Hazard Identification
We need to know what the hazards Where they exist in the process.
Process Information Process Structure
Feed, Product, Byproduct & Waste Structure Inherent Safety Structure
Recycle Structure Separation Structure
Heat Integration
Process Control Structure
Hazard Identification
To reduce or eliminate the hazard.
Inherently Safer Processes Strategies
MINIMIZE Use smaller quantities of hazardous substances.
SUBSTITUTE Replace hazardous substances with a less hazardous ones.
MODERATE Use less hazardous conditions, a less hazardous forms of a material, or less hazardous facilities.
SIMPLIFY Use less complexity.
• Identify the hazards during synthesis and later
• Evaluate them for risk
Recycle, separation, heat integration and process control structures
‘A hazard is an inherent physical or chemical characteristic that has the potential for causing harm.’
We need to identify HAZARDS.
We need to evaluate HAZARDS against acceptable risk criteria.
We need to reduce HAZARDS when criteria aren’t meant.
The Hazard Identification Methodology
which is the focus for design is a disciplined, organized effort to identify significant
HAZARDS in the evolving process.
Hazard Identification
Identify the HAZARD
We are going to use Hazard and Operability Studies on a limited basis.
Evaluate the HAZARD
We are going to use Layer of Protection Analysis. This requires identifying the scenario, identifying the layers of protection,
determining the probability and determining the consequence.
Reduce the HAZARD
We are going to use Inherent Safety Concepts to reduce the hazard where we fail to meet the acceptable risk criteria.
RISK = PROBABILITY * CONSEQUENCE
Hazard Identification
Where does hazard identification fit in the Inherent Safety Structure?
System Description
Hazard Identification
Scenario Identification
Event Probability Event Consequence
Risk Determination
Acceptable? No
Re-Design System Using Inherent Safety
Risk Assessment is an integral part of the design,
start-up, operation procedure.
Our emphasis in synthesis is to eliminate or reduce hazard. Our focus is on
inherent safety. Nevertheless, when hazards still exist in the design, there is the potential that they can escape and cause harm. Once the hazard is identified, we attempt to identify accident or excursion scenarios so that we can
determine the risk and determine whether it is acceptable.
Hazard Identification
This is just the beginning, we are
just scratching the surface.
Yes
The successful Hazard Evaluation program meets the following:
• The need for risk information has been met;
• The results are of high quality and are easy for decision makers to use;
• The study has been performed with the minimum resources needed.
The selection of Hazard Evaluation program is based on the following:
• The motivation for the study and types of results needed
• The type of information available, perceived risks, characteristics
• The resource availability and analyst/management preference
Hazard Identification
• Safety Review -- Qualitative descriptions of potential safety problems
• Checklist -- Written list of items to verify status of system
• Relative Ranking -- A strategy to compare systems for further study
• Preliminary Hazards Analysis -- General method to focus on system
• What-if Analysis -- Brainstorming approach concerning undesired events
• What-if/Checklist -- Combined brainstorming/detailed list
• Hazard and Operability Study -- Systematic method to identification
• Failure Modes and Effects Analysis -- Tabulate equipment failure modes
• Fault Tree Analysis -- Deductive approach from event to cause
• Event Tree Analysis -- Inductive from initiating to all outcomes
• Cause Consequence Analysis -- Combined Fault and Event Trees
• Human Reliability Analysis -- Systematic evaluation of factors affecting personnel
Hazard Identification ?
We are going to be focusing on HazOp.
Examples ~
Seperti checklist untuk untuk process safety, dapat meliputi :
Tata letak
Bangunan / gedung
Proses
Perpipaan
Unit proses (peralatan)
Ventilasi
Instruentasi dan elektrik
Peralatan safety
raw material
Safety Equipment
1. Fire extinguishers required? t required?
2. Special respiratory equipment required ? 3. Diking material required?
4. Colorimetric indicator tubes required?
5. Flammable vapor detection apparatus required?
6. Fire extinguishing materials compatible with process materials? ‘
7. Special emergency procedures and alarms required?
Further study required ?
Does not apply Completed
Contoh 1. Process safety checklist
Raw Materials
1. Any materials and products required special. handling equipment?
2. Any raw materials and product extreme weather conditions?
3. Any products hazardous from a toxic or fire standpoint?
4. Proper containers being used?
5. Containers properly labelled for toxicity, flammability, stability, etc?
6. Consequences of bad spills considered?
7. Special instructions needed for containers or for storage and warehousing by distributors?
8. 8. Does warehouse have operating instructions covering each product regarded as critical?
Identify Are people exposed to harm resulting from the company’s operations?
Assess What are the causes, consequences & effects?
How likely is the loss of control?
What is the risk & is it ALARP?
Control Can the causes be eliminated?
What controls are needed & can they be effective?
Recover Can the potential consequences & effects be mitigated?
What are the recovery measures required?
Are the recovery capabilities suitable & sufficient?
