Methods to Assess and Manage Process Safety in Digitalized Process System PDF
Preview Methods to Assess and Manage Process Safety in Digitalized Process System
VOLUMESIX M ETHODS IN CHEMICAL PROCESS SAFETY MethodstoAssessandManageProcess Safety in Digitalized Process System This page intentionally left blank VOLUMESIX M ETHODS IN CHEMICAL PROCESS SAFETY MethodstoAssessandManageProcess Safety in Digitalized Process System Edited by FAISAL KHAN Mary Kay O’Connor Process Safety Center, Artie McFerrin Department of Chemical Engineering, Texas A&M University; TEES Mary Kay O’Connor Process Safety Center, Texas A&M University System, College Station, TX, United States HANS PASMAN Mary Kay O’Connor Process Safety Center, Artie McFerrin Department of Chemical Engineering, Texas A&M University; TEES Mary Kay O’Connor Process Safety Center, Texas A&M University System, College Station, TX, United States MING YANG Safety and Security Science Section, Department of Values, Technology, and Innovation, Faculty of Technology, Policy, and Management, Delft University of Technology, Delft, The Netherlands AcademicPressisanimprintofElsevier 50HampshireStreet,5thFloor,Cambridge,MA02139,UnitedStates 525BStreet,Suite1650,SanDiego,CA92101,UnitedStates TheBoulevard,LangfordLane,Kidlington,OxfordOX51GB,UnitedKingdom 125LondonWall,London,EC2Y5AS,UnitedKingdom Firstedition2022 Copyright©2022ElsevierInc.Allrightsreserved. Nopartofthispublicationmaybereproducedortransmittedinanyformorbyanymeans,electronic ormechanical,includingphotocopying,recording,oranyinformationstorageandretrievalsystem, withoutpermissioninwritingfromthepublisher.Detailsonhowtoseekpermission,further informationaboutthePublisher’spermissionspoliciesandourarrangementswithorganizationssuch astheCopyrightClearanceCenterandtheCopyrightLicensingAgency,canbefoundatourwebsite: www.elsevier.com/permissions. Thisbookandtheindividualcontributionscontainedinitareprotectedundercopyrightbythe Publisher(otherthanasmaybenotedherein). Notices Knowledgeandbestpracticeinthisfieldareconstantlychanging.Asnewresearchandexperience broadenourunderstanding,changesinresearchmethods,professionalpractices,ormedical treatmentmaybecomenecessary. Practitionersandresearchersmustalwaysrelyontheirownexperienceandknowledgeinevaluating andusinganyinformation,methods,compounds,orexperimentsdescribedherein.Inusingsuch informationormethodstheyshouldbemindfuloftheirownsafetyandthesafetyofothers,including partiesforwhomtheyhaveaprofessionalresponsibility. Tothefullestextentofthelaw,neitherthePublishernortheauthors,contributors,oreditors,assume anyliabilityforanyinjuryand/ordamagetopersonsorpropertyasamatterofproductsliability, negligenceorotherwise,orfromanyuseoroperationofanymethods,products,instructions,orideas containedinthematerialherein. ISBN:978-0-323-98897-1 ISSN:2468-6514 ForinformationonallAcademicPresspublications visitourwebsiteathttps://www.elsevier.com/books-and-journals Publisher:ZoeKruze AcquisitionsEditor:JasonMitchell DevelopmentalEditor:NaizaErminMendoza ProductionProjectManager:VijayarajPurushothaman CoverDesigner:MilesHitchen TypesetbySTRAIVE,India Contents Contributors xi Preface xv 1. Opportunitiesandthreatstoprocesssafetyindigitalizedprocess systems—An overview 1 HansPasman,Hao Sun,MingYang, and FaisalKhan 1. Definitionofdigitalprocess,digitalization,andsafety 1 2. Briefhistoryofprocesssafetyandreasonswhydigitalizationcansupport processsafety 4 3. Processsafetytreatedindigitalizedprocesssystems 13 4. PurposeandorganizationofthisMCPSVolume6 18 References 19 2. State-of-the-artin process safety anddigital system 25 MdTanjinAmin,RajeevanArunthavanathan,MdAlauddin,andFaisalKhan 1. Background 25 2. Currentprogressindigitalprocesssafety 34 3. Afutureroadmapindigitalprocesssafety 41 References 49 Furtherreading 59 3. Data-driven approaches:Use of digitized operational data in process safety 61 YimingBai, Shuaiyu Xiang,ZehengZhao,Borui Yang, and JinsongZhao 1. Importanceofdatainprocesssafety 61 2. Datasource 63 3. Datapreparationstages 65 4. Data-drivenmodelforprocesssafety 70 5. Applicationsofdata-drivenmodels 75 6. Summaryandperspective 87 References 88 4. Industry 4.0 based processdata analytics platform 101 Thumeera R.Wanasinghe, MihiranGalagedarage Don, RajeevanArunthavanathan, and RaymondG.Gosine 1. Abriefoverviewforindustrialrevolution 101 2. Overviewofprocessdataanalyticplatforms&Industry4.0 102 v vi Contents 3. Hardwareandsensinglayer 105 4. Datamanagementlayer 110 5. Networkinglayer 122 6. Applicationlayer 126 7. Cybersecurity 131 8. Summary 132 References 133 