hazard identification (1)
TRANSCRIPT
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Major Hazard FacilitiesHazard Identification
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Overview
This seminar has been split into two sections1. Hazard Identification
2. Major Accident Identification and is! Assessment
The seminar has been developed to provide
" #onte$t with MHF e%&lations
" An overview of what is re'&ired
" An overview of the steps re'&ired
" ($amples of hazards identified
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)ome Abbreviations and Terms
" AFA* + As far as ,reasonabl- practicable" /0 + /an%ero&s %oods
" (mplo-er + (mplo-er who has mana%ement control of thefacilit-
" Facilit- + an- b&ildin% or str&ct&re at which )ched&le 1
materials are present or li!el- to be present for an- p&rpose" FM(AFM(#A + Fail&re modes and effects anal-sis Fail&re
modes and effects criticalit- anal-sis
" FTA + Fa< tree anal-sis
" HAI/ + Hazard identification
" HAO* + Hazard and operabilit- st&d-" H) + Health and safet- representative
" 3O# + 3oss of containment
" 3O*A 4 3a-ers of protection anal-sis
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)ome Abbreviations and Terms
" MHF + Major hazard facilit-" MA + Major accident
" OH) + Occ&pational health 5 safet-
" *F/ 4 *rocess Flow /ia%ram
" *5I/ 4 *ipin% and Instr&mentation /ia%ram
" *)6 4 *ress&re safet- valve
" )M) + )afet- mana%ement s-stem
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Topics #overed In This *resentation
" e%&lations" /efinition 4 Hazard
" Introd&ction
" HAI/ e'&irements
" HAI/ Approach
" #ons<ation
" #ond&ctin% the HAI/
" Overview of HAI/ techni'&es
" eview and evision
" )o&rces of Additional Information
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e%&lations
" Hazard identification (R9.43)" is! assessment ,7.88
" is! control ,i.e. control meas&res ,7.89: )7A 21;
" )afet- Mana%ement )-stem ,7.8
" #ons<ation
Basic outline
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e%&lations
a All reasonabl- foreseeable hazards at the MHF that ma- ca&sea major accident? and
b The !inds of major accidents that ma- occ&r at the MHF: the
li!elihood of a major accident occ&rrin% and the li!el-conse'&ences of a major accident.
Regulation 9.43,Hazard identification states@
The emplo-er m&st identif-: in cons<ation with emplo-ees:contractors ,as far as is practicable and H)s@
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/efinition
Hazard
Regulatory definitionper *art 2; of the Occ&pational Healthand )afet- ,)afet- )tandards e%&lations 1778 @
A hazard means the potential to ca&se inj&r- or illnessB
Interpreted:An- activit-: proced&re: plant: process: s&bstance:sit&ation or other circ&mstance that has the potential to ca&seharm.
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Introd&ction
" HAI/ is critical to safet- d&ties and the safet- report" (mplo-er m&st identif- all major accidents and their related
ca&ses &sin% a s-stematic and doc&mented HAI/ approach
" The process m&st be transparent
" HAI/ res<s m&st be reflected in ris! assessment: )M):
adoption of control meas&res and safet- report
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Introd&ction
An e$ample + 0ramerc- Al&mina efiner-: C) /epartment of
3abor eport I/ Do. 192: 9 E&l- 1777 at 9am
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Introd&ction
Were the hazards identified?
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Introd&ction
" HAI/ process m&st be on%oin% to ens&re e$istin% hazards are!nown: and
" Dew hazards reco%nised before the- are introd&ced@
- *rior to modification of facilit-
- *rior to chan%e in )M) or wor!force
-efore and d&rin% abnormal operations: tro&bleshootin%- *lant condition monitorin%: earl- warnin% si%nals
- (mplo-ee feedbac! from ro&tine participation in wor!
