process hazard analyses: the best methodologies & processes for your organization panelist...

Process Hazard Analyses:The Best Methodologies & Processes for your Organization

PanelistSpeaker

Sajjad Gul, Dir. Business Dev.Rob Bartlett, PSM Consultant

Copyright: All rights reserved by 360factors Inc., and Pareto Eng. and Management Consulting

Zafar Ahmed, Mktng Manager

Host


About – 360factors

Rob Bartlett owns Pareto Engineering & Management Consulting. He uses his over 20 years of experience to partner with companies to create World Class Process Safety Systems.

About – Pareto Eng. & Consulting Management


About Us – Consulting Solutions



7 Offices in 4 Countries

Our Presence

INDUSTRY FOCUSED

Chemicals

Oil & Gas

Mining

Manufacturing

Manila, Philippines

Karachi, Pakistan

Austin, TX(US HQ)

INDUSTRY FOCUSED$40M+ REVENUE400+ EMPLOYEES GLOBAL

PRESENCE

Toronto,Canada

Corpus Christi, TX

San Diego, CA

Houston, TX

Client Concentration - Utilities- 40% market share in

North America including NERC (regulator)

- EHS- 30% of our business comes from EHS solutions

Our Clients & Industry Focus

1984 – Bhopal, India

2000+ fatalities. 170 injuries

2005 – Texas City15 fatalities. 170 injuries

1974 – Flixborough, England

28 fatalities. unknown injuries

1984 – Mexico City650 fatalities. unknown injuries

2014 – Texas City

4 fatalities. unknown injuries

Why Process Safety?


Costs and Benefits of Good Safety Performance

What we seeDirect Costs of Injuries Medical costs

Wage indemnity

Claims administration fees

What we don’t seeThe Hidden Costs of Injuries Damaged equipment, vehicles & goods

Lost production and quality

Process interruptions, yield losses

Replacement labor / Overtime

General liability costs

Litigation

Damage to customer relations & public image

Direct Cost

Indirect Cost

5X


Process Hazard AnalysesThe Best Methodologies & Processes for your Organization


Agenda:

Training Objectives OSHA Requirements Methodologies

- Basic

- Advanced Keys to Excellent PHAs Questions


At the end of the webinar, we hope that you:Understand the requirements that OSHA has

for PHAsUnderstand various tools and methodologies

for PHAs that can be used on a Covered Process

Understand a process that can be used to conduct a PHA, from preparation through completion

Training Objectives



OSHA requires PHAs for PSM-Covered Processes

Invest to reduce risk of catastrophic and serious incidents that effect employees and the community

Invest to reduce risk of significant business interruption caused by incidents

You cannot afford an explosion…a toxic release… a fatality…

Why spend the time & money on PHAs?


Need PHA on covered processes initially & every 5 years appropriate to the complexity of the process identify, evaluate, and control the hazards involved in

the process use one or more of the specified methodologies as

appropriate to determine and evaluate the hazards of the process being analyzed

PHA team needs expertise in process as well as PHA methodology

OSHA Requirements – 1910.119(e)


OSHA Requirements – 1910.119(e) (Contd.)

Need system to “promptly” address recommendations PHA must address:

hazards of the process; previous incidents that could have catastrophic

consequences engineering & administrative controls consequences of failure of controls facility siting & human factors qualitative evaluation of a range of the possible safety and

health effects of failure of controls on employees


Basic methodologies all have the same approach: Brainstorm potential deviations Determine potential consequences of each deviation Identify any existing safeguards to prevent the deviation Qualitatively assess the risk of the deviation causing the

consequence If needed, determine recommendations to reduce risk

Methodology chosen depends on: the level of hazard the process complexity level of understanding of the process

Basic PHA Methodologies

Checklist - Uses list of hazard review questions to prompt brainstorming for hazards

What-If - Loosely structured or unstructured brainstorming for accident scenarios

What-If/Checklist - Similar to What-If but uses categories to provide more structure than What-If

Hazard & Operability Study (HAZOP) - Uses guidewords to structure brainstorming of deviations

Failure Mode and Effects Analysis (FMEA) - Discusses each mode of potential failure of each component of a process

Basic PHA Methodologies (Contd.)



Used primarily for scenarios that need quantitative analysis Layers of Protection (LOPA) Fault Tree Analysis Event Tree Analysis

On average, only 1% - 5% of scenarios need this level of analysis Many PSM processes do not pose an adequate risk to

require

Rigorous PHA Methodologies


Generic PHA Process

.• Prepare

.• Conduct PHA

.• Report & Communicate

.

• Management Review and Implementation


Choose a Facilitator Can be internal or external resource

Select cross-functional team Operators Maintenance Supervision Engineering Others as needed – e.g. chemists, corrosion experts,

contractors Best if Facilitator not filling another role

Generic PHA Process - Preparation


Generic PHA Process – Preparation (Contd.)

