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Processes
Special Issues
Risk Assessment and System Safety in the Process Industry
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Risk Assessment and System Safety in the Process Industry

A special issue of Processes (ISSN 2227-9717). This special issue belongs to the section "Process Control and Monitoring".

Deadline for manuscript submissions: 15 July 2025 | Viewed by 11068

Special Issue Editors

Dr. Xinhong Li

E-Mail Website
Guest Editor
Centre for Pipeline Risk and Reliability Engineering (CPRRE), Department of Safety Engineering, Xi'an University of Architecture and Technology, Xi'an, China
Interests: dynamic risk assessment; process safety management
Special Issues, Collections and Topics in MDPI journals
Dr. Mingyang Yang

E-Mail Website
Guest Editor
Department of Safety Engineering, Xi'an University of Architecture and Technology, Xi'an, China
Interests: safety and risk of energy storage

Special Issue Information

Dear Colleagues,

The complexity of the processes and the nature of volatile petroleum products lead to the frequent occurrence of unexpected failures or accidents, which pose a severe threat to human safety, the environment and assets. Operations in the process industry are challenged by a series of adverse factors, e.g., harsh environment, corrosion, fatigue and natural hazards. The process industry is implementing risk assessment to identify and manage potential failure modes that can interrupt operation processes. Additionally, a series of techniques were utilized to improve the reliability of the process system. Although many efforts were made to oversee operation management to ensure asset integrity, and human and environmental safety, failures and accidents still occur and result in various consequences. Recently, the exploration, exploitation and transportation of emerging energy have brought new questions and challenges. Thus, an improved knowledge of safety, reliability and risk in the process industry is urgent.

This Special Issue pays particular attention to safety, risk and reliability in process industries, including theories, methods and engineering applications, to cope with the challenges of harsh environments, major accidents and new energy.

The potential topics include, but are not limited to, the following:

  • Structural design method in harsh environments;
  • Structural safety assessment of process facilities;
  • Accident modeling in process operations;
  • Risk identification, analysis, assessment;
  • Emergency decision-making and management;
  • Technical safety and loss prevention;
  • Non-destructive detection technique for process facilities;
  • Reliability assessment for process facilities;
  • Transportation safety of emerging energy;
  • Fault diagnostics and prognostics;
  • Risk early warning;
  • AI in safety and reliability;
  • Resilience engineering.

Dr. Xinhong Li
Dr. Mingyang Yang
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Processes is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • risk assessment
  • system safety
  • reliability engineering
  • process industry

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Further information on MDPI's Special Issue policies can be found here.

Published Papers (11 papers)

