Covariate model-based fault tree analysis for risk assessment in chemical process industries: A case study of a chlorine manufacturing facility

Fault tree analysis (FTA) is a promising quantitative technique for risk analysis in chemical process industries (CPIs). In FTA, a certain sequence of basic events (causes) leads to one specific Top event (critical event of interest). However, the conventional fault tree analysis has the limitations of staticity and uncertainty. The staticity in conventional FTA arises due to its inability to accommodate time-dependent characteristics of the process system. Whereas uncertainty primarily lies in the failure probability data of basic events. This paper proposes an innovative methodology that uses a time-dependent covariate model to update the failure probability values of major contributing basic events in FTA. A novel subclass of the family of phase-type distributions is used to model the covariates corresponding to the basic events. The newly developed methodology is applied for a case study in a chlorine manufacturing facility to estimate the chlorine release probability. The blockage in the pipeline was identified as the significant reason for chlorine release from expert opinion and sensitivity analysis. The results of the proposed model of FTA are compared with that of conventional FTA.