Risk assessment and optimization for new or novel processes: Combining task analysis with 4D process simulation-framework and case study

This paper describes work undertaken as part of the TOSCA project to develop approaches integrating and enhancing safety, quality and productivity. The work reported here combines two existing approaches: task analysis and 4D process simulation to model tasks in a 3D environment, thus creating a 4D model. The 4D model is next used for safety analysis (e.g., a structured Hazid study) and optimization (e.g., Pareto type). The approach is demonstrated on an industrial case study involving the planning of a infrequent cold water pressure testing of LPG storage tanks at a partner site. The results of the case study are presented and discussed. The plant management was provided with a detailed list of the main tasks (22), sub-tasks (115), specific risks identified (procedural delays, occupational safety and process safety) and 19 specific recommendations for safety and time optimization of the planned testing procedure.