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Research

Jump to: Review

21 pages, 4153 KiB  
Article
Study on Risk Mitigation Measures for Atmospheric Storage Tank of Acrylic Acid Due to Abnormal Weather Conditions
by Gabgi Jeong, Minseo Nam, Jaeyoung Kim and Byungtae Yoo
Processes 2025, 13(5), 1607; https://doi.org/10.3390/pr13051607 - 21 May 2025
Abstract
This study analyzes the risks posed by high-temperature summer conditions to atmospheric storage tanks containing acrylic acid and proposes mitigation measures. Recent increases in heat waves and tropical nights have led to an increase in the temperatures of acrylic acid storage tanks. This [...] Read more.
This study analyzes the risks posed by high-temperature summer conditions to atmospheric storage tanks containing acrylic acid and proposes mitigation measures. Recent increases in heat waves and tropical nights have led to an increase in the temperatures of acrylic acid storage tanks. This temperature increase results in higher vapor pressure and promotes spontaneous polymerization, thereby increasing the risk of explosions in atmospheric storage tanks. Hazard and operability (HAZOP) analysis identified explosions due to pressure buildup as a major risk scenario. To mitigate this risk, a spray-tower system was introduced through a layer of protection analysis (LOPA), which effectively reduced the hazards associated with atmospheric storage tanks. Additionally, the removal of flame-arrester replacement operations not only achieves economic benefits, such as reduced replacement costs and labor time, but also enhances safety by eliminating worker exposure to hazardous chemicals. These findings have significant implications for improving safety at industrial sites and highlight the potential economic benefits of preventing chemical accidents. Full article
(This article belongs to the Special Issue Risk Assessment and System Safety in the Process Industry)
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28 pages, 1194 KiB  
Article
Monitoring and Identifying Occupational Health and Safety Risks in Various Foundry Processes Using the ELMERI Method
by Beyza Bertan and Hasan Selim
Processes 2025, 13(4), 1132; https://doi.org/10.3390/pr13041132 - 9 Apr 2025
Viewed by 650
Abstract
Accident rates are notably high in industrial metalworking processes. This study aimed to identify and manage occupational health and safety (OHS) risks using the ELMERI observation method to minimize workplace accidents within a foundry operating in the metalworking sector. A quantitative case study [...] Read more.
Accident rates are notably high in industrial metalworking processes. This study aimed to identify and manage occupational health and safety (OHS) risks using the ELMERI observation method to minimize workplace accidents within a foundry operating in the metalworking sector. A quantitative case study was conducted, during which the foundry was monitored quarterly over the course of 1 year. For each of the processes considered—melting, molding, casting and thermal process—1800 observations were made, culminating in a total of 28,800 observations by the end of the year. The average safety index was calculated for each department, and the variability in OHS risks throughout the year was analyzed on a departmental basis. In calculating the safety index, seven key criteria from the ELMERI scale were emphasized, as follows: safety behavior, order and tidiness, machine safety, industrial hygiene, ergonomics, floor and access ways, and first aid and fire safety. Assessing the level of safety in these processes based on these criteria provides a strong foundation for effectively analyzing and managing OHS risks. This case study demonstrates that the periodic application of the ELMERI scale in foundries characterized by hazardous work environments is a valuable tool for managing fluctuating OHS risks. Full article
(This article belongs to the Special Issue Risk Assessment and System Safety in the Process Industry)
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28 pages, 5213 KiB  
Article
Risk Analysis of Hydrogen Leakage at Hydrogen Producing and Refuelling Integrated Station
by Jiao Qu, Ting Zhou, Huali Zhao, Jun Deng, Zhenmin Luo, Fangming Cheng, Rong Wang, Yuhan Chen and Chimin Shu
Processes 2025, 13(2), 437; https://doi.org/10.3390/pr13020437 - 6 Feb 2025
Viewed by 794
Abstract
Hydrogen energy is considered the most promising clean energy in the 21st century, so hydrogen refuelling stations (HRSs) are crucial facilities for storage and supply. HRSs might experience hydrogen leakage (HL) incidents during their operation. Hydrogen-producing and refuelling integrated stations (HPRISs) could make [...] Read more.
Hydrogen energy is considered the most promising clean energy in the 21st century, so hydrogen refuelling stations (HRSs) are crucial facilities for storage and supply. HRSs might experience hydrogen leakage (HL) incidents during their operation. Hydrogen-producing and refuelling integrated stations (HPRISs) could make thermal risks even more prominent than those of HRSs. Considering HL as the target in the HPRIS, through the method of fault tree analysis (FTA) and analytic hierarchy process (AHP), the importance degree and probability importance were appraised to obtain indicators for the weight of accident level. In addition, the influence of HL from storage tanks under ambient wind conditions was analysed using the specific model. Based upon risk analysis of FTA, AHP, and ALOHA, preventive measures were obtained. Through an evaluation of importance degree and probability importance, it was concluded that misoperation, material ageing, inadequate maintenance, and improper design were four dominant factors contributing to accidents. Furthermore, four crucial factors contributing to accidents were identified by the analysis of the weight of the HL event with AHP: heat, misoperation, inadequate maintenance, and valve failure. Combining the causal analysis of FTA with the expert weights from AHP enables the identification of additional crucial factors in risk. The extent of the hazard increased with wind speed, and yet wind direction did not distinctly affect the extent of the risk. However, this did affect the direction in which the risk spreads. It is extremely vital to rationally plan upwind and downwind buildings or structures, equipment, and facilities. The available findings of the research could provide theoretical guidance for the applications and promotion of hydrogen energy in China, as well as for the proactive safety and feasible emergency management of HPRISs. Full article