- After an incident
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Introd&ction
" Information from accident investi%ations can be &sef&l as inp&t todetermine contrib&tin% ca&ses
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HAI/ e'&irements
" A s-stematic: transparent and comprehensive HAI/ processsho&ld be &sed based on a comprehensive and acc&ratedescription of the facilit-
" MAs and the &nderl-in% hazards sho&ld not be disre%ardedsimpl- beca&se@
- The- appear to be ver- &nli!el-
- The- have not happened previo&sl-
- The- are considered to be ade'&atel- controlled b- e$istin%meas&res
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HAI/ e'&irements
The ris! dia%ram can be &sef&l for ill&stratin% this aspect: as
shown below
Consequence Severity
Safety Report Inuence
OH&S CatastrophicFire &Explosion
Maintenance
Protest picetsPersonal in!uryIn"ustrialstoppa#e
Hi#h technolo#y an" hi#h
ha$ar" syste% failuresClass actionsMaret collapse
Fatality fatalities'
(rea"o)nsPu*lic criticis%
Sta+co%plaints
Relativ
e
Fre
quenc
yofO
c
currence
Increasin# ris
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HAI/ e'&irements
" The HAI/ process ,for MHF compliance is not intended toidentif- all personnel safet- concerns
" Man- ind&strial incidents are ca&sed b- personnel safet-breaches: s&ch as the followin%@
- *erson falls from hei%ht
- (lectroc&tion
- Tripsslips
- #ontact with movin% machiner-
- etc
Exclusions
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HAI/ e'&irements
" These are %enerall- incidents that do not relate to the stora%eor processin% of )ched&le 7 materials and are covered b-other parts of an (mplo-erGs safet- mana%ement s-stem for afacilit- s&ch as@
+ *ermit to wor!
+ #onfined space entr- and mana%ement
+ or!in% at hei%hts
+ or! place safet- assessments
+ etc
Exclusions
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HAI/ Approach
" hat can %o wron%
" hat incidents or scenarios co&ldarise as a res< of thin%s %oin%
wron%
" hat co&ld ca&se or co&ldcontrib&te to these incidents
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HAI/ Approach
" #onsiders all operatin% modes of the facilit-: and all activitiesthat are e$pected to occ&r
" H&man and s-stem interfaces to%ether with en%ineerin% iss&es
" /-namic process to sta- ahead of an- chan%es in the facilit-that co&ld erode the safe operatin% envelope or co&ld introd&cenew hazards
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HAI/ Approach
The HAI/ approach is re'&ired to@
" e team+based
" Cse a a process that is s-stematic
" e pro+active in searchin% for hazards
" Assess all hazards" Anal-se e$istin% controls and barriers + preventative and
miti%ative
" #onsider size and comple$it- in selectin% approach to &se
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HAI/ Approach
" #onsideration needs to be %iven in selectin% the HAI/techni'&e
" )ome iss&es to ta!e into acco&nt are@
- 3ife c-cle phase of plant
- #omple$it- and size
- T-pe of *rocess or activit- coverin%@
o (n%ineerin% or proced&ral
o Mechanical: process: or activit- foc&ssed
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HAI/ Approach
" The HAI/ approach can be &sed inthe first sta%es of the life c-clephase of a project
" *rior to desi%n phase: littleinformation will be available and the
HAI/ approach will need to be&nderta!en on flow dia%rams
" Ass&mptions will need to betransparent and doc&mented
Concept
Design
Commission
Production
Decommission
Disposal
Construction
Life Cycle Phases of a Project
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HAI/ Approach
Complexity and ize" The comple$it- and size of a facilit- incl&des the n&mber of
activities or s-stems: the n&mber of pieces of e'&ipment: thet-pe of process: and the ran%e of potential o&tcomes
" )ome HAI/ techni'&es ma- %et bo%%ed down when the- areapplied to comple$ processes
" For e$ample: event tree and fa< tree anal-ses can becometime cons&min% and diffic< to str&ct&re effectivel-
" However: simple techni'&es ma- not provide s&fficient foc&s toreach consens&s: or confidence in the identification of hazards
Conclusion:Start with simple techniques and build
in compleit! as required
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HAI/ Approach
!ype of Process or "cti#ity" here activities are proced&ral or h&man error is dominant
