Functional Safety in Process Industry

Functional Safety (FS) refers to the protection of a system against hazards arising from faulty and interrupted functionality. Internationally, in various industries, there is a need to ensure continuity in requirements, design, operation, modifications, and decommissioning stages in order to maintain functional safety.

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Sectoral Analysis of Chemical-Related Fires and Explosions in the Process Industry: Examination of 64 Different Organizations

ATEX studies are conducted in industrial establishments to prevent and mitigate explosions caused by flammable liquids, vapors, flammable gases, and combustible dust. In this study, conducted in 64 different organizations in the pharmaceutical, food, chemical, energy, cement, foundry, and oil and gas industries, the following were examined:

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Criticality Analyses in Establishing Reliability-Centered Maintenance Programs

Industrial organizations undertake numerous projects to find their place in competitive conditions, utilize their resources effectively, and improve efficiency. Improvements in maintenance operations also occupy a significant place within these projects. The effectiveness of maintenance programs implemented in organizations is crucial for enhancing efficiency and...

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Asset Integrity and Reliability


As it can be clearly understood from lessons learned from past accidents, a significant majority of major accidents occur due to the lack of asset integrity and reliability. In Trevor Kletz's book "What Went Wrong?", it is highlighted that approximately 50% of industrial disasters causing significant destruction are attributed to deficiencies in asset integrity and reliability. To address this issue, the development of a reliability-centered maintenance program plays a crucial role. Criticality analyses serve as an important tool in this process.

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How Should the Ex-Proof Equipment Label Be?


Companies that store, produce, or handle flammable chemicals are within the scope of ATEX regardless of the storage quantities. In this regard, it is required for facilities to prepare or have prepared Explosion Protection Documents according to the "Regulation on the Protection of Workers from Explosive Atmospheres."

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The Importance of Visual Inspection in Hazardous Areas


In our country, many manufacturing facilities knowingly or unknowingly work with or engage in production activities involving flammable chemicals. Once these chemicals reach a certain concentration in the air, they can cause serious loss of life and property by igniting in the presence of an ignition source. One of the most prominent ignition sources is hazardous...

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Development of Industrial Safety with Experienced Accidents


Some industries have rules written in blood. Among them, aviation and process industries stand out. A rule written in blood specifies the mandatory rules that must be applied in future productions or systems by learning lessons from painful experiences. For example, in the fuel sector, when gasoline spills and causes a disaster in a terminal...

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The Importance of Basic Process Control and Independent Systems in Safe Process Design


The aim of industrial process designs is to increase knowledge from research and development stage to commissioning and operation. The existence and adequacy of information in the process life cycle is shown in Figure 1. The knowledge required for routine operations should be put forward in research and development, conceptual design, and detailed engineering stages. Routine...

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Human Factors and Human Error


According to Whittingham, human error is defined as “an undesirable failure of a purposeful action, either alone or as part of a planned series of actions, to achieve a specified outcome, both within the defined tolerance limits for the action itself and the outcome.”[1] As a result of increasing chemical facilities day by day, the number of work accidents due to human origin in the chemical industry is also increasing. Acccidents in chemical industry...

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Preparing Industrial Facilities for Harsh Winter Conditions


Industrial facilities inherently harbor various hazards. Danger is generally defined as chemical and physical conditions that have the potential to cause harm to humans, property, or the environment. In industrial facilities, there are different sources where hazards can arise. Commonly, chemicals present in facilities, operational errors, equipment-related...

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Safe Design and Control in Distillation Columns


Distillation is the process of separating two or more components of a liquid or vapor mixture into their desired purity. The distillation process is based on the principle that components with lower boiling points will be present in greater quantities in the vapor phase, while components with higher boiling points will be present in greater quantities in the liquid phase. The distillation process...

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Quantifying Uncertainties in Process Hazard Analysis Using Fuzzy Logic


Industrial facilities where hazardous chemicals are used, stored, and produced contain various factors that contribute to process safety accidents and involve uncertainties. Designing and modeling a hazard analysis method capable of evaluating all these factors is not possible due to these uncertainties...

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Safety Integrity Levels of Fire and Gas Systems and their Impact on Plant Reliability Objective


According to a study conducted by "Marsh and McLennan Companies," the damage caused by fires and explosions in the 100 largest industrial accidents between 1974 and 2015 amounted to over 25.5 billion dollars. In large industrial accidents that can cause fires and explosions, gas detection, fire prevention, and protection...

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Estimating Time and the Impact of Evaluation Team on Project Budget in Process Hazard Analyses


Process hazard analyses are applied in various stages of organizations, such as R&D, design, review, commissioning, and decommissioning. The chosen analysis tool helps mature the project in terms of hazard and operability. The correct selection of the tool...

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Dust Explosions


From the wood industry to the metal industry, a wide range of dust materials is handled or generated as a result of process conditions. If proper precautions are not taken, the dust material used or released within the facility can cause severe explosions, resulting in loss of life and property damage. Flammable dusts, in general, are those with a particle size of 420 µm or smaller...

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Static Electricity: Industry's Hidden Danger


The word "electricity" is derived from the Greek word "elektron," which means amber (fossilized tree resin). Amber is also used to describe something that emits light. The first observation of electrification occurred during the rapid rubbing of amber. The phenomenon of light emission and the production of small sparks through strong electrification were first demonstrated by Von Guericke approximately 300 years ago...

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Control and Crisis Management of Flammable/Explosive Atmospheres in Industrial Facilities


In our country's industry, there are numerous incidents of fire and explosions resulting in significant loss of life and property. When examining the 2016 firefighting statistics in Kocaeli, which accounts for 27% of our country's chemical industry, a total of 790 fire incidents were responded to. Out of these fires, 140 occurred in industrial facilities...

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