application of various techniques for
DESCRIPTION
APPLICATION of Various Techniques for. IDENTIFICATION OF INDUSTRIALHAZARD. 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. SYSTEM DESCRIPTION. - PowerPoint PPT PresentationTRANSCRIPT
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)