(76f) Using Real Time Process Models to Detect Loss of Containment and Mitigate Hazards

Review of process data from loss of containment incidents reveals that in many cases the loss of containment was detectable for a significant length of time before plant staff became aware of the failure. If operators are alerted to a loss of containment in the early stages of a failure, they can often mitigate the consequences of the event. Real time comparison of process data to simple process models can detect some loss of containment incidents while they are in there early stages. In this presentation we provide examples of loss of containment events that could have been detected by comparison of process data to simple process models. These incidents include:

1) Overflow of a petroleum storage tank in the 2005 Buncefield incident 2) Leak in a hydrocracker preheater 3) Leak of heat transfer fluid into a fixed bed catalyst reactor

In these incidents, early detection of the loss of containment would have allowed operators to take actions to prevent or significantly reduce the eventual consequences of the event.