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Transcript of Process Hazard Analyses: The Best Methodologies & Processes for your Organization Panelist Speaker...
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
Copyright: All rights reserved by 360factors Inc., and Pareto Eng. and Management Consulting
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
Copyright: All rights reserved by 360factors Inc., and Pareto Eng. and Management Consulting
About Us – Consulting Solutions
Copyright: All rights reserved by 360factors Inc., and Pareto Eng. and Management Consulting
Copyright: All rights reserved by 360factors Inc., and Pareto Eng. and Management Consulting
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?
Copyright: All rights reserved by 360factors Inc., and Pareto Eng. and Management Consulting
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
Copyright: All rights reserved by 360factors Inc., and Pareto Eng. and Management Consulting
Process Hazard AnalysesThe Best Methodologies & Processes for your Organization
Copyright: All rights reserved by 360factors Inc., and Pareto Eng. and Management Consulting
Agenda:
Training Objectives OSHA Requirements Methodologies
- Basic
- Advanced Keys to Excellent PHAs Questions
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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
Copyright: All rights reserved by 360factors Inc., and Pareto Eng. and Management Consulting
Copyright: All rights reserved by 360factors Inc., and Pareto Eng. and Management Consulting
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?
Copyright: All rights reserved by 360factors Inc., and Pareto Eng. and Management Consulting
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)
Copyright: All rights reserved by 360factors Inc., and Pareto Eng. and Management Consulting
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
Copyright: All rights reserved by 360factors Inc., and Pareto Eng. and Management Consulting
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.)
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Copyright: All rights reserved by 360factors Inc., and Pareto Eng. and Management Consulting
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
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Generic PHA Process
.• Prepare
.• Conduct PHA
.• Report & Communicate
.
• Management Review and Implementation
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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
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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
Copyright: All rights reserved by 360factors Inc., and Pareto Eng. and Management Consulting
Generic PHA Process – Preparation (Contd.)
Define PHA Nodes - Using Process Flow Diagram
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Generic PHA Process – Preparation (Contd.) Define PHA Nodes – Using P&IDs
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Generic PHA Process – Preparation (Contd.)
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
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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.)
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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
Generic PHA Process – Analysis (Contd.)
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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
Generic PHA Process – Analysis (Contd.)
Risk Rating Example - Severity
Generic PHA Process – Analysis (Contd.)
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Risk Rating Example – Severity
Generic PHA Process – Analysis (Contd.)
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Risk Matrix Example - Frequency
Generic PHA Process – Analysis (Contd.)
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Risk Matrix Example – Risk Ranking
Generic PHA Process – Analysis (Contd.)
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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
Generic PHA Process – Analysis (Contd.)
If any scenarios are high risk, use an advanced method: Layers of Protection (LOPA) Fault Tree Analysis Event Tree Analysis
Generic PHA Process – Analysis (Contd.)
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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
Generic PHA Process – Analysis (Contd.)
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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
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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
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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
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Q&A
At the end of the day, safety is all about care, saving lives, families, and the society we operate in.
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NEXT WEBINAR
Topic: Mechanical Integrity February 26 at 2:00PM CST Webinar Invitation will be emailed
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