Guidelines for Hazard Evaluation Procedures

Front Cover
Dedication
List of Tables
List of Figures
Abbreviations and Acronyms
Glossary
Acknowledgments
Table of Contents
Part I. Hazard Evaluation Procedures
Preface
Management Overview
1. Introduction to the Guidelines
1.1 Background
1.2 Relationship of Hazard Evaluation to Risk Management Strategies
1.3 Anatomy of a Process Incident
1.4 The Role of Safeguards
1.4.1 Contain and Control
1.4.2 Preventive Safeguards
1.4.3 Mitigative Safeguards
1.5 Hazard Evaluation throughout a Plant Lifetime
1.6 Hazard Evaluation and Regulations
1.7 Limitations of Hazard Evaluation
1.7.1 Completeness
1.7.2 Reproducibility
1.7.3 Inscrutability
1.7.4 Relevance of Experience Base
1.7.5 Reliance on Subjective Judgment
References
2. Preparation for Hazard Evaluations
2.1 Infrastructure
2.2 Analysis Objectives
2.3 Developing the Review Scope and Boundaries
2.4 Information Requirements
2.5 Use of Software Programs
2.6 Personnel and Skills
2.7 Schedule and Execution
2.8 Initial Team Review Meeting
2.8.1 Orientation
2.8.2 Process Overview
2.8.3 Facility Walkdown
2.8.4 Documentation of Attendance
2.8.5 Review of Process Safety Documentation
2.8.6 Previous Incidents Review
2.8.7 Hazard Identification and Inherent Safety Review
2.8.8 Global Facility Siting and Human Factors Considerations
References
3. Hazard Identification Methods
3.1 Analyzing Material Properties and Process Conditions
3.2 Using Experience
3.3 Developing Interaction Matrices
3.4 Hazard Identification Results
3.5 Using Hazard Evaluation Techniques to Identify Hazards
3.6 Initial Assessment of Worst-Case Consequences
3.6.1 The Dow Fire/Explosion Index and Chemical Exposure Index
3.7 Hazard Reduction Approaches and Inherent Safety Reviews
3.7.1 Introduction to Hazard Reduction Approaches and Inherently Safer Systems
3.7.2 Inherent Safety Reviews
References
4. Non-Scenario-Based Hazard Evaluation Procedures
4.1 Preliminary Hazard Analysis
4.1.1 Purpose
4.1.2 Description
4.1.3 Types of Results
4.1.4 Resource Requirements
4.1.5 Analysis Procedure
4.1.6 Example
References
4.2 Safety Review
4.2.1 Purpose
4.2.2 Description
4.2.3 Types of Results
4.2.4 Resource Requirements
4.2.5 Analysis Procedure
4.2.6 Example
Reference
4.3 Relative Ranking
4.3.1 Purpose
4.3.2 Description
4.3.3 Types of Results
4.3.4 Resource Requirements
4.3.5 Analysis Procedure
4.3.6 Example
References
4.4 Checklist Analysis
4.4.1 Purpose
4.4.2 Description
4.4.3 Types of Results
4.4.4 Resource Requirements
4.4.5 Analysis Procedure
4.4.6 Example
References
5. Scenario-Based Hazard Evaluation Procedures
5.1 What-if Analysis
5.1.1 Purpose
5.1.2 Description
5.1.3 Types of Results
5.1.4 Resource Requirements
5.1.5 Analysis Procedure
5.1.6 Example
5.1.7 What-if Analyses Used for Further Scenario Evaluations
References
5.2 What-if/Checklist Analysis
5.2.1 Purpose
5.2.2 Description
5.2.3 Types of Results
5.2.4 Resource Requirements
5.2.5 Analysis Procedure
5.2.6 Example
5.2.7 What-if/Checklist Analyses Used for Further Scenario Evaluations
References
5.3 Hazard and Operability Studies
5.3.1 Purpose
5.3.2 Description
5.3.3 Types of Results
5.3.4 Resource Requirements
5.3.5 Analysis Procedure
5.3.6 HAZOP Study Variations
5.3.7 Example
References
5.4 Failure Modes and Effects Analysis
5.4.1 Purpose
5.4.2 Description
5.4.3 Types of Results
5.4.4 Resource Requirements
5.4.5 Analysis Procedure
5.4.6 Example
References
5.5 Fault Tree Analysis
5.5.1 Purpose
5.5.2 Description
5.5.3 Types of Results
5.5.4 Resource Requirements
5.5.5 Analysis Procedure
5.5.6 Example
References
5.6 Event Tree Analysis
5.6.1 Purpose
5.6.2 Description
5.6.3 Types of Results
5.6.4 Resource Requirements
5.6.5 Analysis Procedure
5.6.6 Example
References
5.7 Cause-Consequence Analysis and Bow-Tie Analysis
5.7.1 Purpose
5.7.2 Description
5.7.3 Types of Results
5.7.4 Resource Requirements
5.7.5 Analysis Procedure
5.7.6 Example
5.7.7 Bow-Tie Analysis
References
5.8 Other Techniques
References
