TOPIC : SAFETY ANALYSIS & PREVENTION

DATE : June 2014

LECTURE : DETAILED HAZARD ANALYSIS,
RISK ANALYSIS and Management
Lecturer : Dr Ghulam Murshid (GM)
Health, Safety &
Environment (CCB 2012)
Lecture Content Part 2
Detailed Hazard Analysis
Failure mode and effect analysis (FMEA)
Hazard and operability (HAZOP)
Fault tree analysis (FTA)
Risk analysis (RA)
You should be able to identify, define
and differentiate
Detailed Hazard Analysis (for complex system)
Failure mode and effect analysis (FMEA)
Hazard and operability review (HAZOP)
Human error analysis (HEA)
Fault tree analysis (FTA)
Risk analysis and Management
Lecture Outcome
Proceeds as follows:
Critically examine the system in question.
Divide the system into its various components.
Each component is studied to determine how it
could fail.
Rate each potential failure according to its
consequences (0 to 10).
Failure mode and effect analysis (FMEA)
Weaknesses:
no human error factor.
does not account for component interfaces.
FMEA Example
HAZOP
HAZOP highlights include:
Systematic examination
Multidisciplinary study
Utilization of operational experience
Safety as well as operational evaluations
May indicate solutions to the identified
problems
Considers operational procedures
Led by an independent person
Results are recorded.
Preparation for HAZOP
Detailed information on the process
must be available
Process flow diagrams (PFD), process
and instrumentation diagrams
(P&Ids), detailed equipment
specifications, materials of
construction and mass & energy
balances are very essential for the
study.
Process Flow Diagram (PFD)
HAZOP Guide Word
Guide words describe ways in which the component may
deviate from its design.
No
Less
More
Part of
As well as
Reverse
Other than
Never none
Quantitative decrease
Quantitative increase
Qualitative decrease
Qualitative increase
Opposite of forward
Complete substitution
Guide words
Meaning
Stages of HAZOP as applied to each
component of a chemical processing system
are described below:
1. Identify the design intent of the selected part
of process.
2. Consider each condition or action using the
HAZOP guide word to suggest possible
deviations
3. Consider causes and consequences of the
deviation
4. Define and note the action required to address
the problems.
Procedure
EXAMPLE
The phosphoric acid and ammonia are mixed,
and a non-hazardous product, diammonium
phosphate (DAP), results if the reaction of
ammonia is complete. If too little phosphoric
acid is added, the reaction is incomplete, and
ammonia is produced. Too little ammonia
available to the reactor results in a safe but
undesirable product. The HAZOP team is
assigned to investigate "Personnel Hazards
from the Reaction".
SOLUTION
Storage A
Storage B
Reactor C
Storage C
Valve A
Valve B
Parameter Deviation Possible Causes Consequences Action
Flow NO flow into reactor Blockage or leaking pipe into R Rate of reaction decreases
No reaction occurring
Install flow indicator and flow
control valve
NO flow out of reactor Reactor outlet clogged or
blocked
No flow to subsequent
separation units
Stop operation
Perform reactor maintenance
MORE Control valve failure trim
changed
Exchanger tube leaks
Incorrect instrument readings
Reactants build-up
Increase in reaction rate
Check flow indicators and
controllers
By-pass flow
LESS Blockage or leaking in piping
system into R-100
(line restriction)
Reduced rate of reaction
Less production
Install flow indicator and
controllers
HAZOP
Parameter Deviation Possible Causes Consequences Action
Pressure MORE Reactants build-up
Blocked pipeline
Pressure indicator failure
Pressure build-up inside
reactor
Runaway reaction
Install high pressure alarm
Pressure relief system (PRV)
LESS Leakage in piping of reactor Reduced reaction rate
Reverse flow
Check feed pressure
Install Pressure indicator at
feed to reactor
Temperature MORE Higher reaction rate
Excess feed into reactor
Cooling system failure
Feed heater failure
R-100 out of control
Runaway reaction
Catalyst deactivation
Install high temperature alarm
Install coolant flow meter and
low flow alarm
Perform maintenance on feed
heater
LESS Low feed temperature
Feed heater failure
Low reaction rate
Low product purity
Increase feed temperature
Install temperature indicator
Human Error Analysis (HEA)
It is best to perform HEA together with
either FMEA or HAZOP. This will enhance
the effectiveness of all three processes.
