Dynamic simulation for process hazard analysis: Affordances and limitations in the application to complex process systems

Abstract

Improving process safety is a high priority in process and manufacturing industries to address unwanted accidents and process disruptions. Research into the applications of dynamic simulators for hazard analysis has been rapidly growing. However, there is scant discussion in literature regarding the benefits and limitations associated with the utilization of dynamic simulations for process hazard analysis. A fundamental systems conceptualization, underpinned by the P3 model of people, plant and procedures, provides a framework for the characteristics to be considered by subject matter expertise when identifying the affordances and limitations within a dynamic simulation used for process hazard analysis. This subject matter expertise includes people with operations, process engineering, process safety and process simulation experience. All dynamic simulations will have limitations and understanding the affordances and limitations is crucial for the correct use of a model and the interpretation of results. A case study is presented on the application of a systematic approach for interrogating the dynamic simulation from an industrial operator training simulator of an operating residue catalytic cracking complex with the aim of conducting failure mode and effects analysis by identifying the significant consequences and the associated independent protection layers. Issues with respect to how one could automate the analysis rather than use human observation to assess the outcomes are considered and how to present the outcomes to complement existing process hazard analysis techniques are discussed. Future research requirements and developments that may assist in practically and effectively applying the technique in industry are also discussed.