Transcript BASIC CONCEPRTS OF PROCESS HAZARD & RISK ANALYSIS

APPLICATION
of
Various Techniques
for
HAZARD
A
BIOLOGICAL, CHEMICAL
OR PHYSICAL AGENT THAT
IS REASONABLY LIKELY TO
CAUSE ILLNESS OR INJURY
IN THE ABSENCE OF ITS
CONTROL.
OBJECTIVES
OBJECTIVES
PROCESS HAZARD
IDENTIFICATION
HAZARD IDENTIFICATION AND RISK
ASSESSMENT PROCESS
SYSTEM
DESCRIPTION
HAZARD
IDENTIFICATION
SCENARIO
IDENTIFICATION
ACCIDENT
PROBABILITY
ACCIDENT
CONSEQUENCE
RISK
DETERMINATION
RISK
AND / OR
HAZARD
ACCEPTANCE
BUILD AND / OR
OPERATE SYSTEM
MODIFY
DESIGN
STEPS IN HAZARD IDENTIFICATION
PROCESS
CLASSIFICATION
PHI & PROJECT LIFE CYCLE
PHI & PROJECT LIFE CYCLE
SUITABILITY OF PHI TO DIFFERENT
PHASES
CONCEPT
PROCESS
DESIGN
COMMISSIONING
OPERATION
MODIFICATION
DECOMMISSIONING
NS
NS
MS
MS
MS
MS
MS
S
S
MS
MS
MS
MS
MS
PHA
MS
MS
NS
NS
NS
NS
S
FTA
S
S
MS
MS
MS
MS
MS
Safety
Audit
MS
MS
MS
MS
MS
MS
MS
FMEA
NS
NS
MS
MS
MS
MS
MS
HAZOP
WHAT IF
NS – Not Suitable,
MS – Most Suitable, S - Suitable
Tools for Process Hazard Identification
What if Analysis?
 HAZOP
 FMEA
 ETA
 FTA
 Safety Audit
 Compliance Audit

STEPS IN PHA & RISK ANALYSIS

HAZARD IDENTIFICATION :
I
I
I
I

VULNERABILITY ANALYSIS :
I
I
I
I

CHEMICAL IDENTITY
LOCATION
QUANTITY
NATURE OF THE HAZARD
VULNERABILE ZONES
HUMAN POPULATION
CRITICAL FACILITIES
ENVIRONMENT
RISK ANALYSIS
I
I
LIKELYHOOD OF THE HAZARDOUS EVENT OCCURING
SEVIERITY OF THE CONSEQUENCES
ISSUES THAT PHA ADDRESS TO ARE :
HAZARDS OF PROCESS
 PREVIOUS INCIDENTS AND NEAR- MISSES.
 ENGINEERING & ADMINISTRATIVE CONTROLS.
 CONSEQUENCES OF FAILURE OF THESE CONTROLS.
 QUALITATIVE EVALUATION OF POSSIABLE EFFECTS ON
:
– EMPLOYEES.
– PUBLIC
– ENVIRONMENT

 FACILITY
& PLANT SITING
 HUMAN FACTOR
WHAT IF ANALYSIS





THE WHAT IF ANALYSIS IS AN UNCOMPLICATED
HAZARD EVALUATION PROCESS.
IT REVIEWS THE COMPLETE PROCESS FROM RAW
MATERIAL TO FINISHED PRODUCT.
IN THIS ANALYSIS THE QUESTIONS COVERING EVERY
MODE, COMPONENT OF THE PROCESS ARE ANSWERED
TO EVALUATE THE EFFECTS OF COMPONENT FAILURE
OR PROCEDURAL ERRORS.
FOR MORE COMPLEX PROCESS THE WHAT IF ANALYSIS
CAN BE BEST ORGANISED THROUGH USE OF
CHECKLISTS.
THIS METHOD IS VERY USEFULL IN TRAINING
OPERATING PERSONAL ON THE HAZARDS OF
PERTICULAR OPERATION.
THE TEAM COMPOSITION FOR WHAT IF
ANALYSIS