then tas! anal-sis ma- be appropriate ,e.%. tas! anal-sis:proced&ral HAO*: etc
" here !nowled%e of the fail&re modes of e'&ipment is critical,e.%. control e'&ipment: etc then FM(A ma- be appropriate
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HAI/ Approach
!ype of Process or "cti#ity" here the facilit- is readil- shown on a process flow dia%ram
or a process and instr&mentation dia%ram: then HAO* ma-be &sed
" here m<iple fail&res need to be combined to ca&se anaccident: or m<iple o&tcomes are possible then fa< tree
anal-sis and event tree anal-sis ma- be beneficial
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#ons<ation
" The MHF e%&lations re'&ire (mplo-ers to cons< withemplo-ees in relation to@
+ Identification of major hazards and potential major accidents
+ is! assessment
+ Adoption of control meas&res
+ (stablishment and implementation of a safet- mana%ement
s-stem
+ /evelopment of the safet- report
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#ons<ation
" #ons<ation is also re'&ired in relation to the roles that the(mplo-er defines for emplo-ees
" The ade'&ac- of the cons<ation process is a !e- step indecision+ma!in% with re%ards to the %rantin% of licences
" A teamwor! approach between the (mplo-er: H)s andemplo-ees is stron%l- advocated for the safet- report
development process as a whole
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#ons<ation
" (mplo-ees have a si%nificant effect on the safet- ofoperations: as a res< of their behavio&r: attit&de andcompetence in the cond&ct of their safet-+related roles
" The involvement of the emplo-ees in the identification ofhazards and control meas&res enhances@
- Their awareness of these iss&es
and
- Is critical to the achievement of safe operation in practice
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#ond&ctin% the HAI/
H"$I% !eam election
" The team selection for the area or plant is critical to the wholehazard identification process
" *ersonnel with s&itable s!ills and e$perience sho&ld be
available to cover all iss&es for disc&ssion within the HAI/process
" A well mana%ed: formalised approach with appropriatedoc&mentation is re'&ired
" Team selection and trainin% in methodolo%- &sed is to beprovided
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#ond&ctin% the HAI/
H"$I% !eam election
" Facilitated m<i+disciplinar- team based approach
" )&itabl- '&alified and e$perienced independent person tofacilitate
" )&itabl- e$perienced and '&alified personnel for the process:operations and e'&ipment involved
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#ond&ctin% the HAI/
H"$I% !eam election
" These emplo-ees MAJ ( the H)s b&t /O DOT HA6( TO (
" However: the H)s sho&ld be cons<ed in selection ofappropriate persons + this process m&st be doc&mented and be
transparent" Do sin%le person can cond&ct a HAI/
" A team approach will be most effective
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#ond&ctin% the HAI/
H"$I% tudy !eam
The t-pical st&d- team wo&ld comprise@
" )t&d- facilitator
" Technical secretar-
" Operations mana%ement" H)Operations representative
" *roject en%ineer or project desi%n en%ineer for new projects
" *rocess en%ineer
" Maintenance representative
" Instr&ment electrical representative
Dote@ the above team ma!e &p is indicative onl-
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#ond&ctin% the HAI/
H"$I% Planning
The followin% steps are re'&ired@
" *lannin% and preparation
" /efinin% the bo&ndaries and provide s-stem description" /ivide plant into lo%ical %ro&ps
" eview *5I/s and process schematics to ens&re acc&rac-
" Optimise HAI/ process b- means of preplannin% wor!involvin% relevant sta!eholders ,operations: maintenance:
technical and safet- personnel
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#ond&ctin% the HAI/ 4 #onsider the *ast: *resent and F&t&re
Existing
conditions
!uture
conditions
"istorical
conditions
hat has %one wron% in the past
hat co&ld %o wron% c&rrentl-
hat co&ld %o wron% d&e to chan%e
#oot Cause"istorical #ecordsProcess Experience$ear %isses
&denti'ied
"a(ards")*&D +or,sop")*.P /tud/cenario De'initionsCec,lists
Cange %anagement+at-&' udgementPrediction
un'oreseeale
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#ond&ctin% the HAI/
