Risk-based design of process plants with regard to domino effects and land use planning

Highlights: • A Bayesian network methodology has been developed to estimate the total probability of major accidents in chemical plants. • Total probability of accidents includes the probability of individual accidents and potential domino effects. • The methodology has been extended to calculate on-site and off-site risks. • The results of the risk analysis have been used in a multi-criteria decision analysis technique to risk-based design of chemical plants. - Abstract: Land use planning (LUP) as an effective and crucial safety measure has widely been employed by safety experts and decision makers to mitigate off-site risks posed by major accidents. Accordingly, the concept of LUP in chemical plants has traditionally been considered from two perspectives: (i) land developments around existing chemical plants considering potential off-site risks posed by major accidents and (ii) development of existing chemical plants considering nearby land developments and the level of additional off-site risks the land developments would be exposed to. However, the attempts made to design chemical plants with regard to LUP requirements have been few, most of which have neglected the role of domino effects in risk analysis of major accidents. To overcome the limitations of previous work, first, we developed a Bayesian network methodology to calculate both on-site and off-site risks of major accidents while taking domino effects into account. Second, we combined the results of risk analysis with Analytic Hierarchical Process to design an optimal layout for which the levels of on-site and off-site risks would be minimum.