THE TEAM FOR CONDUCTING THIS ANALYSIS COVERS A
WIDE RANGE OF DISCIPLINES THAT IS :
 PRODUCTION
 MECHANICAL
 CHEMICAL
 SAFETY
THIS PACKAGE INCLUDES INFORMATIONS ON HAZARDS OF
:







MATERIALS
PROCESS
TECHNOLOGY
PROCEDURES
EQUIPMENT DESIGN
INSTRUMENTATION CONTROL ETC.
THE IMPORTANT FEATURES of HAZOP
INTENTION
DEVIATION
CAUSES
CONSEQUENCES
HAZARDS
OPERATING DIFFICULTIES
HAZOP - DEFINITION
HAZOP = HAZard and OPerability Study


Method for identifying (and assessing) problems that
may represent risks to personnel or equipment, or
prevent efficient operation
Systematic and qualitative method based on the use of
 Guide words
 Multi- disciplinary team effort
TYPES of HAZOPs




Process HAZOP
– The HAZOP technique was originally developed to assess
plants and process systems
Human HAZOP
– A family of more specialized HAZOPs
– More focused on Human Errors than technical failures
Procedure HAZOP
– Review of procedures or operational sequences
– Sometimes denoted SAFOP - SAFe Operation Study
Software HAZOP
– Identification of possible errors in the development of
software
PROCESS HAZOP




Review of complete process through P& IDs and /
or flow diagrams
Breakdown of the system into segments
Standardized guide- words / parameters
Application of guide - words to different process
parameters to identify possible deviations
HUMAN HAZOP



Based on some form of task analysis
Other input is procedures, workplace layout
schematics, man/ machine interface description
Covers a ‘ family’ of specialized HAZOPs:
– Errors associated with design and use of computerbased interfaces
– Errors associated with the use of interlocks
– Function allocation HAZOP: errors associated with
determining the role of the operator in the system.
PROCEDURE HAZOP




Can be applied to all sequences of operations
Focus on both human errors and failures of
technical systems
Best suited for detailed assessments, but can also
be used for coarse preliminary assessments
Flexible approach with respect to use of guidewords
Procedure HAZOP Guide- words (I)
Standard guide - words of Human HAZOP
can be applied to the steps in the procedure
 In addition a Procedure HAZOP should
highlight:
– TIMING/ SEQUENCE: The steps are not
performed in the correct sequence

Applications of Procedure HAZOP


All operations that are potentially hazardous and that
are not identical to operations analyzed before should
be subject to a HAZOP
Examples that should be HAZOPed:
– Start up and shut down procedures
– Purging operations
– Maintenance of critical equipments
– Complex lifting operations
Success Factors



The `right’ composition of the HAZOP team
Experienced and contributing team members
Properly prepared procedures
–
–

Possibly developed using task analysis
Clear and unambiguous work description
Experienced HAZOP leader/ chairman
–
–
–
Familiar with the type of work being analyzed
Sufficient authority to control the discussion
Skills as ‘ catalyst’
Necessary documentation
Description of operations (sequential
breakdown, procedure)
 Descriptions and drawings of equipment
involved in the operations,
 Critical data:
– Critical values of parameters
– Process conditions
– Critical controls.

Planning and preparation





Ensure that necessary documentation is prepared
Decide level of detail of the assessment
– Depending on documentation available
Set time frame
– Depending on level of detail
– can be from a few hours to days and even weeks
Compose the HAZOP team
Send call for meeting, including:
– time and venue
– list of participants
– background documentation
HAZOP Team (I)


HAZOP leader/ chairman:
– Independent (i. e., no responsibility for performance of the
operations)
– responsible (together with the HAZOP initiator) for planning
and preparation of the HAZOP
– Chairing the HAZOP meeting:
 trigger the discussion using the guide- words
 follow- up progress according to schedule/ agenda
 ensure completeness of the assessment
– Responsible for final reporting
HAZOP secretary
– Preparing HAZOP work- sheets
– Recording the discussion in the HAZOP meeting
– Preparation of draft report
HAZOP Team (II)