Gather & prepare Process Safety Information (PSI) Process Flow and Process & Instrumentation Diagrams

• Verify that they are up-to-date and accurate

Any other pertinent engineering drawings• Ventilation Design

• Fire Suppression System Design

• Electrical Classification Drawings

Most recent SDS’s• Raw materials, intermediates, and final products

Other information should be available if needed



Define PHA Nodes - Using Process Flow Diagram


Generic PHA Process – Preparation (Contd.) Define PHA Nodes – Using P&IDs



Prepare a list of all changes (MOCs) completed since the last PHA

Prepare a list of all incidents involved with the process since the last PHA Include incidents at other similar facilities within the company

and from other companies


Gather team in an area separate from the process Choose PHA Methodology Generate scenarios and assess risk

Most companies use a risk matrix based on severity and frequency to determine risk

For scenarios that the team deems risk should be reduced, document recommendations

Generic PHA Process – Analysis

Example of a What-If Analysis

Node What if… Consequences Safeguards

Reactor Operator fails to close the hatch fully?

Escape of flammables into the room with risk of fire/explosion

1) Hatch proximity switch alarms and is interlocked to reactor heat

2) Area is rated Class I, Div. 1

Reactor Rupture disk fails and reactor pulls a vacuum?

Suck oxygen into an environment with flammable hot flammable liquids

1) Rupture disk tellback alarms if failure under vacuum

Reactor Reflux valve fails closed?

All liquid would boil off and polymer would harden in the reactor – operability issue only

1) Top of column temp controlled by PLC & alarm for high temp

Generic PHA Process – Analysis (Contd.)


Example of HAZOP

Node Variable Keyword Consequences Safeguards

Reactor Pressure High Vessel rupture causing severe injuries and equipment/building damage

1) Pressure control by PLC

2) Rupture Disk with tellback

Reactor Pressure Low No consequences of interest 1) Vessel rated for full vacuum

Reactor Temperature High Runaway reaction leading to excessive pressure build-up with potential vessel rupture causing severe injuries and equipment/building damage

1) Temperature control of hot oil system by PLC

2) Rupture Disk with tellback



Example of an FMEA

Node Failure Mode Possible Cause

Consequences Safeguards

Drum packout Ignition of flammable vapors

1) Static discharge from personnel

2) Static discharge from equipment

3) Static discharge from excessive flow rate

Flash fire at drum causing potentially serious injury

1) Operators are bonded to discharge piping

2) -All equip is grounded- Ground Verification System to ground drum

3) Orifice in pipe limits flow to below critical rate


Risk Rating Example - Severity



Risk Rating Example – Severity



Risk Matrix Example - Frequency



Risk Matrix Example – Risk Ranking



Example of full PHA Worksheet

Node Failure Mode

Possible Cause

Consequences Safeguards Sev Freq Risk Recommendation

Drum packout

Ignition of flammable vapors

Static discharge from personnel

Flash fire at drum causing potentially serious injury

Newson-Gale Ground Verification System

3 2 M Bond operators to drum via wrist strap


If any scenarios are high risk, use an advanced method: Layers of Protection (LOPA) Fault Tree Analysis Event Tree Analysis



Examples of Recommendations Consider installing proximity switch on valve and

interlocking to pump. Verify that inspection and testing of relief device is

adequate. Consider installing flow meters that can be connected to

the PLC and implementing interlocks to prevent overfill. Keys to success

Do not be too prescriptive Not every item needs a recommendation – risk or existing

safeguards can be adequate



Document PHA with Recommendations Generate a report that includes:

• specifics about the PHA sessions (e.g. attendees, job positions, dates and times)

• fully document all scenarios, risks assessments, & recommendations

Communicate results to Management & Affected Employees Affected employees include those who work in areas that

are or may be effected by scenarios and recommendations

Generic PHA Process - Reporting


Management Review of PHA Team’s Recommendations for any rejected, document the reason for rejection report the results of Management Review to PHA Team to

allow for rebuttal if necessary. Implement accepted Recommendations

no specific requirement for timing develop closure timing policy based on risk

Once all are complete: document disposition of all Recommendations in a final report communicate to Management and all Affected Employees

Generic PHA Process - Implementation


Choose an excellent, multidisciplinary team Allow team sufficient time to complete PHA Always consider previous incidents Always evaluate designed and engineered safeguards Always evaluate human errors and Human/Machine

Interfaces (HMI) Include evaluation of relevant external influences (e.g.,

weather, earthquakes, etc.) Analyze for hazards during all modes of operation (e.g.

start-up, shutdown, emergency shutdown, start-up after an emergency)

Keys to Excellent PHAs


Q&A

At the end of the day, safety is all about care, saving lives, families, and the society we operate in.


NEXT WEBINAR

Topic: Mechanical Integrity February 26 at 2:00PM CST Webinar Invitation will be emailed


process hazard analyses: the best methodologies & processes for your organization panelist...

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