It is temptin% to disre%ard Don+#redibleB )cenarios CT
" Don+credibleB scenarios have happened to others
" orst cases are important to emer%enc- plannin%
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It happened to someone else K
Aftermath of an e$plosion,C.). #H(MI#A3 )AF(TJ AD/ HAA/ ID6()TI0ATIOD OA/: )I(A
#H(MI#A3 #OM*ADJ (*OT DO. 7L+;;1+I+D6: Ean&ar- 17LL
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#ond&ctin% the HAI/
Issues for consideration
" ('&ipment can be off+line
" )afet- devices can be disabled or fail to operate
" )everal tas!s ma- be conc&rrent
" *roced&res are not alwa-s followed" *eople are not alwa-s available
" How we act is not alwa-s how we plan to act
" Thin%s can ta!e twice as lon% as planned
" Abnormal conditions can cross section limits
4 *ower fail&re
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#ond&ctin% the HAI/ 4 HAI/ *rocess
Existing studies
De'ine oundar /stem description
Diide sstem into sections
/stematicall record all a(ards
&ndependent cec,
#eisit a'ter ris, assessment"a(ard #egister
/elected metods
asset or euipment 'ailure
external eents process operational deiations a(ards associated it all materials uman actiities ic could contriute to incidents interactions it oter sections o' te 'acilit
Analyse each section
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#ond&ctin% the HAI/
&eeting 'enue
" Hold on site if possible
" Avoid interr&ptions if possible
" )ched&le within the normal wor! pattern: or within the safet-
report activities" Meetin%s less than > ho&rs are not effective
" Meetin%s that last all da- are also not effective: howeverpracticalities ma- re'&ire all da- meetin%s
" /onGt &nderestimate the time re'&ired
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#ond&ctin% the HAI/
Recording %etail" The level of detail is important for@
- #larit-
- Transparenc- and
- Traceabilit-
" A s-stem ,hazard re%ister is re'&ired for !eepin% trac! of theprocess for each anal-sed section of the facilit-
" The items to be recorded are@
+ )t&d- team
+ )-stem bein% eval&ated
+ Identified hazard scenario
+ #onse'&ences of the hazard bein% realised
+ #ontrols in place to prevent hazard bein% realised and theirade'&ac-
+ Opport&nit- for additional controls
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HAI/ Techni'&es + Overview
" #hec!lists + (uestions to assist in hazard identification
" rainstormin% + )hate#er anyone can thin* of
" hat If Anal-sis + possi+le outcomes of change
" HAO* + identifies ,process plant- type incidents
" FM(AFM(#A + e(uipment failure causes
" Tas! Anal-sis 4 maintenance acti#ities. procedures
" Fa< Tree Anal-sis + com+inations of failures
&ncreasinge''o
rtre5uired
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#hec!lists
" )imple set of prompts or chec!list '&estions to assist in hazardidentification
" #an be &sed in combination with an- other techni'&es: s&ch ashat IfB
" #an be developed pro%ressivel- to capt&re corporate learnin% ofor%anisation
" *artic&larl- &sef&l in earl- anal-sis of chan%e within projects
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Initiating
E#ents
/eneral Causes Initiating Causes
Overfills And)pills
ImproperOperation
Operatin% (rror
Inade'&ate Incorrect *roced&re
Fail&re To Follow *roced&re
O&tside Operatin% (nvelope
Inade'&ate Trainin%
6esselTan!er)hell Fail&re
#orrosion et H2) #rac!in%
0eneral *rocess
#oolin% ater
)team #ondensate
)ervice ater
MechanicalImpact
Missiles
#rane
6ehicles
#hec!lists
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#hec!lists
"d#antages" Hi%hl- val&able as a cross chec! review tool followin%
application of other techni'&es
" Csef&l as a shop floor tool to review contin&ed compliancewith )M)
%isad#antages
" Tends to stifle creative thin!in%
" Csed alone introd&ces the potential of limitin% st&d- toalread- !nown hazards + no new hazard t-pes are identified
" #hec!lists on their own will rarel- be able to satisf- re%&lator-re'&irements
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rainstorm
" Team based e$ercise" ased on the principle that several e$perts with different
bac!%ro&nds can interact and identif- more problems whenwor!in% to%ether
" #an be applied with man- other techni'&es to var- thebalance between free flowin% tho&%ht and str&ct&re
" #an be effective at identif-in% obsc&re hazards which othertechni'&es ma- miss