Representatives of all disciplines/ parties involved
in the operations
– give input based on their responsibility in the
performance of the operations
Ideally, the HAZOP team should consist of 6- 10
persons in order to work effectively
How to be a good HAZOP participant
Be active! Everyone’s contribution is
important
 Be to the point. Avoid endless
discussion of details
 Be critical in a positive way - not
negative, but constructive
 Be responsible. He who knows should
let the others know

HAZOP MEETING



Proposed agenda:
– Introduction and presentation of participants
– Overall presentation of operations subject to
HAZOP
– Description of HAZOP method
– Presentation of first logical part of operations
– Analysis of first part of operations using the guidewords
– Continue presentation and analysis
– Coarse summary of findings
Focus should be on potential hazards as well as
potential operational problems
Each session of the HAZOP meeting should not exceed
two hours
HAZOP RECORDING


The HAZOP meeting is recorded by the HAZOP secretary
using work- sheets, either:
– Filling in paper copies of the work- sheets, or
– Using a PC connected to a projector
HAZOP work- sheets may be somewhat different
depending on the scope of the study - generally the following
columns are included:
– Ref. no [Step no.]
– Guide- word
– Deviation
– Potential cause/ source
– Potential consequences
– Action/ recommendation
– Follow- up - responsibility
System/ Equipment :
Executed By:
REF. DIAGRAM / DRAWING NO :
DATE:
Parameter
Protection
Measures
HAZOP REPORTING




There is no ‘ correct answer’
– depends on the experience of the participants
– depends on priorities
Preliminary findings/ conclusions presented
at the end of the meeting
Draft work- sheets are issued to all
participants for review and comments
The HAZOP report is issued when all
corrections to the work- sheets have been
incorporated
HAZOP RESULTS




Improvement of operations
– reduced risk - better contingency
– more efficient operations
Improvement of procedures
– logical order
– completeness
General awareness among involved parties
Team building
FALURE MODE & EFFECT ANALYSIS
(FMEA)


FMEA IS A DISCIPLINED DESIGN REVIEW TECHNIQUE
THAT FOCUSES ON THE DEVELOPMENT OF PRODUCTS
AND PROCESSES ON PRIORITIZED ACTIONS TO REDUCE
THE RISK OF PRODUCT FIELD FAILURES, AND
DOCUMENTS THOSE ACTIONS AND REVIEW PROCESS.
IT :



RECOGNIZE & EVALUATE THE POTENTIAL FAILURE OF A
PRODUCT/COMPONENT OR PROCESS AND ITS EFFECTS.
IDENTIFY ACTIONS WHICH COULD ELIMINATE OR REDUCE
THE CHANCE OF POTENTIAL FAILURE OCCURING.
DOCUMENT THE PROCESS.
THE FMEA PROCESS
Identify Elements of System
Identify Functions
Identify Failure Modes
Identify Possible Causes
Identify Effects on the System
Identify Effects on other System
Final Risk Assessment
Take Action to Reduce the Risk
Safety Audit
Regulatory requirement
 System Review
 Physical Review
 Submission of Reports
 Implementation of Recommendations
 Follow up responsibilities

AUDIT
AN AUDIT IS A SYSTEMATIC
INDEPENDENT REVIEW TO VERIFY
CONFORMANCE WITH ESTABLISHED
GUIDE LINES OR STANDARDS. IT
EMPLOYS WELL DEFINED REVIEW
PROCESS TO ENSURE CONSISTENCE
AND TO ALLOW THE AUDITOR TO
REACH DEFENSIBLE CONCLUSIONS.
What is Safety Audit
Verifying the existence and implementation
of elements of occupational safety and
health system and for verifying the system’s
ability to achieve defined safety objectives
Why Safety Audit
To know the compliance of health and
safety policy and management systems.
 To find out strengths and weaknesses
of safety program.
 To identify areas of high risk and
vulnerability and recommend for more
detailed risk analysis.
 To find out potential hazards present
in the existing plants.

