Lessons learned from process equipment failures in the chemical process industry

Process equipment failures play significant roles in most accidents that occur and recur in the chemical process industry (CPI). In this study, 50 equipment comprehensive accident investigation reports, extracted from the U.S. Chemical Safety and Hazard Investigation Board (CSB) and U.S. National Transportation Safety Board (NTSB) were analyzed to generate lessons learned. Based on the analysis, the synergy between major hazards i.e. fire, explosion, and toxic release has resulted in catastrophic accidents in the CPI. The emphasis on procedural equipment failure prevention does not provide sufficient hierarchy of controls in the CPI. Balance and integrated accident prevention is required to solve human unreliability that often leads to improper problem-solving, inappropriate actions, and ill-timed responses. To minimize losses, facilities and equipment should be designed and prepared for the worst-case scenario. Moreover, occurrence and recurrence of the accidents could be prevented using inclusive and updated communication systems through cooperation between various governmental agencies, industry players, and the public to disseminate lessons learned and promote safety in the industry