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

MODIFY DESIGN

BUILD AND / OR OPERATE SYSTEM

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

HAZOP NS NS MS MS MS MS MS

WHAT IF 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

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 CHEMICAL IDENTITYI LOCATIONI QUANTITYI NATURE OF THE HAZARD

VULNERABILITY ANALYSIS :I VULNERABILE ZONESI HUMAN POPULATIONI CRITICAL FACILITIESI ENVIRONMENT

RISK ANALYSISI LIKELYHOOD OF THE HAZARDOUS EVENT OCCURINGI 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

HAZARDS OPERATING DIFFICULTIES

CONSEQUENCES

CAUSES

DEVIATION

INTENTION

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 computer- based 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 guide-

words

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 guide-

words– 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

ParameterProtection Measures

 System/ Equipment :  Executed By:

REF. DIAGRAM / DRAWING NO : DATE:

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

AUDITAUDIT

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

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.

Benefits of Safety Audit

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)