Paul Amyotte

Safety analysis in process facilities: Comparison of fault tree and Bayesian network approaches

Safety analysis in gas process facilities is necessary to prevent unwanted events that may cause catastrophic accidents. Accident scenario analysis with probability updating is the key to dynamic safety analysis. Although conventional failure assessment techniques such as fault tree (FT) have been used effectively for this purpose, they suffer severe limitations of static structure and uncertainty handling, which are of great significance in process safety analysis. Bayesian network (BN) is an alternative technique with ample potential for application in safety analysis. BNs have a strong similarity to FTs in many respects; however, the distinct advantages making them more suitable than FTs are their ability in explicitly representing the dependencies of events, updating probabilities, and coping with uncertainties. The objective of this paper is to demonstrate the application of BNs in safety analysis of process systems. The first part of the paper shows those modeling aspects that are common between FT and BN, giving preference to BN due to its ability to update probabilities. The second part is devoted to various modeling features of BN, helping to incorporate multi-state variables, dependent failures, functional uncertainty, and expert opinion which are frequently encountered in safety analysis, but cannot be considered by FT. The paper concludes that BN is a superior technique in safety analysis because of its flexible structure, allowing it to fit a wide variety of accident scenarios.

Dynamic risk analysis using bow-tie approach

Accident probability estimation is a common and central step to all quantitative risk assessment methods. Among many techniques available, bow-tie model (BT) is very popular because it represent the accident scenario altogether including causes and consequences. However, it suffers a static structure limiting its application in real-time monitoring and probability updating which are key factors in dynamic risk analysis. The present work is focused on using BT approach in a dynamic environment in which the occurrence probability of accident consequences changes. In this method, on one hand, failure probability of primary events of BT, leading to the top event, are developed using physical reliability models, and constantly revised as physical parameters (e.g., pressure, velocity, dimension, etc) change. And, on the other hand, the failure probability of safety barriers of the BT are periodically updated using Bayes’ theorem as new information becomes available over time. Finally, the resulting, updated BT is used to estimate the posterior probability of the consequences which in turn results in an updated risk profile.

Fault and Event Tree Analyses for Process Systems Risk Analysis: Uncertainty Handling Formulations

Quantitative risk analysis (QRA) is a systematic approach for evaluating likelihood, consequences, and risk of adverse events. QRA based on event (ETA) and fault tree analyses (FTA) employs two basic assumptions. The first assumption is related to likelihood values of input events, and the second assumption is regarding interdependence among the events (for ETA) or basic events (for FTA). Traditionally, FTA and ETA both use crisp probabilities; however, to deal with uncertainties, the probability distributions of input event likelihoods are assumed. These probability distributions are often hard to come by and even if available, they are subject to incompleteness (partial ignorance) and imprecision. Furthermore, both FTA and ETA assume that events (or basic events) are independent. In practice, these two assumptions are often unrealistic. This article focuses on handling uncertainty in a QRA framework of a process system. Fuzzy set theory and evidence theory are used to describe the uncertainties in the input event likelihoods. A method based on a dependency coefficient is used to express interdependencies of events (or basic events) in ETA and FTA. To demonstrate the approach, two case studies are discussed.

Inherent safety in offshore oil and gas activities: a review of the present status and future directions

Abstract Inherent safety is a proactive approach for hazard/risk management during process plant design and operation. It has been proven that, considering the lifetime costs of a process and its operation, an inherently safer approach is a cost-optimal option. Inherent safety can be incorporated at any stage of design and operation; however, its application at the earliest possible stages of process design (such as process selection and conceptual design) yields the best results. Although it is an attractive and cost-effective approach to hazard/risk management, inherent safety has not been used as widely as other techniques such as HAZOP and quantitative risk assessment. There are many reasons responsible for this; key among them are a lack of awareness and the non-availability of a systematic methodology and tools. The inherent safety approach is the best option for hazard/risk management in offshore oil and gas activities. In the past, it has been applied to several aspects of offshore process design and operation. However, its use is still limited. This article attempts to present a complete picture of inherent safety application in offshore oil and gas activities. It discuses the use of available technology for implementation of inherent safety principles in various offshore activities, both current and planned for the future.

Domino Effect Analysis Using Bayesian Networks

A new methodology is introduced based on Bayesian network both to model domino effect propagation patterns and to estimate the domino effect probability at different levels. The flexible structure and the unique modeling techniques offered by Bayesian network make it possible to analyze domino effects through a probabilistic framework, considering synergistic effects, noisy probabilities, and common cause failures. Further, the uncertainties and the complex interactions among the domino effect components are captured using Bayesian network. The probabilities of events are updated in the light of new information, and the most probable path of the domino effect is determined on the basis of the new data gathered. This study shows how probability updating helps to update the domino effect model either qualitatively or quantitatively. The methodology is applied to a hypothetical example and also to an earlier-studied case study. These examples accentuate the effectiveness of Bayesian network in modeling domino effects in processing facility.

