ExSys-LOPA for the chemical process industry |
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| Authors: | Adam S. Markowski M. Sam Mannan |
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| Affiliation: | 1. Process Safety and Ecological Division, Faculty of Process and Environmental Engineering, Technical University of Lodz, 90-133 Lodz, ul. Wolczanska 213, Poland;2. Mary Kay O’Connor Process Safety Center, Artie McFerrin Department of Chemical Engineering, Texas A&M University System, 3122 TAMU, College Station, TX 77843-3122, USA;1. Laboratory of Research in Industrial Prevention (LRIP), Health and Occupational Safety Institute, Safety Department, University of Batna, Med El-Hadi Boukhlouf Street, Batna 05000, Algeria;2. Entreprise Nationale des Travaux aux Puits (ENTP Company), B.P. 206, Hassi-Messaoud, Algeria;1. Prevention Management International BVBA, Waterstraat 63, B-2970 Schilde, Belgium;2. Swissi Process Safety Gmbh, Schwarzwaldallee 215, CH-4002 Basel, Switzerland;3. Mary Kay O’Connor Process Safety Center, Artie McFerrin Department of Chemical Engineering, Texas A&M University, College Station, TX 77843, USA;4. DICCA, Civil, Chemical and Environmental Engineering Department, Polytechnic School, University of Genoa, Via Opera Pia 15, 16145 Genoa, Italy;1. Industrial and System Engineering, University of New Haven, West Haven, CT 06516, USA;2. Department of Paints Production, Yemen Company for Paints & Derivatives Ltd., Taiz, Yemen;1. LISES-DICAM Dipartimento di Ingegneria Civile, Chimica, Ambientale e dei Materiali, Alma Mater Studiorum – Università di Bologna, via Terracini 28, 40131 Bologna, Italy;2. Department of Production and Quality Engineering, Norwegian University of Science and Technology NTNU, S.P. Andersens veg 5, 7031 Trondheim, Norway;3. SINTEF Technology and Society, Safety Research, S.P. Andersens veg 5, 7031 Trondheim, Norway;4. Safety and Risk Engineering Group (SREG), Faculty of Engineering and Applied Science, Memorial University of Newfoundland, St. John’s, NL A1B 3X5, Canada;1. Departamento de Proyectos de Ingeniería, Universitat Politècnica de València, Camino de Vera s/n, 46022, Valencia, Spain;2. Departamento de Ingeniería de Construcción y Fabricación, ETSII, UNED, C/Ciudad Universitaria S/N, 28040, Madrid, Spain;3. Universitat de València, Avda. de la Universidad s/n, 46100, Burjassot, Valencia, Spain;4. Departamento de Ingeniería Química, Universitat de València, Avda de la Universidad s/n, 46100, Burjassot, Spain |
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| Abstract: | The chemical process industries are characterized by the use, processing, and storage of large amounts of dangerous chemical substances and/or energy. Among different missions of chemical plants there are two very important ones, which: 1. provide a safe work environment, 2. fully protect the environment. These important missions can be achieved only by design of adequate safeguards for identified process hazards. Layer of Protection Analysis (LOPA) can successfully answer this question. This technique is a simplified process of quantitative risk assessment, using the order of magnitude categories for initiating cause frequency, consequence severity, and the likelihood of failure of independent protection layers to analyze and assess the risk of particular accident scenarios. LOPA requires application of qualitative hazard evaluation methods to identify accident scenarios, including initiating causes and appropriate safeguards. This can be well fulfilled, e.g., by HAZOP Studies or What-If Analysis. However, those techniques require extensive experience, efforts by teams of experts as well as significant time commitments, especially for complex chemical process units. In order to simplify that process, this paper presents another strategy that is a combination of an expert system for accident scenario identification with subsequent application of LOPA. The concept is called ExSys-LOPA, which employs, prepared in advance, values from engineering databases for identification of loss events specific to the selected target process and subsequently a accident scenario barrier model developed as an input for LOPA. Such consistent rules for the identification of accident scenarios to be analyzed can facilitate and expedite the analysis and thereby incorporate many more scenarios and analyze those for adequacy of the safeguards. An associated computer program is under development. The proposed technique supports and extends the Layer of Protection Analysis application, especially for safety assurance assessment of risk-based determination for the process industries. A case study concerning HF alkylation plant illustrates the proposed method. |
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