Process Hazard Analysis Based on Modeling and Simulation Tools

Júlia Pinto Athanázio De Azevedo,José Carlos Pinto,Maurício Bezerra De Souza

doi:10.3390/pr10020386

Júlia Pinto Athanázio De Azevedo, José Carlos Pinto + Show 1 more

Open Access

https://doi.org/10.3390/pr10020386

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Journal: Processes	Publication Date: Feb 17, 2022
Citations: 5	License type: CC BY 4.0

Affiliation: Universidade Federal do Rio de Janeiro

Abstract

Chemical and oil processes are intrinsically sources of potential hazards. Although traditional qualitative hazard identification methods are simple, systematic, and flexible, such methodologies present limitations related to the inherent subjectivity, dependence on the team’s level of experience, and widespread time consumption of the members involved. In this context, the present work aims to develop a systematic way to use computational modeling and simulation tools for hazard identification. After extensive literature review, the present work proposes a methodology based on the association of the main points of previous works, with new contributions regarding the preparation for the simulations and the characterization of the minimum set of process variables that can enable appropriate interpretation of the results. The propene polymerization process (LIPP-SHAC process) was used as a case study to illustrate the proposed procedure. The paper explores how the model can be adapted for safety analyses and simulations for different hazard scenarios. The results obtained with different models are discussed and compared to those obtained with a traditional hazard identification approach to discuss how computational process modeling and simulation tools can sum to heuristic analysis. In conclusion, the use of simulations complementing the human-based approach can indeed enhance the understanding of mechanisms of hazardous scenarios, lessen conservative decision-making, and avoid overlooking device failures that can pose a severe hazard to the process.

Highlights

Chemical and oil processes are intrinsically sources of potential hazards due to the necessity of dealing with toxic compounds, higher-energy substances, and large-scale equipment
One of the most applied methods for hazard identification used worldwide is the so-called hazard and operability analysis (HAZOP), which must be recognized as an important systematic and practical tool that, when applied to an experienced group, can bring beneficial results regarding safety and operability. It is well-known that HAZOP is a “time-consuming”, “labor-intensive” [9], and an experience-dependent approach, and sometimes it can be overly conservative once accurate process behavior against process deviations is not available
Among the methods given in the literature, the malfunction procedure [16] systematically proposed the use of simulations for hazard identification

Summary

Introduction

Chemical and oil processes are intrinsically sources of potential hazards due to the necessity of dealing with toxic compounds, higher-energy substances, and large-scale equipment. History has shown that if these processes are not adequately managed, the results can be catastrophic [1,2,3]. The causes of major accidents have been mainly related to a lack of knowledge about process and system safety [4]. Over the past 40 years, many efforts have been made to develop and regulate the safe operation of industrial plants [4]. The accident causes are often more related to cost considerations and pressure on decision-making than to lack of knowledge. Assessment of process risks, development of cost and time-saving tools, and application of systematic approaches for process safety management are crucial to allow efficient risk-informed decision-making and, to avoid accidents and losses [4]

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