Towards limiting potential domino effects from single flammable substance release in chemical complexes by risk-based shut down of critical nearby process units

The explosion load is a significant escalation factor possibly influencing the potential occurrence of domino accidents in chemical plants. It is not economical to install explosion isolation systems (e.g., extinguishing barrier) for all equipment or process units across a chemical plant. Although shutting down all equipment or process unit can prevent an explosion, it may also cause further economic losses. To prevent domino accidents, the process unit that needs to be shut down accurately should be selected, and the normal operation of other units needs to be ensured. A method to select the process unit to be isolated based on the Dimensioning Accidental Load (DAL) is proposed. By calculating the occurrence probability and consequences of the accident scenarios, the DAL of the surrounding units is determined. DAL is used as the impact intensity of the accident unit on the surrounding units. The probit model is used to calculate the damage probability of surrounding units. The case analysis results show that the method of selecting the process unit to be isolated based on DAL quantifies the impact intensity of the exploded unit on surrounding units from probability and consequence. Under the premise of meeting the acceptable risk criteria, the method can determine which units should be shut down and which units can operate normally when a release accident occurs. While preventing domino accidents, economic losses caused by the shutdown of all process units are reduced and a theoretical basis for accident prevention and safe operation of the plant is provided.