Accident modelling and analysis in process industries

Accident modelling is a methodology used to relate the causes and effects of events that lead to accidents. This modelling effectively seeks to answer two main questions: (i) Why does an accident occur, and (ii) How does it occur. This paper presents a review of accident models that have been developed for the chemical process industry with in-depth analyses of a class of models known as dynamic sequential accident models (DSAMs). DSAMs are sequential models with a systematic procedure to utilise precursor data to estimate the posterior risk profile quantitatively. DSAM also offers updates on the failure probabilities of accident barriers and the prediction of future end states. Following a close scrutiny of these methodologies, several limitations are noted and discussed, and based on these insights, future work is suggested to enhance and improve this category of models further.

[1]  D. Dokken,et al.  Climate change 2001 , 2001 .

[2]  Faisal Khan,et al.  Dynamic risk assessment using failure assessment and Bayesian theory , 2009 .

[3]  Linda-Jo Schierow Chemical Plant Security , 2003 .

[4]  Nancy G. Leveson,et al.  A new accident model for engineering safer systems , 2004 .

[5]  Warren D. Seider,et al.  Real-time risk analysis of safety systems , 2008, Comput. Chem. Eng..

[6]  Faisal Khan,et al.  Risk-Based Inspection and Maintenance (RBIM): Multi-Attribute Decision-Making with Aggregative Risk Analysis , 2004 .

[7]  O. O. Oyeleye,et al.  Qualitative simulation of chemical process systems: Steady‐state analysis , 1988 .

[8]  Tasneem Abbasi,et al.  A scheme for the classification of explosions in the chemical process industry. , 2010, Journal of hazardous materials.

[9]  Daniel Straub,et al.  Risk based inspection planning , 2002 .

[10]  David W. Jones,et al.  How to Select Appropriate Quantitative Safety Risk Criteria Applications from the Center for Chemical Process Safety (CCPS) Guidelines on Quantitative Safety Risk Criteria , 2010 .

[11]  Faisal Khan,et al.  TOPHAZOP: a knowledge-based software tool for conducting HAZOP in a rapid, efficient yet inexpensive manner , 1997 .

[12]  Vicki M. Bier Statistical methods for the use of accident precursor data in estimating the frequency of rare events , 1993 .

[13]  Nir Keren,et al.  Operational risk assessment of chemical industries by exploiting accident databases , 2007 .

[14]  Warren D. Seider,et al.  Plant-specific dynamic failure assessment using Bayesian theory , 2006 .

[15]  Nigel Hyatt Guidelines for Process Hazards Analysis , 2013 .

[16]  M Sam Mannan,et al.  Fuzzy risk matrix. , 2008, Journal of hazardous materials.

[17]  Tasneem Abbasi,et al.  The boiling liquid expanding vapour explosion (BLEVE): mechanism, consequence assessment, management. , 2007, Journal of hazardous materials.

[18]  Faisal Khan,et al.  Precursor-based hierarchical Bayesian approach for rare event frequency estimation: A case of oil spill accidents , 2013 .

[19]  Borut Mavko,et al.  Application of the fault tree analysis for assessment of power system reliability , 2009, Reliab. Eng. Syst. Saf..

[20]  M. Harbawi,et al.  Rapid analysis of risk assessment using developed simulation of chemical industrial accidents software package , 2008 .

[21]  Mike Harper,et al.  Modeling of time‐varying dispersion for releases including potential rainout , 2014 .

[22]  Kin Keung Lai,et al.  Risk avoidance in bidding for software projects based on life cycle management theory , 2006 .

[23]  G. Bennett Lees’ Loss Prevention in the Process Industries: Hazard Identification, Assessment and Control, vol. III, third ed., Sam Mannan (Ed.). Elsevier, Butterworths, Heinemann, Burlington, MA (2005), three-volume set, US$ 476.00, 1071 pp.), ISBN 0-7506-7555-1 (three-volume set), ISBN 0-7506-7589-3 (vol. II , 2005 .

[24]  Jiang Juncheng,et al.  An improved probit method for assessment of domino effect to chemical process equipment caused by overpressure. , 2008, Journal of hazardous materials.

[25]  Shahid Abbas Abbasi,et al.  OptHAZOP—an effective and optimum approach for HAZOP study , 1997 .