(This article belongs to the Special Issue Risk Assessment and System Safety in the Process Industry)
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22 pages, 16301 KiB  
Article
Stress State and Fatigue Life Assessment of the Bolts at the Outlet End of Fracturing Pump
by Haibo Liu, Xiaogang Wang, Yuanyuan Wang, Xian Shi, Wang Tian, Bingsheng Wang and Rui Sun
Processes 2025, 13(2), 355; https://doi.org/10.3390/pr13020355 - 27 Jan 2025
Viewed by 881
Abstract
The fracturing pump serves as a critical piece of equipment in enhancing oil and gas recovery rates. However, under the coupled action of high-pressure fluid pulsation circulation in the pump body and the vibration of fracturing equipment, the bolts connecting the fracturing pump [...] Read more.
The fracturing pump serves as a critical piece of equipment in enhancing oil and gas recovery rates. However, under the coupled action of high-pressure fluid pulsation circulation in the pump body and the vibration of fracturing equipment, the bolts connecting the fracturing pump and fracturing manifold flange are prone to fatigue failure. In this paper, a three-dimensional finite-element model of the threaded bolt connection structure at the fracturing pump outlet end with a fine thread structure was established, and the measured vibrational displacement of the fracturing pump under different driven modes was used as the load to obtain the internal stress state of the full-thread bolt and the double-headed bolt used in the fracturing operation site. Based on the stress state, the fatigue life of the two types of bolts under various loading conditions was then simulated using the Brown—Miller fatigue damage criterion. The results indicate that for bolts of the same structural type, the maximum stress and stress variation amplitude increase in the sequence of the diesel-driven, single-motor-driven, and dual-motor-driven methods. Additionally, under the same load, the stress of the full-thread bolt is lower than that of double-headed bolt. The fatigue life analysis results show that under the vibrational load of diesel drive, the full-thread bolt can obtain a longer fatigue life of approximately 2042.89 h. However, under the load of dual-motor-driven method, the fatigue life of double-headed bolt is the lowest, only 717.46 h. A comparison with the fatigue life of bolts in actual engineering projects indicates that the predicted fatigue life of the bolts is consistent with the actual service life, which can provide effective guidance for the inspection and maintenance of fracturing pump equipment. Full article
(This article belongs to the Special Issue Risk Assessment and System Safety in the Process Industry)
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21 pages, 5005 KiB  
Article
A Machine Learning-Based Risk Assessment Study of Unsafe Behavior of Workers in Nuclear Power Plants Under Construction
by Xueqiang Shan, Weibo Yang, Xia Liu, Kai Yu and Hui Cui
Processes 2025, 13(2), 340; https://doi.org/10.3390/pr13020340 - 26 Jan 2025
Viewed by 511
Abstract
Most accidents during the construction of nuclear power plants are caused by human unsafe behavior. How to scientifically determine the risk management priority of human unsafe behaviors is the basis for effectively preventing accidents in under-construction nuclear power plants. Although employees are adopted [...] Read more.
Most accidents during the construction of nuclear power plants are caused by human unsafe behavior. How to scientifically determine the risk management priority of human unsafe behaviors is the basis for effectively preventing accidents in under-construction nuclear power plants. Although employees are adopted for control in under-construction nuclear power plants, the records of unsafe behaviors are mostly recorded by inspectors, and the records of behaviors may have missing values. To overcome the above problems, this paper applies machine learning algorithms to construct an employee behavioral risk assessment model. Firstly, by analyzing the influencing factors of unsafe behaviors, the assessment indexes are proposed, then the Random Forest algorithm is used to obtain the characteristic importance of the proposed indexes and exclude those with smaller characteristic importance. Finally, the harmony search (HS) algorithm is used to optimize the back propagation (BP) neural network to construct an assessment model and compare with the BP evaluation model. The results show that the HS-BP model is more accurate and efficient. The results show that the method can comprehensively and effectively analyze workers‘ unsafe behaviors, and the BP neural network is optimized to construct the assessment model using the Harmonic Search algorithm, which is more accurate than the original model. The use of the machine learning method to assess workers’ behaviors can objectively output the risk level and overcome the one-sidedness and subjectivity of the traditional expert evaluation method. Full article