6. Selection of Hazard Evaluation Techniques
6.1 Factors Influencing the Selection of Hazard Evaluation Techniques
6.1.1 Motivation for the Hazard Evaluation
6.1.2 Type of Results Needed
6.1.3 Type of Information Available to Perform the Study
6.1.4 Characteristics of the Analysis Problem
6.1.5 Perceived Risk of the Subject Process or Activity
6.1.6 Resource Availability and Preference
6.2 Decision-Making Process for Selecting Hazard Evaluation Techniques
6.3 Example Using the Proposed Selection Criteria
6.4 Hazard Reviews for Management of Changes
6.4.1 In-Depth Change Reviews
6.5 Combined Hazard Reviews
6.5.1 Types of Combined Hazard Reviews
6.5.2 Benefits of Combined Hazard Reviews
6.5.3 Potential Pitfalls of Combined Hazard Reviews
6.5.4 Strategies for Combined Hazard Reviews
6.6 Hazard Evaluation at Different Plant Lifetime Stages
6.6.1 Process Development
6.6.2 Detailed Design
6.6.3 Construction and Start-up
6.6.4 Operating Lifetime
6.6.5 Extended Shutdowns
6.6.6 Decommissioning
6.6.7 Hazard Evaluation of Mega-Projects
6.6.8 Hazard Evaluation during Mergers and Acquisitions
6.7 Integrating Occupational Safety, Environment, Reliability, Maintainability, Quality, and Security into Hazard Evaluations
6.7.1 Occupational Safety Considerations
6.7.2 Environmental Protection Considerations
6.7.3 Reliability, Maintainability, and Quality Considerations
6.7.4 Site Security Considerations
References
7. Risk-Based Determination of the Adequacy of Safeguards
7.1 Scenarios from Scenario-Based Hazard Evaluations
7.2 Severity of Consequences
7.2.1 Mitigative Safeguards and Scenario Impacts
7.3 Frequency of Initiating Causes
7.4 Effectiveness of Safeguards
7.5 Risk Estimation Using Risk Matrix or Direct Calculation
7.6 Layer of Protection Analysis
7.6.1 Purpose
7.6.2 Types of Results
7.6.3 Resource Requirements
7.6.4 Description
7.6.5 Anticipated Work Product
References
8. Analysis Follow-up Considerations
8.1 Development of Recommendations
8.2 Prioritization of Hazard Evaluation Results
8.2.1 Types of Results
8.2.2 Basis for Prioritization
8.2.3 Approaches for Prioritizing Study Recommendations
8.3 Documentation of Hazard Evaluations
8.4 Development of a Management Response to a Hazard Evaluation
8.5 Resolution of Action Items
8.6 Communication of Special Findings/Sharing of Information
8.7 Use of Hazard Evaluation Results over the Plant Lifetime
References
9. Extensions and Special Applications
9.1 Hazard Evaluation of Procedure-Based Operations
9.1.1 Overview of Methodology
9.1.2 Purpose
9.1.3 HAZOP Method for Analyzing Deviations of Procedural Steps
9.1.4 Two Guide Word Method for Analyzing Deviations of Procedural Steps
9.1.5 What-if Method for Analyzing Deviations of Procedural Steps
9.1.6 Choosing the Right Method for Analysis of Procedure-Based Operations
9.1.7 Case Study
9.1.8 Linkage to Detailed Human Reliability Analysis
References
9.2 Hazard Evaluation of Processes Controlled by Programmable Systems
9.2.1 Software Failures in Programmable Systems
9.2.2 Hardware Failures in Programmable Systems
9.2.3 Systematic Hazard Evaluation of Processes with Programmable Systems
References
9.3 Hazard Evaluation of Chemical Reactivity Hazards
References
9.4 Combinations of Tools
9.4.1 What-if/LOPA and HAZOP/LOPA
9.5 Human Factors and Human Reliability Analysis
9.5.1 Purpose
9.5.2 Types of Results
9.5.3 Resource Requirements
9.5.4 Technical Approach
9.5.5 Analysis Procedure
9.5.6 Anticipated Work Product
References
9.6 Facility Siting
9.6.1 Facility Location
9.6.2 Facility Layout
9.6.3 Personnel Protection
References
Part II. Worked Examples
Preface to the Worked Examples
Management Overview of the Worked Examples
10. Introduction to the Worked Examples
10.1 Purpose
10.2 Instructional Strategy
10.3 How to Use the Worked Examples
Reference
11. Description of the Example Facility and Process
11.1 Company and Facility Background
11.2 Process Overview
11.3 Description of the Process Lifetime
