Origin of equipment design and operation errors |
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| Authors: | Kamarizan Kidam Markku Hurme |
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| Institution: | 1. Aalto University, Department of Biotechnology and Chemical Technology, P.O. Box 16100, 00076 Aalto, Finland;2. Universiti Teknologi Malaysia, Department of Chemical Engineering, 81310 UTM Skudai, Malaysia;1. Faculty of Computer Science, Dalhousie University, 6050 University Avenue, PO BOX 15000, Halifax, Canada NS B3H4R2;2. Centre de Visio per Computador, Campus UAB, Edifici O, Bellaterra, 08193 Barcelona, Spain;3. Department of Mathematics, University of Barcelona, Gran Via de les Corts 585, 08007 Barcelona, Spain;1. Key Laboratory of Applied Chemistry, Yanshan University, Qinhuangdao 066004, China;2. State Key Laboratory of Metal Matrix Composites, Shanghai Jiaotong University, Shanghai 200240, China;3. Beidaihe Center Experiment Station, Chinese Academy of Fishery Science, 066100 Beidaihe, China;1. Paul Scherrer Institut, Switzerland;2. Leibstadt Nuclear Power Plant, Switzerland;1. Vanderbilt University, United States;2. United States Department of Energy, Office of Environmental Management, United States;1. The Petroleum Institute, Chemical Engineering Department, P.O. Box 2533, Abu Dhabi, United Arab Emirates;2. Eindhoven University of Technology, Department of Chemical Engineering and Chemistry, Separation Technology Group, Den Dolech 2, 5612 AZ Eindhoven, Netherlands;1. BITS Pilani Duba Campus, Dubai 345055, United Arab Emirates;2. Department of Mechanical Engineering, BITS Pilani Dubai Campus, Dubai 345055, United Arab Emirates |
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| Abstract: | The paper discusses the origin of chemical process equipment accidents by analyzing past accident cases available in the Failure Knowledge Database (FKD). The design and operation errors of the process equipment that caused the accidents were analyzed together with their time of occurrence. It was found that design errors contributed to 79% of accidents while the rest were only due to human and organizational errors in the operation stage and external factors. The most common types of errors were related to layout, organizational errors in the operation stage, considerations of reactivity and incompatibility, and wrongly selected process conditions (each approx. 13% of total accident contributors). On average there were about 2 design errors per accident. The timing of the errors was quite evenly distributed between various lifecycle stages. Nearly half (47%) of the errors were made in process design-oriented stages, one fourth (26%) in detailed engineering, and one fifth (20%) in operation. In addition, the most frequent design and operation errors for each equipment type were identified. A points-to-look-for list was created for each equipment type, showing also the typical time of occurrence of the error. The knowledge of type and timing of design errors can be utilized in design to focus the hazard analysis in each stage on the most error-prone features of design. |
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