[26]  Xiaoping Zheng,et al.  An overview of accident forecasting methodologies , 2009 .

[27]  S A Abbasi,et al.  Analytical simulation and PROFAT II: a new methodology and a computer automated tool for fault tree analysis in chemical process industries. , 2000, Journal of hazardous materials.

[28]  C. Kirchsteiger Impact of accident precursors on risk estimates from accident databases , 1997 .

[29]  Faisal Khan,et al.  Accident modelling and safety measure design of a hydrogen station , 2014 .

[30]  I. Svedung,et al.  Proactive Risk Management in a Dynamic Society , 2000 .

[31]  James W. Johnson,et al.  The US NRC's accident sequence precursor program: an overview and development of a Bayesian approach to estimate core damage frequency using precursor information , 1996 .

[32]  M Colombi,et al.  Consequence analysis in LPG installation using an integrated computer package. , 2000, Journal of hazardous materials.

[33]  Fabrizio Ruggeri,et al.  Modeling External Risks in Project Management , 2007, Risk analysis : an official publication of the Society for Risk Analysis.

[34]  Faisal Khan,et al.  Dynamic safety analysis of process systems by mapping bow-tie into Bayesian network , 2013 .

[35]  Ümit V. Çatalyürek,et al.  Dynamic generation of accident progression event trees , 2008 .

[36]  Chen-Shan Kao,et al.  Acrylic reactor runaway and explosion accident analysis , 2002 .

[37]  Davide Manca,et al.  The Viareggio LPG railway accident: event reconstruction and modeling. , 2010, Journal of hazardous materials.

[38]  Ioannis A. Papazoglou,et al.  Probabilistic safety analysis in chemical installations , 1992 .

[39]  Faisal Khan,et al.  SHIPP methodology: Predictive accident modeling approach. Part II. Validation with case study , 2011 .

[40]  Eric R. Ziegel,et al.  System Reliability Theory: Models, Statistical Methods, and Applications , 2004, Technometrics.

[41]  Josep Arnaldos,et al.  Mathematical modelling of accidental gas releases , 1998 .

[42]  P. K. Marhavilas,et al.  Risk analysis and assessment methodologies in the work sites: On a review, classification and comparative study of the scientific literature of the period 2000–2009 , 2011 .

[43]  Robin Pitblado,et al.  Risk assessment in the process industries , 1996 .

[44]  Faisal Khan,et al.  Risk-based maintenance (RBM): a quantitative approach for maintenance/inspection scheduling and planning , 2003 .

[45]  T. W. van der Schaaf,et al.  Near Miss Reporting as a Safety Tool , 1991 .

[46]  Valerio Cozzani,et al.  The quantitative assessment of domino effects caused by overpressure. Part I. Probit models. , 2004, Journal of hazardous materials.

[47]  W Slob,et al.  Assessment factors for human health risk assessment: a discussion paper. , 1999, Critical reviews in toxicology.

[48]  Alexander Solomon PRINCIPLES OF ACCIDENT PREVENTION IN THE NIGERIAN OIL INDUSTRIES. A CASE STUDY OF KADUNA REFINING AND PETROCHEMICAL COMPANY (KRI)C) , 2013 .

[49]  Feng Yaorong,et al.  Mathematical modeling of gas release through holes in pipelines , 2003 .

[50]  Luis Enrique Sucar,et al.  Bayesian Networks for Reliability Analysis of Complex Systems , 1998, IBERAMIA.

[51]  Shahid Abbas Abbasi,et al.  Multivariate hazard identification and ranking system , 1998 .

[52]  Toshio Wakabayashi,et al.  Component-based modeling of systems for automated fault tree generation , 2009, Reliab. Eng. Syst. Saf..

[53]  Philippe Ciais,et al.  The dispersion of the Buncefield oil fire plume: An extreme accident without air quality consequences , 2007 .

[54]  Faisal Khan,et al.  Risk Assessment and Management Using Accident Precursors Modeling in Offshore Process Operation , 2009 .

[55]  Marvin Rausand,et al.  System Reliability Theory: Models, Statistical Methods, and Applications , 2003 .

[56]  Ccps Guidelines for Chemical Process Quantitative Risk Analysis , 1999 .

[57]  Erik Hollnagel,et al.  Cognitive reliability and error analysis method : CREAM , 1998 .