For predicting human error before accidents occur
by:
observing employees at work and noting
hazards.
actually performing job tasks to get a first hand
feel for hazards.
FTA
The analysis process is displayed visually.
Between Basic event and Top Event.
Uses symbols derived from Boolean
algebra.
The resultant model looks like a logic
diagram or a flow chart.
Fault Tree Analysis (FTA)
OR gate
AND gate
Top event
Intermediate
event
Basic event
Undeveloped
event
External or
house event
Transfer
IN-OUT
Logic and Event Symbols
Top Event
Contributing
Events
Undeveloped Event
Basic Event
The Fault
Tree
Concept
Fault
Tree
Fault tree: top-down approach starting
with the unwanted consequences as the
top event & identifying all factors that
could contribute to the top event.
Used to think through possible causes
of a loss, to find most probable
sequence of events leading to the loss
& to quantify the probability of loss.
Steps: FTA
To draw a fault tree take the following
steps.
1. Determine undesirable event, which is to be the Top
Event.
2. Determine the Basic Events, which could immediately
cause the Top Event.
3. Determine the relationship between the Basic
Events and the Top Event in terms of AND and OR
gates.
4. Determine whether any of the Basic Events need
further analysis, if so repeat steps 2 & 3.
Example: Fault Tree
Consider a case of a motor overheated. The
Basic Events could be the primary motor fails
or excessive current load to the motor.
The current load might be excessive due to
excess current flow in the circuit and failure of
the fuse.
It could be either short circuiting or a power
surge that contributed to the excess current
flow.
Example: Fault Tree
Motor Overheated
Primary
Motor
Failure
A
Fuse
Fails
B
Excessive
Current to
Motor
Excess
Current In
Circuit
Short
circuit
C
Power
Surge
D
AND
OR
OR
The probability of the Top Event (the
motor overheated) is obtained by
combining the base events according
to the logic rules:
For this case, probability
= [(C+D) x B] + A
For an OR gate (ADD the
probabilities)
For an AND gate
(MULTIPLY the value)
Example: Fault Tree
Motor Overheated
Primary
Motor
Failure
0.05
Fuse
Fails
0.1
Excessive
Current to
Motor
Excess
Current In
Circuit
Short
circuit
0.007
Power
Surge
0.003
AND
OR
OR
The probability of the Top Event
(the motor overheated) is
obtained by combining the base
events according to the logic
rules:
For this case, probability
= [(0.007+0.003) x 0.1] + 0.05
= 0.051
Risk Analysis (RA)
Decision-making tool normally associated
with insurance and investments.
It can also be used to analyse the
workplace, identify hazards and develop
strategies for overcoming hazards.
Focuses on TWO questions:
How frequently does a given event
occur?
How severe are the consequences of a
given event?
What is a risk?
Risk may be considered as the potential for
adverse effects resulting from an activity or
event
Acceptable level of risk
This is generally determined by what is
prepared to be lost balanced against possible
gains
The Risk Management Process
The total procedure associated with
identifying a hazard,
assessing the risk,
putting in place control measures,
and reviewing the outcomes.
Hazard Identification
Remember Hazard:
Risk Assessment
Risk Control
Risk Assessment
Risk:
The possibility of an unwanted event
occurring
Likelihood:
The chance of an event actually occurring.
Likelihood
Very Likely -- Could happen frequently
Likely -- Could happen occasionally
Unlikely -- Could happen, but only rarely
Highly Unlikely -- Could happen but
probably never will
When evaluating the likelihood of an accident,
a factor that will modify the likelihood category, is
exposure.
Very Rare -- Once per year or less
Rare -- A few times per year
Unusual -- Once per month
Occasional -- Once per week
Frequent -- Daily
Continuous -- Constant
Likelihood
Consequences
FATAL Death
MAJOR INJURIES Normally irreversible injury or
damage to health requiring extended time off work to effect
best recovery.
MINOR INJURIES Typically a reversible injury or
damage to health needing several days away from work to
recover. Recovery would be full and permanent.
NEGLIGIBLE INJURIES Would require first aid and may
need the remainder of the work period or shift off before
being able to return to work.