PROCESS HAZARD EVALUATION Checklists

Plant & Environmental Safety

Colin S. Howat Ph.D., P.E.

Checklist - PES - CSH

1998 C. S. Howat

Process Hazard Evaluation - Checklists

Lecture: Title: Thought: One Class Period Introduction to Checklists in Process Hazard Evaluation Not to know what happened before you were born is to be ever a child.
Cicero, The Orator

Question:

Many engineers prepare a daily, weekly, monthly list of things to do. Many ignore this list once prepared. What incentive can you provide to ensure that people use checklists? Introduce and discuss a typical checklist
1998 C. S. Howat

Purpose:
Checklist - PES - CSH

From the Loss Prevention Lecture ~

Checklists

Identify Potential Hazards and Events Minimize Frequency of Initiation Maximize Probability of Benign Termination Minimize Consequence of Malevolent Termination
The identification of hazards and the scenarios of failure typically require experience or detailed procedure to develop properly..
Checklist - PES - CSH
1998 C. S. Howat

From the Hazard Identification Introduction ~

System Description

Hazard Identification

Scenario Identification

Event Probability

Event Consequence

Risk Determination

Acceptable?

No

Re-Design System
4

Checklist - PES - CSH

1998 C. S. Howat

Checklists
Process Hazard Checklists ! ! ! ! ! This is a list of items that the reviewer needs to consider. This list contains itemizes problems and failures. The items on the list may or not apply to the situation. The list acts as a reminder to stimulate thought. The list can be used for: Conceptual Design Pilot Plant Operation Detailed Design Construction Start up Routine Operation Modification/Expansion Decommissioning
1998 C. S. Howat

Checklist - PES - CSH

Checklists
The checklist reminds the reviewer or operator of potential problem areas. A check-off is required. For a checklist to be effective the reviewer or operator must respond. ACTION REQUIRED!
All controls fail safe?
Further Study Requied Does Not Apply Completed

The following is an example from Crowl & Louvar.

Checklist - PES - CSH
1998 C. S. Howat

Further Study Requied Does Not Apply Completed

General Layout
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Areas properly drained? Aisle ways provided? Fire walls, dikes and special guardrails needed? Hazardous underground obstructions? Hazardous overhead restrictions? Emergency accesses and exits? Enough headroom? Access for emergency vehicles? Safe storage space for raw materials and finished products? Adequate platforms for safe maintenance operations? Hoists and elevators properly designed and safeguarded? Clearance for overhead power lines?

Checklist - PES - CSH

1998 C. S. Howat

Further Study Requied Does Not Apply Completed

Buildings
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Adequate ladders, stairways and escape-ways? Fire doors required? Head obstructions marked? Ventilation adequate? Need for ladder or stairway to roof? Safety glass specified where necessary? Need for fireproofed structural steel?

Checklist - PES - CSH

1998 C. S. Howat

Further Study Requied Does Not Apply Completed

Process
1. Consequences of exposure to adjacent operations considered? 2. Special fume or dust hoods required? 3. Unstable materials properly stored? 4. Process laboratory checked for runaway explosive conditions? 5. Provisions for protection from explosions? 6. Hazardous reactions possible due to mistakes or contamination? 7. Chemistry of processes completely understood and reviewed? 8. Provisions for rapid disposal of reactants in an emergency? 9. Failure of mechanical equipment possible cause of hazards? 10. Hazards possible from gradual or sudden blockages in piping? 11. Hazards possible from gradual or sudden blockages in equipment? 12. Public liability risks possible from sprays, fumes, mists or noise? 13. Provisions made for disposal of toxic materials? 14. Material safety data sheets available for all chemical species? 15. Hazards possible from simultaneous loss of two or more utilities?

Checklist - PES - CSH

1998 C. S. Howat

Further Study Requied Does Not Apply Completed

Process (cont.)
16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. Hazards involved in sewering materials? Safety factors altered by design revisions? Consequences of reasonably worst incident reviewed? Consequences of combination of incidents reviewed? Process diagrams correct and up-to-date?