[58]  Robin Pitblado,et al.  Consequences of liquefied natural gas marine incidents , 2005 .

[59]  Vasilis Fthenakis,et al.  Hazard and operability (HAZOP) analysis. A literature review. , 2010, Journal of hazardous materials.

[60]  Ioannis A. Papazoglou,et al.  Functional Block Diagrams and Automated Construction of Event Trees (PSAM-0057) , 1998 .

[61]  Brian Veitch,et al.  Occupational accident models—Where have we been and where are we going? , 2006 .

[62]  Waldemar Karwowski System Safety Engineering and Risk Assessment , 2006 .

[63]  Jan Erik Vinnem,et al.  Offshore Risk Assessment: Principles, Modelling and Applications of QRA Studies , 1999 .

[64]  Roger M. Cooke,et al.  Applications of some risk assessment techniques: Formal expert judgement and accident sequence precursors , 1997 .

[65]  B. Fischhoff,et al.  Rating the Risks , 1979 .

[66]  Jan Erik Vinnem,et al.  A decision framework for risk management, with application to the offshore oil and gas industry , 2007, Reliab. Eng. Syst. Saf..

[67]  홍유신 A Bayesian Approach to Prediction of System Failure Rates by Criticalities under Event Trees , 1997 .

[68]  S. K. Gupta,et al.  Application of PSA based operational event analysis to Indian nuclear power plants , 2010, 2010 2nd International Conference on Reliability, Safety and Hazard - Risk-Based Technologies and Physics-of-Failure Methods (ICRESH).

[69]  P. Showalter Natural disasters in the United States as release agents of oil, chemicals, or radiological materials between 1980-1989: analysis and recommendations. , 1996 .

[70]  En Sup Yoon,et al.  A study on the financial approach of risk assessment using chemical accident records in chemical process industries , 2011 .

[71]  Faisal Khan,et al.  Accident modeling approach for safety assessment in an LNG processing facility , 2012 .

[72]  Faisal Khan,et al.  Models for domino effect analysis in chemical process industries , 1998 .

[73]  M. Liang,et al.  Evaluating the carbonation damage to concrete bridges using a grey forecasting model combined with a statistical method , 2001 .

[74]  Faisal Khan,et al.  Techniques and methodologies for risk analysis in chemical process industries , 1998 .

[75]  B. Walker Deepwater horizon oil spill. , 2010, Journal of environmental health.

[76]  K. Gugan,et al.  Unconfined vapour cloud explosions , 1979 .

[77]  Michael R. Beauregard,et al.  The Basics of FMEA , 1996 .

[78]  Frank Pearson Lees,et al.  Loss prevention in the process industries : hazard identification, assessment, and control , 1980 .

[79]  Howard Kunreuther,et al.  Near‐Miss Incident Management in the Chemical Process Industry , 2003, Risk analysis : an official publication of the Society for Risk Analysis.

[80]  Clifton A. Ericson,et al.  Hazard Analysis Techniques for System Safety , 2005 .

[81]  Chi-Min Shu,et al.  Loss prevention in the petrochemical and chemical-process high-tech industries in Taiwan , 2010 .

[82]  Benoît Iung,et al.  Overview on Bayesian networks applications for dependability, risk analysis and maintenance areas , 2012, Eng. Appl. Artif. Intell..

[83]  Faisal Khan,et al.  Accident modeling and risk assessment framework for safety critical decision-making: application to deepwater drilling operation , 2013 .

[84]  William Marsh,et al.  Generalising Event Trees Using Bayesian Networks with a Case Study of Train Derailment , 2005, SAFECOMP.

[85]  Jens Rasmussen,et al.  Risk management in a dynamic society: a modelling problem , 1997 .

[86]  En Sup Yoon,et al.  The Estimation of Hazardous Gas Release Rate Using Optical Sensor and Neural Network , 2010 .

[87]  Jun g Sik Kong,et al.  Quantitative risk evaluation based on event tree analysis technique: Application to the design of shield TBM , 2009 .

[88]  Mohanad El-Harbawi,et al.  SMAH: a new software package for evaluating major accident hazard , 2005, 2005 IEEE International Conference on Systems, Man and Cybernetics.

[89]  Faisal Khan,et al.  Modelling of BP Texas City refinery accident using dynamic risk assessment approach , 2010 .