Safety assessment in plant layout design using indexing approach: implementing inherent safety perspective. Part 1 - guideword applicability and method description.

Layout planning plays a key role in the inherent safety performance of process plants since this design feature controls the possibility of accidental chain-events and the magnitude of possible consequences. A lack of suitable methods to promote the effective implementation of inherent safety in layout design calls for the development of new techniques and methods. In the present paper, a safety assessment approach suitable for layout design in the critical early phase is proposed. The concept of inherent safety is implemented within this safety assessment; the approach is based on an integrated assessment of inherent safety guideword applicability within the constraints typically present in layout design. Application of these guidewords is evaluated along with unit hazards and control devices to quantitatively map the safety performance of different layout options. Moreover, the economic aspects related to safety and inherent safety are evaluated by the method. Specific sub-indices are developed within the integrated safety assessment system to analyze and quantify the hazard related to domino effects. The proposed approach is quick in application, auditable and shares a common framework applicable in other phases of the design lifecycle (e.g. process design). The present work is divided in two parts: Part 1 (current paper) presents the application of inherent safety guidelines in layout design and the index method for safety assessment; Part 2 (accompanying paper) describes the domino hazard sub-index and demonstrates the proposed approach with a case study, thus evidencing the introduction of inherent safety features in layout design.

Prevention and mitigation of dust and hybrid mixture explosions

The results presented in this article focus on the importance of the prevention and mitigation of dust and hybrid mixture explosions. The main objective is to demonstrate the use of the inherent safety principle of moderation to achieve a significant reduction of the risk of explosions. Experiments and a companion modeling study were conducted with a test matrix composed of various size fractions of polyethylene powder together with concentrations of hydrocarbon gas (ethylene, hexane, and propane). The results quantitatively show the increased hazard posed by fine particle sizes of dust and the addition of flammable gases. There are clear implications for industry in terms of moderating the risk of an explosion.

Safety assessment in plant layout design using indexing approach: implementing inherent safety perspective. Part 2-Domino Hazard Index and case study.

The design of layout plans requires adequate assessment tools for the quantification of safety performance. The general focus of the present work is to introduce an inherent safety perspective at different points of the layout design process. In particular, index approaches for safety assessment and decision-making in the early stages of layout design are developed and discussed in this two-part contribution. Part 1 (accompanying paper) of the current work presents an integrated index approach for safety assessment of early plant layout. In the present paper (Part 2), an index for evaluation of the hazard related to the potential of domino effects is developed. The index considers the actual consequences of possible escalation scenarios and scores or ranks the subsequent accident propagation potential. The effects of inherent and passive protection measures are also assessed. The result is a rapid quantification of domino hazard potential that can provide substantial support for choices in the early stages of layout design. Additionally, a case study concerning selection among various layout options is presented and analyzed. The case study demonstrates the use and applicability of the indices developed in both parts of the current work and highlights the value of introducing inherent safety features early in layout design.

Quantification of inherent safety aspects of the Dow indices

Abstract The Dow fire and explosion index (F&EI) and chemical exposure index (CEI) have been successfully implemented in a Visual Basic environment as a tool for the inherent safety assessment of chemical processes. Subprograms were developed to quantify the inherent safety aspects of the Dow indices. These aspects are presented graphically with the indices on the vertical axis and an inherent safety indicator on the horizontal axis. Dow indices of the MIC storage unit involved in the Bhopal disaster were evaluated to quantify the effects of process temperature, pressure and inventory of hazardous materials on the index values. As operating pressure was reduced, the F&EI decreased in accordance with the principles of inherent safety. The change in F&EI due to reduction of inventory was more significant than that resulting from pressure reduction. The results show that the F&EI change, given the same range of the independent variables (quantity of hazardous materials, operating temperature and pressure), is larger when a unit in the process area is evaluated compared to a unit in a storage area (tank farm). Reduction of the inventory of hazardous materials had no direct effect on the CEI for vapor releases, whereas the size of the hole diameter impacted the CEI to a great extent. However, there is a significant change in the CEI as the inventory of materials decreases for liquid releases involving temperatures above their flash and boiling points. Pressure reduction decreases the CEI, whereas temperature reduction leads to an increase in the CEI when these parameters are treated independently.

Incorporation of inherent safety principles in process safety management

Process safety management (PSM) deals with the identification, understanding, and control of process hazards to prevent process‐related injuries and incidents. Explicit incorporation of the principles of inherent safety in the basic definition and functional operation of the various PSM elements can help to improve the quality of the safety management effort.