生原因、風險等級、製程風險評估、雇主責任及緊急應變，以及火災爆炸預防自主檢查表。其中，有關雇主責任與緊急應變內容，針對電氣危害預防、靜電危害預防與化學品安全危害預防等作了最基本的描述。在消防安全方面則參照內政部於2023年7月10日訂定「輔導既存工廠自設滅火設備及替代設施指導原則」。此PU泡綿製造業火災爆炸預防自主檢查表，分為一般企業標準版與微型企業簡易版兩種。微型企業簡易版主要是針對10人以下之小規模企業。

The purpose of this study is to reduce the occurrence of fire and explosion accidents in the polyurethane (PU) foam manufacturing industry. This study interviewed 10 manufacturers and divided the PU foam foaming process into three types, including manual process, semi-automatic process and fully automatic process, and divided the factory into process area, storage area (finished product or waste), Toluene diisocyanate (TDI) storage area and plant-wide consideration. Hazard and Operability Studies (Hazop).correction methods and Job Safety Analysis (JSA) consider possible risks from eight aspects. The potential human operation risks of hot operation Standard Operation Procedure (SOPs) and painting SOPs were analyzed. In addition to the above analysis, the deficiencies identified through on-site visits are also included in the contents of the checklist.
The content of the checklist established includes: PU foam process operation (unit) description and standard operating procedures, common causes of fire explosions, risk levels, process risk assessment, employer responsibilities and emergency response, and fire and explosion prevention self-checklist. Among them, the content related to employer responsibilities and emergency response is aimed at electrical hazard prevention, electrostatic hazard prevention, chemical safety hazard prevention, etc. etc. made the most basic description. In terms of fire safety, refer to the Ministry of the Interior's ''Guiding Principles for Guiding Existing Factories to Install Their Own Fire Extinguishing Equipment and Alternative Facilities'' on July 10, 112. This PU foam manufacturing industry fire and explosion prevention self-checklist is divided into two types: general enterprise standard version and micro enterprise simplified version. The Micro Business Lite version is mainly aimed at small businesses with less than 10 employees.