Hazards Identification
AS LOW AS REASONABLY PRACTICABLE
HAZARD - Definition
Hazard is defined as:
Anything that has the potential to cause harm, ill health and injury, damage to property, products or the
environment, production losses or increase liabilities
Hazard At workplace categorized:
Physical, Chemical, Biological & Physcosocial Step 1- Hazard
Identify all HAZARDS
Hazard - examples
• Hydrocarbon under pressure
• Smoke
• Toxic material
• Volatile fluids in tanks Chemical
• Moving road tankers / vehicles
• Elevated objects
• Noise
• People working at heights
• High voltage Physical
Hazard - examples
• Toxicological lab
(catering facility at distant work station) Biological
• Working outside the country without family members.
Physcosocial
Step 2 - Top Event
List Top Events or Incidents which will result when hazards are released and relate them to the hazards identified
Top Event - definition
Top Event is defined as:
The incident which occurs as a result of the hazard being released
Hazard Top Event
(Incident)
Top Event - examples
• Loss of containment
• Electrical shock
• Fall from heights
• Exposure to toxic material
• Exposure to radioactive material
• Effluent discharge into waterways
• Emissions of toxic gases
Consequence - definition Consequence is defined as:
An event or chain of events that results from the hazard being released
Hazard Top Event
(Incident)
Asset Damage
People
Environment
Reputation
Consequences - examples
• Serious injury
• Death
• Latent illness or disease which has long gestation period
• Property damage - own or public
• Environmental damage
• Loss of reputation leading to loss in current and prospective business
• Loss of revenue - paying for compensation, medical expenses, production loss or deferment
Step 4 - Hazard register
Compile a Hazards & Effects register listing Hazards, Top Event & Consequences
Hazard Threats Barriers Top Event
Recovery Measures
P A E R
Initial Risk
Final Risk Risk
Rating Remedial
Action Required HAZARDS & EFFECTS REGISTER
X
X
X
X
X
X
X
X
X
X
X
X
Consequences
Step 5 -Risk ranking
Using the Risk Matrix & brainstorming techniques rank the hazards and consequences based on the probabilities of the Top Event occurring
RISK MATRIX
RATING
0 1 2 3 4 5
A B C D E
CONSEQUENCE INCREASING PROBABILITY
PEOPLE ASSETS ENVIRONMENT REPUTATION NEVER HEARD OF IN
INDUSTRY
HEARD OF INCIDENT IN
INDUSTRY
INCIDENT HAS
OCCURRED IN OUR COMPANY
HAPPENS SEVERAL TIMES PER YEAR IN CO.
HAPPENS SEVERAL TIMES PER YEAR AT LOCATION No
injury No
damage No
impact
No impact Slight
injury
Slight
damage Slight impact
Slight impact Minor
injury Minor damage
Minor impact
Limited impact Major
injury
Local damage
Localised impact
Considerable impact Single
fatality Multiple fatalities
Major damage Extensive damage
Major impact
Major national Massive
impact
Major
international
Demonstrate ALARP
INTOLERABLE
RM
RM
RM
RM
RM
RM
Prepare HSE Case Incorporate Risk
Reduction measures Manage for
Continuous Inprovement
Ranking Risk Probability
Hazard Threats Barriers Top Event
Recovery Measures
P A E R
Initial Risk
Final Risk Risk
Rating Remedial
Action Required HAZARDS & EFFECTS REGISTER
X
X
X
X
X
X
X
X
X
X
X
X X
X
X
X X
X
X
X X
X
X
X
X
X
X
X Consequences
X
X
X
X
No. Description
0 No Injury or damage to Health
1 Slight Injury or health effects (including first aid case and medical traement case) -Not affecting work performance or causing disability
2 Minor injury or health effects(Lost Time Injury) - Affecting work performance, such as restriction to work activities (Restricted Workday Case) or a need to take a few days to fully recover(Lost Workday Case).
Limited health effects are reversible e.g. skin irritation, food poisoning.
3. Major injury or health effects ( including Permanent Partial Disability) - Affecting work performance in the longer term,such as prolonged absence from work. Irreversible health damage without loss of life, e.g. noise induced hearing loss, chronic back injuries
4. Single fatality- From accident or occupational illness ( poisoning, cancer) 5. Multiple fatalities - From accident or occupational illness(poisoning, cancer)
Harm to people
Consequence - definition
No. Description
0 Zero Damage
1 Slight damage - No disruption to operation
2 Minor damage - Brief disruption
3. Local damage - Partial shutdown
4. Major damage - Partial operation loss
5. Extensive damage - Substantial or total loss of operations
Consequence - definition
Damage to Asset
Consequence - definition
No. Description
0 Zero effect - No environmental damage. No cahange in environment. No financial consequences 1 Slight effect - Local environment damage. Within the fence and within systems. Negligible financial consequences
2 Minor effect - Contamination. Damage sufficiently large to attack the environment. Single exceedance of statutory or prescribed criterion. Single complaint. No permanent effect on the environment.
3. Localised effect - Limited loss of discharges of known toxicity. Repeated exceedance of statutory or prescribed limit. Affecting neighbourhood.
4. Major effect - Severe environmental damage. The company is required to take extensive measures to restore the contaminated environment to its original state. Extended exceedance of statutory or prescribed limits
5. Massive effect - Persistent severe environmental damage or severe nuisance extending over a large area.
In terms of commercial or recreational use of nature conservancy, a major economic loss for the company. Constant, high exceedance of statutory or prescribed limits.
