Challenges and needs for process safety in the new millennium

Process industries have made quite a bit of progress in process safety since the tragic night of December 2, 1984 in Bhopal. Nonetheless, incidents continue to occur on a regular basis due to insufficient understanding of the urgency to identify best practices and drive for process safety improvements in the organization. This paper addresses some of the critical challenges in implementing effective safety programs: (a) failure to learn from past incidents and to capture those lessons into process design, procedures, training, maintenance, and other programs, (b) insufficient attention to leading indicators, and (c) an increase in complexity of process operations and lack of communication. In the presence of these challenges, there is a great need to develop better solutions by utilizing good science based approaches and best practice studies. Potential research areas include, but are not limited to, incident database analysis, reactive chemicals, inherently safer design, combustible dust explosion, facility siting, and the flammability of fuel mixtures and aerosols. In addition, an example was presented on LNG industry safety to illustrate that science-based research is needed to ensure the safe operation and to avoid or mitigate unintended consequences.

► Changes in industry, society and technology can cause new hazardous event scenarios.
► Optimizing production and ensuring process safety is daunting and complex task.
► Consequence modeling of LNG release for determining potential hazard zones.
► Experimental investigation of water curtain and expansion foam.
► Characteristics of chemicals & reaction mixtures to trace possible runaway pathways.