Safety-oriented Resilience Evaluation in Chemical Processes

In the area of process safety, many efforts have focused on studying methods to prevent the transition of the state of the system from a normal state to an upset and/or catastrophic state, but many unexpected changes are unavoidable, and even under good risk management incidents still occur. The aim of this work is to propose the principles and factors that contribute to the resilience of the chemical process, and to develop a systematic approach to evaluate the resilience of chemical processes in design aspects.

Based on the analysis of transition of the system states, the top-level factors that contribute to Resilience were developed, including Design, Detection Potential, Emergency Response Planning, Human, and Safety Management. The evaluation framework to identify the Resilience Design Index is developed by means of the multifactor model approach. The research was then focused on developing complete subfactors of the top-level Design factor. The sub-factors include Inherent Safety, Flexibility, and Controllability.

The proposed framework to calculate the Inherent Safety index takes into account all the aspects of process safety design via many sub-indices. Indices of Flexibility and Controllability sub-factors were developed from implementations of well-known methodologies in process design and process control, respectively. Then, the top-level Design index was evaluated by combining the indices of the sub-factors with weight factors, which were derived from Analytical Hierarchical Process approach. A case study to compare the resilience levels of two ethylene production designs demonstrated the proposed approaches and gave insights on process resilience of the designs.