Abnormal process situation may lead to tremendous negative impact on sustainability, wellbeing of workers and adjacent communities, company's profit, and stability of supply chains. Failure of equipment and process subsystems are among the primary causes of abnormal situations. The conventional approach in handling failure-based abnormal situations has usually focused on operational strategies. Such an approach overlooks the critical role of process design in mitigating failure, while simultaneously considering the effects of such failure on process economic performance. The aim of this work is to introduce a systematic methodology that accounts for failure early enough during the conceptual design stages. Once a base-case design is developed, the methodology starts by identifying the sources of failure that are caused by reliability issues including equipment, operational procedures, and human errors for a given process system or subsystem. This allows for the identification of critical process subsystem(s) that are more failure-prone or cause greater downtime than other subsystems. Bayesian updating and Monte Carlo techniques are utilized to determine the appropriate distributions for the failure and repair scenario(s), respectively, in question. Markov analysis is used to determine the system availability. Next, the process revenue is described as a function of inherent availability. The effects of failures are incorporated into profitability calculations to establish an economic framework for trading off failure and profitability. In the proposed framework, the economic potential of alternative design scenarios is evaluated and an optimization formulation with the objective of maximizing incremental return on investment (IROI) is utilized to make a design decision. A case study on an ethylene plant is solved to demonstrate the applicability and value of the proposed approach.

异常的过程状况可能会对可持续性，工人和邻近社区的福祉，公司的利润以及供应链的稳定性造成巨大的负面影响。设备和过程子系统的故障是异常情况的主要原因。处理基于故障的异常情况的常规方法通常集中于操作策略。这种方法忽略了过程设计在减轻故障中的关键作用，同时考虑了此类故障对过程经济性能的影响。这项工作的目的是介绍一种系统的方法，以在概念设计阶段就尽早解决故障。一旦开发了基本案例设计，该方法首先要确定由可靠性问题（包括设备，操作程序和给定过程系统或子系统的人为错误）引起的故障根源。这允许识别比其他子系统更容易出现故障或导致更大停机时间的关键过程子系统。贝叶斯更新和蒙特卡洛技术分别用于确定故障和修复方案的适当分布。马尔可夫分析用于确定系统可用性。接下来，将过程收益描述为固有可用性的函数。失败的影响被合并到获利能力计算中，以建立折衷失败和获利能力的经济框架。在提议的框架中，评估替代设计方案的经济潜力，并以最大化投资回报率（IROI）为目标的优化公式来做出设计决策。解决了对乙烯厂的案例研究，以证明该方法的适用性和价值。