[90]  J. M. van Noortwijk,et al.  Inspection and maintenance decisions based on imperfect inspections , 2003 .

[91]  S. Clementel,et al.  The use of the event tree in the design of nuclear power plants , 1984 .

[92]  Brian Veitch,et al.  Methodology for computer aided fuzzy fault tree analysis , 2009 .

[93]  Marko Čepin,et al.  Assessment of Power System Reliability , 2011 .

[94]  Ralph R. Fullwood Probabilistic safety assessment in the chemical and nuclear industries , 1999 .

[95]  David F. Montague Process risk evaluation ― What method to use? , 1990 .

[96]  Annamaria Petrone,et al.  Evaluating The Hse Risk Costs and Reputational Implications of Major Accident Hazards In E&P Activities , 2013 .

[97]  Laura J. Steinberg,et al.  When Natural and Technological Disasters Collide: Lessons from the Turkey Earthquake of August 17, 1999 , 2004 .

[98]  Faisal Khan,et al.  Risk analysis of a typical chemical industry using ORA procedure , 2001 .

[99]  Roger M. Cooke,et al.  The accident sequence precursor methodology for the European post-Seveso era , 1990 .

[100]  Erik Hollnagel,et al.  Cognitive reliability and error analysis method , 1998 .

[101]  Nima Khakzad,et al.  Risk-based design of process systems using discrete-time Bayesian networks , 2013, Reliab. Eng. Syst. Saf..

[102]  Masoud Soroush,et al.  Dynamic risk analysis using alarm databases to improve process safety and product quality: Part I—Data compaction , 2012 .

[103]  K S Crump,et al.  A new method for determining allowable daily intakes. , 1984, Fundamental and applied toxicology : official journal of the Society of Toxicology.

[104]  J. W. Minarick,et al.  Precursors to potential severe core damage accidents, 1969-1979, a status report , 1982 .

[105]  Faisal Khan,et al.  Development of a risk-based maintenance (RBM) strategy for a power-generating plant , 2005 .

[106]  D. Thompson,et al.  Construction of Bayesian networks for diagnostics , 2000, 2000 IEEE Aerospace Conference. Proceedings (Cat. No.00TH8484).

[107]  Vicki M. Bier,et al.  The analysis of accident precursors and near misses: Implications for risk assessment and risk management , 1990 .

[108]  Ali Siadat,et al.  Dynamic risk management unveil productivity improvements , 2009 .

[109]  Maryam Kalantarnia,et al.  Dynamic risk assessment using accident precursor data and Bayesian theory , 2009 .

[110]  Brian Veitch,et al.  A Grid Based Approach for Fire and Explosion Consequence Analysis , 2006 .

[111]  Gilles Dusserre,et al.  OSIRIS: software for the consequence evaluation of transportation of dangerous goods accidents , 2002, Environ. Model. Softw..

[112]  Theo Vermeire,et al.  Risk assessment of chemicals : an introduction , 2007 .

[113]  Zahid H. Qureshi,et al.  A review of accident modelling approaches for complex socio-technical systems , 2007 .

[114]  Li-Chang Hsu,et al.  Forecasting the output of integrated circuit industry using a grey model improved by the Bayesian analysis , 2007 .

[115]  Cruz Naranjo Ana-Maria,et al.  Analysis of Natech Accidents Recorded in Major Accident Databases , 2008 .

[116]  Chunyong Huo,et al.  Simplified expression for estimating release rate of hazardous gas from a hole on high-pressure pipelines , 2006 .

[117]  Melvin E. Andersen,et al.  A Multiple Dose-Route Physiological Pharmacokinetic Model for Volatile Chemicals Using ACSL/PC, , 1986 .

[118]  Angela E. Summers,et al.  Consistent consequence severity estimation , 2012 .

[119]  John A. Davenport,et al.  A survey of vapor cloud explosions: Second update , 1993 .

[120]  Vicki M. Bier,et al.  An Application of Copulas to Accident Precursor Analysis , 1998 .

[121]  L. Morawska,et al.  A review of dispersion modelling and its application to the dispersion of particles : An overview of different dispersion models available , 2006 .

[122]  Masoud Soroush,et al.  Dynamic risk analysis using alarm databases to improve process safety and product quality: Part II—Bayesian analysis , 2012 .

