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Procedures of Hazard identification, risk evaluation and information collection of the FCC process are presented for the design and development of a safety monitoring and management system. A novel structure of the safety monitoring system is proposed. Design and realization of comprehensive functions that the safety system should perform, which cover real-time parameters monitoring, safety analysis, safety information fusion, video monitoring, early-warning, dynamic safety management, etc, is explored in detail. Application of the proposed system shows that the system provides a systematic, comprehensive real-time analysis, monitoring, early-warning and management of overall process safety and steady operation.