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rainstorm
"d#antages" Csef&l startin% point for man- HAI/ techni'&es to foc&s a
%ro&pGs ideas: especiall- at the projectGs concept phase
" Facilitates active participation and inp&t
" Allows emplo-ees e$perience to s&rface readil-
" (nables thin!in% o&tside the s'&areB" 6er- &sef&l at earl- sta%es of a project or st&d-
%isad#antages
" 3ess ri%oro&s and s-stematic than other techni'&es
" Hi%h ris! of missin% hazards &nless combined with other tools" #a&tion re'&ired to avoid overloo!in% the detail
" elies on e$perience and competenc- of facilitator
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hat If
" hat if anal-sis is an earl- method of identif-in% hazards" rainstormin% approach that &ses broad: loosel- str&ct&red
'&estionin% to post&late potential &psets that ma- res< in anincident or s-stem performance problems
" It can be &sed for almost ever- t-pe of anal-sis sit&ation:especiall- those dominated b- relativel- simple fail&re
scenarios
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hat If
" Dormall- the st&d- leader will develop a list of '&estions toconsider at the st&d- session
" This list needs to be developed before the st&d- session
" F&rther '&estions ma- be considered d&rin% the session
" #hec!lists ma- be &sed to minimise the li!elihood of omittin%some areas
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hat If
($ample of a hat If report for a sin%le assessed item
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hat If
"d#antages" Csef&l for hazard identification earl- in the process: s&ch as
when onl- *F/s are available
" hat If st&dies ma- also be more beneficial than HAO*swhere the project bein% e$amined is not a t-pical stead- stateprocess: tho&%h HAO* methodolo%ies do e$ist for batch and
se'&ence processes
%isad#antages
" Inabilit- to identif- pre+release conditions
" Apparent lac! of ri%o&r
" #hec!lists are &sed e$tensivel- which can provide t&nnelvision: thereb- r&nnin% the ris! of overloo!in% possibleinitiatin% events
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HAO*
" A HAO* st&d- is a widel- &sed method for the identification ofhazards
" A HAO* is a ri%oro&s and hi%hl- str&ct&red hazardidentification tool
" It is normall- applied when *F/s and *5I/s are available
" The plantprocess &nder investi%ation is split into st&d- nodesand lines and e'&ipment are reviewed on a node b- node basis
" 0&ideword and deviation lists are applied to processparameters to develop possible deviations from the desi%nintent
H"#$% results in a &er! a s!stematic assessment of hazards
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HAO*
($ample of a HAO* report for a sin%le assessed item
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HAO*
"d#antages" ill identif- hazards: and events leadin% to an accident:
release or other &ndesired event
" )-stematic and ri%oro&s process
" The s-stematic approach %oes some wa- to ens&rin% allhazards are considered
%isad#antages
" HAO*s are most effective when cond&cted &sin% *5I/s:tho&%h the- can be done with *F/s
" e'&ires si%nificant reso&rce commitment
" HAO*s are time cons&min%
" The HAO* process is '&ite monotono&s and maintainin%participant interest can be a challen%e
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FM(AFM(#A
" Objective is to s-stematicall- address all possible fail&remodes and the associated effects on a technical s-stem
" The &nderl-in% e'&ipment and components of the s-stem areanal-sed in order to eliminate: miti%ate or red&ce the fail&reor the fail&re effect
" est s&ited for mechanical and electrical hardware s-stems
eval&ations
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FM(AFM(#A
($ample of an FM(AFM#(A report for a sin%le assessed item
Potential
0ailure
&ode
Potential
Effects of
0ailure
Potential
Causes
of0ailure
Comments Recommendations
Open
indicator
switch failed
ron%
indication of
valve bac! to
control s-stemca&sin%possible
incorrect
controlleraction to be
ta!en
ear and
tear
#ommissionin%
and test
proced&res
m&st ens&rethat all divertere'&ipment
indicators are
correctl- wiredto the diverter
control s-stem
The inte%rit- of the
position indicators for
the /iverter s-stem
e'&ipment is critical tothe lo%ic of the controls-stem.
