Recognizing design issues in process industry for safer design

Abstract

In this study, accident cause analysis was used to generate a number of design failure elements (DFEs) that highlight the general classification of design errors. Then, a database of cases, suggesting design changes from unsafe to safe design, was compiled from journals, accident corrective action, and patents to identify the chemical industry design issues (DIs). The DIs were then classed under DFEs and into five main equipment categories, namely, reaction, separation, heat transfer, storage, and pipe and piping system. The database analysis reveals that the layout accounts for 17.4 % of DFEs, followed by equipment error (17.29 %) and reaction and reactive condition (16.86 %). For the equipment category, the reaction equipment had the highest DI which was related to the DFE of reaction and the reactive condition.