Table Of ContentVOLUMESIX
M
ETHODS IN
CHEMICAL PROCESS
SAFETY
MethodstoAssessandManageProcess
Safety in Digitalized Process System
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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
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Firstedition2022
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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