(This article belongs to the Special Issue Risk Assessment and System Safety in the Process Industry)
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20 pages, 3515 KiB  
Article
Comprehensive Analysis of the Annulus Pressure Buildup in Wells with Sustained Gas Leakage Below the Liquid Level
by Siqi Yang, Jianglong Fu, Nan Zhao, Changfeng Xu, Lihong Han, Jianjun Wang, Hailong Liu, Yuhang Zhang and Jun Liu
Processes 2024, 12(12), 2631; https://doi.org/10.3390/pr12122631 - 22 Nov 2024
Viewed by 1418
Abstract
During the process of natural gas development, sustained casing pressure (SCP) frequently occurs within the annulus of the gas wells; we specifically referred to the “A” annular space located between the tubing and the production casing in this paper. SCP in an annulus [...] Read more.
During the process of natural gas development, sustained casing pressure (SCP) frequently occurs within the annulus of the gas wells; we specifically referred to the “A” annular space located between the tubing and the production casing in this paper. SCP in an annulus poses a paramount safety challenge, universally acknowledged as a significant threat to gas field development and production, jeopardizing well integrity, personnel safety, and environmental protection. There are multiple factors that contribute to this issue. Due to the multitude of factors contributing to SCP in an annulus and the unclear mechanisms underlying the pressure buildup in wells, an early assessment of downhole leakage risks remains challenging. Hence, this study focused on a comprehensive analysis of the SCP in the annulus of gas wells. A detailed experimental study on the pressure buildup in an annulus due to tubing leakage below the liquid level was conducted, and the variation patterns of the annulus pressure under various leakage conditions were explored. The findings indicated that the equilibrium attainment time of annulus pressure at the wellhead subsequent to tubing leakage decreases with the increase in the pressure difference between the tubing and the casing, the liquid level height, the leakage orifice diameter, and the quantity, while it increases with the increase in the leakage position and gas temperature. According to the theory of gas fluid dynamics, a predictive model of the annulus pressure buildup with sustained gas leakage below the liquid level was proposed, which was well-validated against experimental results, achieving a model accuracy of over 95%. This study provided a theoretical framework for diagnosing SCP in the annulus of gas wells and developing mitigation strategies, thereby contributing to the advancement of the research field and ensuring the safety of industrial operations. Full article
(This article belongs to the Special Issue Risk Assessment and System Safety in the Process Industry)
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17 pages, 5559 KiB  
Article
Poisoning and Asphyxiation Risk Assessment in a Steel Plant Based on Fuzzy Bayesian Network
by Qianqian Li, Qingzhou Yang, Wei Liu, Ping Dai and Yuenan Yang
Processes 2024, 12(10), 2102; https://doi.org/10.3390/pr12102102 - 27 Sep 2024
Cited by 1 | Viewed by 844
Abstract
There is a lack of a quantitative assessment of the risk factors associated with poisoning and asphyxiation accidents in steel enterprises, especially the insufficient treatment of uncertainty in risk analysis. To address this issue, this work proposed a risk assessment method based on [...] Read more.
There is a lack of a quantitative assessment of the risk factors associated with poisoning and asphyxiation accidents in steel enterprises, especially the insufficient treatment of uncertainty in risk analysis. To address this issue, this work proposed a risk assessment method based on fuzzy Bayesian network (FBN), which established a risk assessment indicator system for poisoning and asphyxiation from four aspects, including human, material, environmental, and management factors, and illustrated the relationship between these risk factors through fault tree analysis (FTA). Taking a steel plant in China as an example, fuzzy set theory (FST) and expert surveys were combined to determine the prior probabilities and conditional probabilities of Bayesian network (BN) nodes. The results show that (i) the probability of poisoning and asphyxiation accidents in this steel plant is 74%; (ii) among the various influencing factors, defective or inadequate monitoring and alarm devices, isolation devices, equipment inspection systems, and toxic gas operation management are identified as the critical contributors; and (iii) this accident probability has decreased to 47% after rectification measures and reassessment. The findings of this research offer valuable insights for steel enterprises in preventing poisoning and asphyxiation accidents. Full article
(This article belongs to the Special Issue Risk Assessment and System Safety in the Process Industry)
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13 pages, 5688 KiB  
Article
Modification of the Mohr–Coulomb Criterion and Its Application in the Cracking of Ring-Stiffened Cylinders Made of Titanium Alloy
by Xiangyu Yu, Kewang Xu, Qiang Xu, Aifeng Zhang and Hao Zhang
Processes 2024, 12(8), 1732; https://doi.org/10.3390/pr12081732 - 17 Aug 2024
Viewed by 1004
Abstract
TC4 ELI alloy is widely used in the marine, medicine, and aviation fields. The failure performance of TC4 ELI alloy is significantly different from that of other metal materials, such as steels. In this paper, a modified Mohr–Coulomb criterion is calibrated based on [...] Read more.
