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Accident prevention approach throughout process design life cycle
Affiliation:1. Department of Chemical Engineering, Universiti Teknologi Malaysia, Malaysia;2. Department of Biotechnology and Chemical Technology, Aalto University, Finland;1. National Institute for Minamata Disease, Kumamoto, Japan;2. Brain Research Institute, Niigata University, Niigata, Japan;3. Laboratory of Toxicology and Environmental Health, School of Medicine, IISPV, Universitat “Rovira I Virgili”, Reus, Spain;4. Laboratory of Drug Metabolism and Pharmacokinetics, Showa Pharmaceutical University, Tokyo, Japan;5. Universidade Federal do Oeste do Pará, ICED-PPGBIO-PPGRNA-LABBEX, Santarém, Brazil;6. Akita University School of Medicine, Akita, Japan;1. State Key Laboratory of Chemical Engineering, Department of Chemical Engineering, Tsinghua University, Beijing 100084, China;2. Division of Technology, Industry and Economics, United Nations Environment Programme (UNEP), 15 rue de Milan, Paris, France;3. European Commission, Joint Research Centre, 2749 via Enrico Fermi, TP 720, 21027 Ispra, VA, Italy
Abstract:The accident rate in the chemical process industry (CPI) has not been decreasing although majority of accident causes have been identified and could have been prevented by using existing knowledge. These recurring accidents show that the existing knowledge has not been used effectively. In this paper, accident knowledge learned from earlier accident analyses are utilized to predict the common design errors during chemical plant design. An accident prevention approach throughout process design life cycle is proposed for a safer design consideration where designers are guided to identify common design errors, accident contributors and critical points to look for. The accident prevention approach has been applied to analyze the BP Texas City Refinery Explosion and Fire tragedy.
Keywords:Accidents  Errors  Process design life cycle  Plant design  Loss prevention  Learning from accident
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