Effect on the Environment
Consequence - definition
Impact on Reputation
No. Description
0 No impact - No public awareness.
1 Slight impact - Public awareness may exist, but there is no public concern.
2 Limited impact - Some local public concern. Some local media and / or local political attention with potentially adverse aspects for company operations.
3. Considerable impact - Regional public concern. Extensive adverse attention in local media. Slight national media and/ or local / regional political attention. Adverse stance of local government and / or action groups.
4. National impact - National public concern. Extensive adverse attention in the national media. Regional / national policies with potentially restrictive measures and / or impact on grant of licences. Mobilisation of action groups.
5. International impact - International public attention. Extensive adverse attention in international media.
National / International policies with potentially severe impact on access to new areas, grants of licences and / or tax legislation
Step 6 - Threats
For all hazards and consequences which have been ranked as HIGH risks, identify all threats or causes which can release the hazard to become a top event
Threat - definition Threat is defined as:
A possible cause that will release the hazard to become a top event- includes thermal, biological, electrical, chemical, kinetic, climatic, radiation or human factors
Hazard Top Event
(Incident)
Asset Damage
People
Environment
Reputation Threat
Threat
Threat
Threat - examples
• High temperature
• Corrosion
• Bacteria
• Overpressure
• Erosion
• High voltage
• Ultraviolet radiation
• Environmental conditions
• Human incompetence
• Design / process unknowns
Barrier - definition A Barrier is defined as :
A measure which is put in to prevent the release of a hazard or to prevent the occurrence of a top event once the hazard is released - barriers may be physical or non- physical
Hazard Top Event
(Incident)
Asset Damage
People
Environment
Reputation Threat
Threat
Threat
Barrier
Barrier Barrier
Barrier Barrier
Barrier
Barrier - examples
• Guards or protective shields e.g. protective coatings, corrosion inhibitors, machine guards, fencing etc.
• Pressure / safety relief valves
• High temperature cut-off switches
• Correct / valid operating procedures
• Time delays in processes
• Lowering speeds of equipment
• Carrying maintenance when it is due
• Reducing congestion in operating areas
Step 8 - Recovery Measures
Determine the Recovery Measures to reduce the
impact of the Consequences due to the occurrence of the Top Event
Recovery Measures
H A Z A R D
T H R E A T
B A R R I E R
TOP EVENT
C O N T A I N M E N T
M I T I G A T I O N
R E S T O R A T I O N
P A
E R
Activity or Condition which causes hazard release
Proactive control
Incident
Recovery Measures
Consequences
Recovery Measures - examples
• Gas, fire & smoke alarms
• Emergency Shutdown systems
• Firewater deluge systems
• Fire and blast walls
• Emergency Response plans, training & drills
• Business Resumption Plans
Step 9 - Escalation factors
Identify Escalation Factors which will reduce the effectiveness or operation of the barriers or
recovery measures and implement additional measures to compensate for these factors
Escalation Factors - definition Escalation Factors are defined as:
Conditions that lead to increased risk due to loss of barriers or loss of recovery measures especially life saving or mitigating capabilities
Hazard Top Event
(Incident)
Asset Damage
People
Environment
Reputation Threat
Threat
Threat
Barrier
Barrier Barrier
Barrier Barrier
Barrier
Recovery Measures Recovery Measures Recovery Measures
Recovery Measures Escalation
controls
Escalation Controls - Examples
• Abnormal operating condition e.g critical standby
equipment is under maintenance during an emergency
• Plant operating outside the design envelope
• Extreme environmental conditions - may not allow the activation of planned recovery measures
• Incorrect operation of the plant due to unavailability of updated operating procedures
• Human error due to lack of competence or ineffective training
Full hazard analysis
Hazard Top Event
(Incident)
Asset Damage
People
Environment
Reputation Threat
Threat
Threat
Barrier
Barrier Barrier
Barrier Barrier
Barrier
Recovery Measures Recovery Measures Recovery Measures
Recovery Measures Escalation
controls
Proactive Controls Reactive Controls
Hazard Threats Barriers Top Event
Recovery Measures
P A E R
Initial Risk
Final Risk Risk
Rating Remedial
Action Required HAZARDS & EFFECTS REGISTER
X
X
X
X
X
X
X
X
X
X
X
X X
X
X
X X
X
X
X X
X
X
X C5 D4,5 E3,4,5
X
X Consequences
X X X
C5 D4,5 E3,4,5
X X X
X
X
X
X
X
X
Completed Hazards & Effects Register
Step 11
Link Barriers and Recovery Measure controls to HSE Critical Activities
which are part of Business Activities
HSE Critical Activities
•HSE Critical Activities are the activities that require to be carried out to ensure the effectiveness and
correct operation of the Barriers and Recovery Measures at all times
•These activities are broken down into tasks
•For all these tasks, standards have to be specified and clear & valid procedures should be available
•Competency requirements for the staff to carry out the task and also for the supervisors should be made clear.
Where there are gaps, they should be sent for training