It is recommended that
the position indicatorsare discretel- f&nctiontested prior to
commencement of eachpro%ram
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FM(AFM(#A
"d#antages" 0enerall- applied to solve a specific problem or set ofproblems
" FM(AFM(#A was primaril- considered to be a tool or processto assist in desi%nin% a technical s-stem to a hi%her level ofreliabilit-
" /esi%ned correction or miti%ation techni'&es can beimplemented so that fail&re possibilities can be eliminated orminimized
%isad#antages
" It is ver- time cons&min% and needs specialist s!ills from
different bac!%ro&nds to obtain ma$im&m effect" 6er- hard to assess operational ris!s within an FM(AFM(#A
,li!e the- can be within a HAO* or hat if st&d-
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Tas! Anal-sis
" Techni'&e which anal-ses h&man interactions with the tas!sthe- perform: the tools the- &se and the plant: process orwor! environment
" Approach brea!s down a tas! into individ&al steps andanal-ses each step for the presence of potential hazards
" Csed widel- to mana%e !nown inj&r- related tas!s in
wor!place
" ($cellent tool for hazard identification related to h&man tas!s
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Tas! Anal-sis
%isad#antages" /oes not address plant process deviations which are not related
to h&man interaction
Caution
" elies on m<i+disciplined inp&t with specific inp&t of personwho normall- carries o&t the tas!
" Often ass&med to be the onl- tool of hazard identification orris! assessment: as it is &sed %enerall- at the shop floor
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Fa< Tree Anal-sis
" 0raphical techni'&e approach" *rovides a s-stematic description of the combinations of
possible occ&rrences in a s-stem which can res< in anidentified &ndesirable o&tcome ,top event
" This method combines hardware fail&res and h&man fail&res
" Cses lo%ic %ates to define modes of interaction ,AD/s Os
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Fa< Tree Anal-sis
,-. OR
PSV does not
relieve
Process
pressure
rises
Control
'ails ig
P/ too
small
/et point
too ig
P/ stuc,
closed
!ouling inletor outlet
Pressure
rises
Process
vessel over
pressured
,-.
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Fa< Tree Anal-sis
"d#antages" &antitative + defines probabilities to each event which can be
&sed to calc&late the probabilit- of the top event
" (as- to read and &nderstand hazard profile
" (asil- e$panded to bow tie dia%ram b- addition of event tree
%isad#antages
" Deed to have identified the top event first
" More diffic< than other techni'&es to doc&ment
" Fa< trees can become rather comple$
" Time cons&min% approach" &antitative data needed to perform properl-
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eview and evision
")*&D
#eision
.rgani(ational
canges
Process or
condition
monitoring
canges&ncident
inestigation
results
)normal conditions
troug design enelope
canges
$e
proects
The followin% are e$amples of when a HAI/ revision sho&ld occ&r
) f Addi i l I f i
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)o&rces of Additional Information
" 'oss %re&ention n he %rocess ndustries: )econd (dition: eed(d&cational and *rofessional *&blishin%: F. * 3ees:177