TC4 ELI alloy is widely used in the marine, medicine, and aviation fields. The failure performance of TC4 ELI alloy is significantly different from that of other metal materials, such as steels. In this paper, a modified Mohr–Coulomb criterion is calibrated based on several kinds of specimens under different stress states and a 3D geometric representation of a modified Mohr–Coulomb fracture locus for TC4 ELI is obtained based on these parameters. The effectiveness of the modified M-C criterion is studied by a ring-stiffened cylinder made of TC4 ELI. The ultimate strength of the cylinder obtained in the simulation with the modified M-C criterion is close to that obtained in an external pressure experiment, which shows that the modified M-C criterion is suitable for predicting failure in pressure hulls made of titanium alloy used in the deep-sea field. Full article
(This article belongs to the Special Issue Risk Assessment and System Safety in the Process Industry)
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19 pages, 1406 KiB  
Article
Research on Occupational Risk Assessment for Welder Occupation in Romania
by Valentin Pirvu, Corneliu Rontescu, Ana-Maria Bogatu, Dumitru-Titi Cicic, Adrian Burlacu and Nadia Ionescu
Processes 2024, 12(7), 1295; https://doi.org/10.3390/pr12071295 - 22 Jun 2024
Viewed by 1663
Abstract
The ever-increasing needs of the working population have led to the development of various branches of industry, an increase in the number of employees, and a rise in the number of work-related accidents. The welder occupation is one of the most sought after [...] Read more.
The ever-increasing needs of the working population have led to the development of various branches of industry, an increase in the number of employees, and a rise in the number of work-related accidents. The welder occupation is one of the most sought after occupations in Europe, according to the EURopean Employment Services (EURES) statistics. Taking into account the work system in which welders conduct their activity (uncomfortable working positions, splashes, high temperatures, mechanical factors, gases and fumes, magnetic fields due to electric current), the paper presents the risk factors identified for the welder occupation, based on the occupational injury and illness risk assessments. Following the analysis of 25 risk assessments, carried out by the assessment team that must include qualified evaluators, process specialists, the workers’ representative, occupational health and safety responsible at various industrial economic agents, a total of 70 main risk factors of occupational accidents and diseases were identified for the welder occupation. Risk factors were classified according to four main work components: worker, workload, work environment, and means of production. To reflect the importance of the identified risk factor, the number of organizations that considered that the risk was likely to occur but also the possibility that the risk was above the acceptable limit, calculated using the National Institute for Research and Development for Labor Protection “Alexandru Darabont” (INCDPM) method, a method often used in Romania, was identified from the analyzed assessments. Finally, a prevention and protection plan was drawn up with regard to the risks identified for the welder occupation, the final aim of which was to respectively reduce the probability of occurrence with the severity of the risks identified. Full article
(This article belongs to the Special Issue Risk Assessment and System Safety in the Process Industry)
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28 pages, 12230 KiB  
Article
A Novel Underlying Algorithm for Reducing Uncertainty in Process Industry Risk Assessment
by Yuanyuan Zhang and Long Zhao
Processes 2024, 12(7), 1292; https://doi.org/10.3390/pr12071292 - 21 Jun 2024
Cited by 4 | Viewed by 1133
Abstract
Normal fuzzy fault tree is a classic model in the field of process industry risk assessment, and it can provide reliable prior knowledge for machine learning. However, it is difficult to adapt the traditional approximate calculation method to highly nonlinear problems, and this [...] Read more.
Normal fuzzy fault tree is a classic model in the field of process industry risk assessment, and it can provide reliable prior knowledge for machine learning. However, it is difficult to adapt the traditional approximate calculation method to highly nonlinear problems, and this may introduce model uncertainty. To solve this problem, this study proposes an accurate calculation algorithm. In the proposed algorithm, first, an exact α-cut set of normal fuzzy fault tree is derived according to the exact calculation formula of normal fuzzy numbers and in combination with the cut-set theorem. Subsequently, the relationship between the membership function and the exact cut set is derived based on the representation theorem. Finally, according to the previous derivation, the coordinates of the point on the exact membership curve are found within the range of x from 0 to 1. Based on this, an accurate membership graph is drawn, the membership curve is evenly divided with the area enclosed by the x-axis, and the fuzzy median is obtained. The results of the two chemical accident cases demonstrate that the proposed algorithm has a strong ability to handle uncertainty and can significantly reduce the uncertainty of the process industry risk assessment results. The results also reveal that the superiority of the accurate calculation algorithms becomes more obvious when the mean failure probability of basic events is larger or the accident tree is more complex. This study provides a high-accuracy underlying algorithm for process industry risk assessment, and it is of great value for improving system security. Full article
(This article belongs to the Special Issue Risk Assessment and System Safety in the Process Industry)
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Review