Checklist - PES - CSH

1998 C. S. Howat

10

Further Study Requied Does Not Apply Completed

Piping
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Safety showers and eye baths required? Sprinkler systems required? Provisions for thermal expansion? All overflow lines directed to safe areas? Vent lines directed safely? Piping specifications followed? Washing-down hoses needed? Check valves provided as needed? Protection and identification of fragile pipe considered? Possible deterioration of exterior of piping by chemicals? Emergency valves readily accessible? Long and large vent lines supported? Steam condensate piping safely designed? Relief valve piping designed to prevent plugging? Drains to relieve pressure on suction and discharge of all process pumps?

Checklist - PES - CSH

1998 C. S. Howat

11

Further Study Requied Does Not Apply Completed

Piping (cont.)
16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. City water lines not connected to process pipes? Flammable fluids feeding production units hut off from safe distance? Personnel protective insulation provided? Hot steam lines insultated?

Checklist - PES - CSH

1998 C. S. Howat

12

Further Study Requied Does Not Apply Completed

Equipment
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Designs correct for maximum operating pressure? Corrosion allowance considered? Special isolation for hazardous equipment? Guards for belts, pulleys, sheaves and gears? Schedule for checking protective devices? Dikes for any storage tanks? Guard rails for storage tanks? Construction materials compatible with process chemicals? Reclaimed and replacement equipment checked structurally? Reclaimed and replacement equipment checked for process pressures? Pipelines independently supported to relieve pumps? Pipelines independently supported to relieve other equipment? Automatic lubrication of critical machinery? Emergency standby equipment needed?

Checklist - PES - CSH

1998 C. S. Howat

13

Further Study Requied Does Not Apply Completed

Venting
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Relief valves or rupture disks required? Materials of construction corrosion resistant? Vents properly designed? (Size, direction, configuration) Flame arrestors required on vent lines? Relief valves protected from plugging by rupture disks? Telltale pressure gauges installed between rupture disk and relief valve?

Checklist - PES - CSH

1998 C. S. Howat

14

Further Study Requied Does Not Apply Completed

Instrument and Electrical

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. All controls fail safe? Dual indication of process variables necessary? All equipment properly labeled? Tubing runs protected? Safeguards provided for process control when instrument out of service? Process safety affected by response lag? Labels for all start-stop switches? Equipment designed to permit lockout protection? Electrical failures cause unsafe conditions? Sufficient lighting for both outside and inside operations? Lights provided for all sight glasses, showers and eye-baths? Breakers adequate for circuit protection? All equipment grounded? Special interlocks needed for safe operation? Emergency standby power on lighting equipment required?

Checklist - PES - CSH

1998 C. S. Howat

15

Further Study Requied Does Not Apply Completed

Instrument and Electrical (cont.)

16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. Emergency escape lighting required during power failures? All necessary communications equipment provided? Emergency disconnect switches properly marked? Special explosion proof electrical fixtures required?

Checklist - PES - CSH

1998 C. S. Howat

16

Further Study Requied Does Not Apply Completed

Safety Equipment
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Fire extinguishers required? Special respiratory equipment required? Diking material required? Colorimetric indicator tubes required? Flammable vapor detection apparatus required? Fire extinguishing materials compatible with process materials? Special emergency procedures and alarms required?

Checklist - PES - CSH

1998 C. S. Howat

17

Further Study Requied Does Not Apply Completed

Raw Materials
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Any materials and products require special handling equipment? Any raw materials and products affected by extreme weather conditions? Any products hazardous from a toxic or fire standpoint? Proper containers being used? Containers properly labeled for toxicity, flammability, stability, etc.? Consequences of bad spills considered? Special instructions needed for containers? Special instructions needed for storage and warehousing distributors? Does warehouse have operating instructions covering each product?

Checklist - PES - CSH

1998 C. S. Howat

18

Checklists are not a substitute for a more rigorous approach. However, they can be a constant reminder to reviewers of items to consider for the situation at hand. They can be used as a stimulant for more formal studies.

Checklist - PES - CSH

1998 C. S. Howat

19