[123]  Chris W. Johnson,et al.  A survey of logic formalisms to support mishap analysis , 2003, Reliab. Eng. Syst. Saf..

[124]  Brian Veitch,et al.  Revised fire consequence models for offshore quantitative risk assessment , 2005 .

[125]  Faisal Khan,et al.  SHIPP methodology: Predictive accident modeling approach. Part I: Methodology and model description , 2011 .

[126]  Shahid Abbas Abbasi,et al.  HAZDIG: a new software package for assessing the risks of accidental release of toxic chemicals , 1999 .

[127]  Faisal I. Khan,et al.  MAXCRED - a new software package for rapid risk assessment in chemical process industries , 1998, Environ. Model. Softw..

[128]  Chia-Yon Chen,et al.  Applications of improved grey prediction model for power demand forecasting , 2003 .

[129]  Zahid H Qureshi,et al.  A Review of Accident Modelling Approaches for Complex Critical Sociotechnical Systems , 2008 .

[130]  Gilles Dusserre,et al.  Are dispersion models suitable for simulating small gaseous chlorine releases , 2006 .

[131]  Mohanad El-Harbawi,et al.  SCIA: GIS-Based Software for Assessing the Impacts from Chemical Industrial Accidents , 2010 .

[132]  Faisal I Khan,et al.  Risk-based maintenance of ethylene oxide production facilities. , 2004, Journal of hazardous materials.

[133]  Nigel Hyatt Guidelines for Process Hazards Analysis (PHA, HAZOP), Hazards Identification, and Risk Analysis , 2003 .

[134]  T. C. McKelvey How to improve the effectiveness of hazard and operability analysis , 1988 .

[135]  Jeff Johnson,et al.  Two Plant Blasts Kill Three People , 2014 .

[136]  Brian Veitch,et al.  Methodology for Computer-Aided Fault Tree Analysis , 2007 .

[137]  Vicki M. Bier,et al.  A Bayesian method for analyzing dependencies in precursor data , 1995 .

[138]  Faisal Khan,et al.  A conceptual offshore oil and gas process accident model , 2010 .

[139]  Adam S. Markowski,et al.  Fuzzy logic for piping risk assessment (pfLOPA) , 2009 .

[140]  Erik Hollnagel,et al.  Barriers And Accident Prevention , 2004 .

[141]  Kenkichi Tamura Risk-Based Inspection and Risk-Based Maintenance( Risk) , 2009 .

[142]  Norman A. Eisenberg,et al.  Vulnerability model. A simulation system for assessing damage resulting from marine spills. Final report , 1975 .

[143]  Joseph J Myers Risk-Based Decision Making: A Tool for Effective Management , 2007 .

[144]  Li-Chang Hsu,et al.  Applying the Grey prediction model to the global integrated circuit industry , 2003 .

[145]  Luigi Portinale,et al.  Improving the analysis of dependable systems by mapping fault trees into Bayesian networks , 2001, Reliab. Eng. Syst. Saf..

[146]  Anjana Meel Dynamic risk assessment of inherently safer chemical processes: An accident precursor approach , 2007 .

[147]  Theo Vermeire,et al.  Risk assessment of chemicals , 2021, Bioanalytical Tools in Water Quality Assessment.

[148]  Michael K. Lindell,et al.  Hazardous Materials Releases in the Northridge Earthquake: Implications for Seismic Risk Assessment , 1997 .

[149]  Clifton A. Ericson,et al.  Hazard Analysis Techniques for System Safety: Ericson/Hazard Analysis Techniques for System Safety , 2005 .

[150]  H. Pasman Loss prevention in the process industries , 2002 .

[151]  Chris Chapman,et al.  Project risk analysis and management - PRAM the generic process , 1997 .

[152]  Stan Kaplan,et al.  ‘Expert information’ versus ‘expert opinions’. Another approach to the problem of eliciting/ combining/using expert knowledge in PRA , 1992 .

[153]  Lei Zhang,et al.  Dynamic accident modeling for high-sulfur natural gas gathering station , 2014 .

[154]  Jan Erik Vinnem,et al.  Risk Management: With Applications from the Offshore Petroleum Industry , 2007 .

[155]  Daniel A. Crowl,et al.  Chemical Process Safety: Fundamentals with Applications , 2001 .