12. Hazard Identification for the Example Process
12.1 Analysis of Material Properties
12.2 Review of Experience
12.3 Interaction Matrix
12.4 Hazard Evaluation Techniques Used for Hazard Identification
12.5 Summary
References
13. Research and Development Phase
13.1 Problem Definition
13.1.1 Background
13.1.2 Available Resources
13.1.3 Selection of Hazard Evaluation Technique
13.1.4 Study Preparation
13.2 Analysis Description
13.3 Discussion of Results
13.4 Follow-up
13.5 Conclusions and Observations
14. Conceptual Design Phase
14.1 Problem Definition
14.1.1 Background
14.1.2 Available Resources
14.1.3 Selection of Hazard Evaluation Technique
14.1.4 Study Preparation
14.2 Analysis Description
14.3 Discussion of Results
14.4 Follow-up
14.5 Conclusions and Observations
15. Pilot Plant Operation Phase
15.1 Problem Definition
15.1.1 Background
15.1.2 Available Resources
15.1.3 Selection of Hazard Evaluation Technique
15.1.4 Study Preparation
15.2 Analysis Description
15.3 Discussion of Results
15.4 Follow-up
15.5 Conclusions and Observations
15.6 Cause-by-Cause Alternative Approach
15.7 Extension of Cause-by-Cause Approach Using Scenario Risk Estimates
16. Detailed Engineering Phase
16.1 Problem Definition
16.1.1 Background
16.1.2 Available Resources
16.1.3 Selection of Hazard Evaluation Technique
16.1.4 Study Preparation
16.2 Analysis Description
16.3 Results
16.4 Follow-up
16.5 Conclusions and Observations
17. Construction/Start-up Phase
17.1 Problem Definition
17.1.1 Background
17.1.2 Available Resources
17.1.3 Selection of Hazard Evaluation Technique
17.1.4 Study Preparation
17.2 Analysis Description
17.3 Discussion of Results
17.4 Follow-up
17.5 Conclusions and Observations
18. Routine Operation Phase
18.1 Problem Definition
18.1.1 Background
18.1.2 Available Resources
18.1.3 Selection of Hazard Evaluation Technique
18.1.4 Study Preparation
18.2 Analysis Description
18.3 Discussion of Results
18.4 Follow-up
18.5 Conclusions and Observations
19. Routine Operation Phase
19.1 Problem Definition
19.1.1 Background
19.1.2 Available Resources
19.1.3 Selection of Hazard Evaluation Technique
19.1.4 Study Preparation
19.2 Analysis Description
19.3 Discussion of Results
19.4 Follow-up
19.5 Conclusions and Observations
20. Plant Expansion Phase
20.1 Problem Definition
20.1.1 Background
20.1.2 Available Resources
20.1.3 Selection of Hazard Evaluation Techniques
20.1.4 Study Preparation
20.2 Analysis Description
20.2.1 Relative Ranking
20.2.2 HAZOP Study
20.3 Discussion of Results
20.3.1 Relative Ranking
20.3.2 HAZOP Study
20.4 Follow-up
20.4.1 Relative Ranking
20.4.2 HAZOP Study
20.5 Conclusions and Observations
20.5.1 Relative Ranking
20.5.2 HAZOP Study
Reference
21. Incident Investigation Phase
21.1 Problem Definition
21.1.1 Background
21.1.2 Available Resources
21.1.3 Selection of Hazard Evaluation Technique
21.1.4 Study Preparation
21.2 Analysis Description
21.3 Discussion of Results
21.4 Follow-up
21.5 Conclusions and Observations
22. Decommissioning Phase
22.1 Problem Definition
22.1.1 Background
22.1.2 Available Resources
22.1.3 Selection of Hazard Evaluation Technique
22.1.4 Study Preparation
22.2 Analysis Description
22.3 Discussion of Results
22.4 Follow-up
22.5 Conclusions and Observations
Appendices
Appendix A: Additional Checklists and Forms
A.1 Example Checklist for Evaluating Changes
A.2 Example Management of Change Hazard Review Form
A.3 Example Reactivity Checklist
A.4 An Inherently Safer Process Checklist
Appendix B: Supplemental Questions for Hazard Identification
B.1 Process
B.2 Equipment
B.3 Operations
B.4 Maintenance
B.5 Personnel Safety
B.6 Fire Protection
B.7 Environmental Protection
B.8 Management and Policy Issues
Appendix C: Symbols and Abbreviations for Example Problem Drawings
Appendix D: Software Aids
Appendix E: Chemical Compatibility Chart
References
Appendix F: Organizations Offering Process Safety Enhancement Resources
Selected Bibliography
Index
A
B
C
D
E
F
G
H
I
J
L
M
N
O
P
Q
R
S
T
V
W