5. Digitalprocess safety management 139 MarkSlezak,Stewart Behie,and HansPasman 1. Introduction 139 2. Basicdigitalconcepts 141 3. Thecasefordigitalprocesssafetymanagement 143 4. ApplicationofdigitaltechnologiesinPSM 146 5. Futureimprovementsinprocesssafetythroughdigitaltechnology:Limited literaturesurvey 172 Acknowledgment 176 References 176 6. Statisticalapproaches and artificialneuralnetworks for process monitoring 179 MdAlauddin,RajeevanArunthavanathan,MdTanjinAmin,andFaisalKhan 1. Introduction 179 2. Statisticalprocessmonitoring 192 3. Artificialneuralnetworkforprocessmonitoring 202 4. Conclusions 211 References 211 Furtherreading 226 7. Alarm management techniques to improveprocesssafety 227 FanYang, Jiandong Wang,Mohsen Asaadi, WenkaiHu, Zhen Wang, and YinongZhang 1. Philosophyofalarmmanagement 227 2. Conventionalalarmsystemsvs.advancedalarmsystems 231 3. Conventionalalarmmanagementtechniqueswithimprovements 232 4. Advancedalarmmanagementtechniques 249 5. Applicationsofalarmmanagement 274 6. Conclusions 277 References 278 Contents vii 8. Performance evaluation of digitalized safety barriers 281 AiboZhang andYiliuLiu 1. Introduction 281 2. Failureandoperationalanalysisofsafetybarriers 282 3. Measuresforperformanceevaluation 285 4. Modelingapproaches 287 5. Integrityanalysisandevaluationofsafetybarriers 296 6. Digitaltwinapproachforcondition-basedevaluationandprognosis 301 7. Closureandfurtherreading 305 References 306 9. Dynamicoperational riskassessment in process safety management 309 Xinhong Li,Luyao Zhang,FaisalKhan,and GuomingChen 1. Necessityofdynamicriskassessment 309 2. Dynamicriskassessmentmethodology 311 3. CaseStudy1:Dynamicriskassessmentofsubseapipelineleak 325 4. CaseStudy2:Dynamicpredictionofsubseapipelinescorrosion degradation 339 5. Conclusions 349 References 349 10. Risk ofcascading effectsin digitalized process systems 353 MatteoIaiani, AlessandroTugnoli, and Valerio Cozzani 1. Introduction 353 2. Definitionofcascadingevent 357 3. Specificcausesofcascadingeventsindigitalizedprocesssystems 359 4. Layersofprotection(LOP)inchemicalandprocessfacilities 365 5. Unintentionalcascadingeffectsindigitalizedprocesssystems 368 6. Intentionalcascadingeventsindigitalizedprocesssystems 371 7. Conclusions 383 References 384 11. Uncertaintymodeling in riskassessment of digitalized process systems 389 Mohammad Yazdi,Esmaeil Zarei, SidumAdumene, RouzbehAbbassi, and PayamRahnamayiezekavat 1. Introduction 389 2. Thedefinitionofuncertainty 391 viii Contents 3. Reviewingthecategoryofuncertainty 393 4. Uncertaintycontributors 397 5. Uncertaintypropagation 401 6. Conclusion:Challengesandfuturedirection 409 Reference 409 12. Human factors in digitalized process operations 417 RajagopalanSrinivasan, BabjiSrinivasan, andMohd UmairIqbal 1. Introduction 417 2. Humanfactors 420 3. Humanerrors 426 4. Humanerrorreductionindigitalizedoperations 443 5. Summary 454 References 454 13. Safetyassessment ofcomplex socio-technical systems 461 Nicola Paltrinieri 1. Introduction 461 2. ExamplesofAI-basedprediction 463 3. Method 469 4. Resultsanddiscussion 472 5. Conclusion 475 References 475 14. Security ofdigitalized process systems 479 Ahmed HamdyEl-Kady, Syeda Halim,Hans Pasman,and FaisalKhan 1. Introduction 479 2. Reviewofphysicalandcyberthreatsindigitalizedprocesssystems 480 3. Reviewofphysicalandcyberdefense/protectionmeasures 487 4. Conclusions 503 Appendix:Principlesofgametheoryandwhyitcancontributetosecurity 505 References 512 15. Integrated dynamic risk management inprocess plants 525 Mohammed Taleb-Berrouane and Hans Pasman 1. Generalintroduction 525 2. Real-timeriskassessmentofprocessoperations 526 3. Safetyvssecurityrisk 533 Contents ix 4. Economicsofriskreduction;applicationsofLFs 550 5. Progressandfutureopportunities 554 References 554 Furtherreading 560 16. Use of digital twins for process safety management 561 Arvind Keprateand Nikhil Bagalkot 1. Introductiontodigitaltwin 561 2. Processsafetymanagementofsmall-borepiping 566 3. Digitaltwinforsmallborepiping 569 4. Illustrativecasestudy 572 5. Conclusion 587 References 587 17. Resilience analysis ofdigitalized process systems 591 Rioshar Yarveisy,Hao Sun,MingYang, andHans Pasman 1. Whatisresilience? 591 2. Whyseekresiliency? 595 3. Howtoattainresilience? 600 4. Resilienceassessmentmethods 604 5. Conclusion 624 References 625 18. Risk assessment inIndustry4.0 631 Md TanjinAmin and FaisalKhan 1. Introduction 631 2. RiskassessmentandIndustry4.0 639 3. Conclusionsandfuturedirections 644 References 645
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