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30 pages, 4606 KiB  
Review
Quantitative Risk Analysis with the Possibility of Stochastic and Deterministic Simulation of Failure Trends from the Point of View of Expressing the Probability of Two Parameters
by Alena Breznická, Marcel Kohutiar, Michal Krbata, Maroš Eckert and Pavol Mikuš
Processes 2024, 12(11), 2394; https://doi.org/10.3390/pr12112394 - 30 Oct 2024
Cited by 1 | Viewed by 1149
Abstract
The aim of this paper is to present theoretical starting points in the field of risk analysis. This paper is formulated as a systematic overview of the latest knowledge and trends, which are supported by the simulation of selected risk parameters intended for [...] Read more.
The aim of this paper is to present theoretical starting points in the field of risk analysis. This paper is formulated as a systematic overview of the latest knowledge and trends, which are supported by the simulation of selected risk parameters intended for the prediction of adverse events. The analysis and assessment of technical risk allow not only for indicating negative events detected in a process but also for taking corrective measures based on systematic reductions in technical system failures. This article refers to the use of mathematical experiments of risk modelling and simulation because mathematical modelling and simulation are very suitable methods for the analysis, modelling, and prediction of random phenomena in risk theory and assessment. The analytical approach is based on stochastic and deterministic risk modelling procedures and on the principle of risk evaluation through the effects of two factors: the probability of occurrence of negative events and consequences and their impact from the point of view of malfunctions. The analytical approach is based on a mathematical model that considers the intersection of two phenomena in terms of expressing the probability of two different statistical distributions in a stochastic expression. The analysis and assessment of technical risk allow not only for indicating negative events detected in a process but also for taking corrective measures. The aim of this article is to formulate a method that can be used to set and evaluate the technical risk of the cutting process from an organizational point of view. Full article
(This article belongs to the Special Issue Risk Assessment and System Safety in the Process Industry)
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