To ensure that operation and
maintenance are carried out according
to the plant manual without any
serious deviation.
 To rectify and bring forth any design
or process deficiency, which has come
up during modification.
 To ensure the compliance of important
statutory requirements.
 To check the existing fire fighting,
first-aid and training facilities.

To know the status of emergency
preparedness and regular drills.
 To know the personal attitudes of
employees and public relation both
inside and outside the factory.
 To
study the existing systems,
procedures
and
measures
for
controlling the hazards besides the
provisions of Factories Act 1948 and
other legislation enforces the industrial
or process units for safety audits.

Manufacture, Storage and import of
Hazardous Chemicals Rules, 1989
Safety Audit is required to be carried out by
by the occupiers of both the new and the
existing industrial activities with the help of
an expert not associated with such industrial
activities.
 This is required under Rule No.10-subrule
(4)
 This has come into effect from 3/10/94

SCOPE OF AUDIT
FIRE AND EXPLOSION; PREVENTION,
PROTECTION AND EMERGENCY
MANAGEMENT.
 WORK INJURY PREVENTION.
 HEALTH HAZARDS CONTROL.
 CONSEQUENCES OF EMERGENCIES.
 ON SITE EMERGENCY CONTROL

Benefits of Safety Audit



It helps in safeguarding people,plant and the
environment from the effects of malfunctioning of
the plant.
It ensures the compliance with local, regional and
national laws and regulations.
It ensures independent verification, it identifies
matters needing attention and provides timely
warning to the organisation and management at
various levels of potential future problems.







It helps in improving overall safety performance at
operating facilities.
Accelerate the overall development of process safety
management and control systems.
Improves the risk management system and develops
the basis for optimizing safety resources.
Increase employees awareness of safety policies and
responsibilities.
Identify potential cost savings by reducing lapses in
safety, quality and production.
Provide an information base for use in emergencies and
evaluating the effectiveness of emergency response
arrangements.
Enables management to give credit of good safety
performance.
MANAGEMENT CONCERNS
QUANTITY PRODUCED IN RELATION
TO PRODUCTION SCHEDULE AND
MARKET REQUIREMENT
 PRODUCT QUALITY
 PRODUCTION COSTS
 INTEGRATING THE STAKEHOLDERS
CONCERNS

•Is Safety Important? Not always
TYPES OF AUDIT
Electrical Audit
 Fire Safety Audit
 Pressure vessels Audit
 Lifting Tackles Audit
 Statutory Regulations Compliance Audit
 Emergency Communication Audit
 Pipe lines Audit

Elements of Occupational Safety
and Health System-IS14489








Occupational Health and Safety Policy
OS&H organizational set up
Education and Training
Employees participation in OS&H
Management
Motivational and Promotional measures for
OS&H
Safety Manual and Rules
Compliance with Statutory Requirements
New Equipment review and inspection
Elements contd..









Accident reporting analysis investigation and
implementation and recommendations
Risk Assessment including hazard identification
Safety inspections
Health and safety improvement plan/targets
First aid facilities-Occupational health center
Personal Protective Equipment
housekeeping
Machine and general area guarding
Material handling equipment
Elements contd..








Electrical and Personal safeguarding
Work environment monitoring system
Prevention of occupational diseases including
periodic medical examination
Safe operating procedures
Work Permit systems
Fire Prevention, Protection and fighting
systems
Emergency Preparedness plans(onsite/offsite)
Process Plant modification procedure
Elements contd..
Transportation of hazardous substances
 Hazardous waste treatment and disposal
 Safety in storage and warehousing
 Contractor safety systems
 Safety for customers(including MSDS)
