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Inherently safer design review and their timing during chemical process development and design

Institution:	1. Centre of Hydrogen Energy, Institute of Future Energy, Universiti Teknologi Malaysia, 81310, UTM Johor Bahru, Malaysia;2. Department of Chemical Engineering, Universiti Teknologi Malaysia, 81310, UTM Johor Bahru, Malaysia;3. Department of Biotechnology and Chemical Technology, Aalto University, P.O. Box 16100, 00076, Aalto, Finland;1. Center of Advanced Process Safety (CAPS), Chemical Engineering Department, Universiti Teknologi PETRONAS, 32610, Bandar Seri Iskandar, Perak Darul Ridzuan, Malaysia;2. Department of Chemical Engineering, Mehran University of Engineering and Technology, 76062, Jamshoro, Sindh, Pakistan;3. Department of Chemical Process Engineering, Malaysia - Japan International Institute of Technology (MJIIT), Universiti Teknologi Malaysia (UTM), Jalan Sultan Yahya Petra, 54100, Kuala Lumpur, Malaysia;1. Centre of Advanced Process Safety (CAPS), Chemical Engineering Department, Universiti Teknologi PETRONAS, 32610, Bandar Seri Iskandar, Perak Darul Ridzuan, Malaysia;2. Training and Assessment Research Group (TARG), Department of Maritime Operations, University of South-Eastern Norway, Postboks 4, 3199, Borre, Norway;3. Industrial Bioprocess Engineering Laboratory, Department of Chemical Engineering, Faculty of Engineering, Universitas Indonesia, Kampus UI Depok, Depok, 16424, Indonesia;4. Department of Chemical Process Engineering, Malaysia - Japan International Institute of Technology (MJIIT), Universiti Teknologi Malaysia (UTM), Jalan Sultan Yahya Petra, 54100, Kuala Lumpur, Malaysia;1. School of Chemical and Energy Engineering, Faculty of Engineering, Universiti Teknologi Malaysia, 81310, UTM Johor Bahru, Malaysia;2. Process System Engineering Centre (PROSPECT), Universiti Teknologi Malaysia, 81310, UTM Johor Bahru, Malaysia;3. Institute of Hydrogen Economy (IHE), Universiti Teknologi Malaysia, 81310, UTM Johor Bahru, Malaysia;1. Qatar University, Department of Chemical Engineering, College of Engineering, Doha, P.O. Box-2713, Qatar;2. University of Applied Sciences – TEI of Thessaly, Department of Business Administration, 41110, Larissa, Greece

Abstract:	This paper discusses the enhancement of inherent safety review and its implementation in the chemical process development and design. The aim is to update and improve the existing inherently safer design review (ISDR) practices during design of chemical process plant by exploiting major accident cases from the U.S. Chemical Safety Board (CSB) and Failure Knowledge Database (FKD). Although the basic guidelines to conduct ISDR during design phase are available, however they are too general and incomplete. The review criteria and their best timing for application are still missing. This paper attempts to develop the accident-based ISDR for chemical process plant design. The proposed accident-based ISDR is supported with detail review criteria for each phase of process design. The timing of ISDR application is corresponding to the common design tasks and decisions made in the design project. Therefore, timely design review could be done at the specific design task and the findings help designer to make a correct decision making.

Keywords:	Accident analysis Design errors Process lifecycle Inherent safety Review criteria ISD timing
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