Industrial Training - The Best for Less

Risk assessment and process safety management ebook

Process Hazards Analysis

By Ian Sutton

This 310 page manual is a great enterprise risk management tool related to HAZOP study and process FMEA.

epa, fmea, rmp, and hazop help

Free book sample - Contents

Process Hazards Analysis Ebook
ESBN: C60-802C-2c45-72D2
Description:  

Process Hazards Analyses (PHAs) are an integral part of any process safety program. If you cannot identify hazards then you can nether remove them nor mitigate against them. This book describes in detail how to run a Process Hazards Analysis, and how to effectively identify hazards. The book focuses on real-world issues such as the role of the leader, team selection,  writing the final report, quantification of risk, and follow-up to findings.

Quotations and topics raised in the book include the following:

  • A PHA leader "comforts the afflicted but afflicts the comfortable"
  • Don't confuse "common cause" with "root cause"
  • If it's not there, it can't leak
  • Deciding whether to focus on high risk or on high consequence hazards
  • The importance of MAWP values
  • Distinguish between Findings, Recommendations and Action Items

hazop Chemical HazardThis book has been reviewed by the authoritative journal Chemical Engineering. A copy of that review (.pdf file, one page) is available. 



Download E-book immediately after purchase

Price:  US$65.00  US$ 59.99

Shop More

Automated download system is powered by our preferred method of payment, secure PayPal. If you prefer us to manually process your order or would like to mail or fax order in, please click CD and Book Order Form on our secure servers.

 


Table of Contents

Chapter 1
Process Hazards Analysis Basics

   Introduction
   Background 
      Historical Review
      Elements of a PHA
      Intentional Error
      Process Safety Management
   Standard Worked Example         
   Safe Operating Limits       
      Maximum Allowable Working Pressure
      PHA Team Estimate
`
      Unsafe Mixing Scenarios       
      Materials of Construction Matrix        
   Risk               
     
Components of Risk       
      Subjective Nature of Risk
      Fixation
      Experience of Events
      Quantifying Risk
   Risk Matrices        
      Consequence Matrix        
      Frequency Matrix        
      Risk Matrix        
   Hazard Identification      
      Extrapolation Of Experience      
      Creative Thinking      
      Checklists And Standards      
      Formal Logic Analysis         
   Safeguards
      Defining A Safeguard
      Levels Of Protection
   Occupational Safety

   PHA Techniques        
     
Hazard And Operability Method (HAZOP)      
      What-If Method       
      Checklists       
      What-If/Checklist Method         
      Failure Modes & Effects Analysis (FMEA)     
     
Fault Tree Analysis                 
      Other Appropriate Methods 
   Major Hazards Screening       
   Design PHAs         
      Leading a Design PHA
      Sequence of PHAs
      Conceptual Design          
      Preliminary Design      
      Final Design      
      Prestartup Safety Review
      Management of Change         
      Decommissioning / Demolition     
      Insurance PHA

   Strengths And Limitations of PHAs   
      Strengths of PHAs       
      Limitations of PHAs          
   Non-Process Applications

   Conclusions

Chapter 2
Organization Of A PHA

   Introduction 
   Organization
   Client / Customer
      Senior Management
      Plant Manager
   Steering Committee
   Corporate Guidance       
   Project Manager
   The PHA Team       
      Leader      
      Scribe       
      Operations Personnel
      Process Engineers
      Mechanical/Maintenance/Instrument Personnel 
      Specialists
      Designers

   Alternative Team Approaches        
   PHA Preparation         
      1. Issue a Charge Letter       
      2. Issue Documentation        
      3. Choose a Meeting Room       
      4. Select Computer System     
      5. Establish The Meeting Rules   
     
6. Kick-Off Meeting         
   Steps Of A PHA         
      1. Node Selection and Definition     
      2. Process Guideword / Safe Limits       
      3. Identification of Hazards and their Causes     
      4. “Announcement" of the Hazard    
      5. Identification of Safeguards   
      6. Hazard Consequences     
      7. Predicted Frequency of Hazard       
     
8. Risk Ranking          
      9. Findings         
      10. Next Process Guideword / Node
   Shorter PHAs
   Conclusions

Chapter 3
Hazard And Operability Method: HAZOP

   Introduction 
   Mechanics of a HAZOP      
      Node Selection        
      Process Guidewords        
      Deviation Guidewords        
      Team Discussion      
  
Common Issues
      Loss Of Containment
      Reference Previous Nodes      
      High Flow
      Low/No Flow
      Reverse Flow
      High Pressure
      High Temperature
      High Level
   Batch Processes      
   Metrics          
   Conclusions

Chapter 4
What-If Method

   Introduction 
   Node Review      
   Equipment and Function Review
  
   What-If for Batch Processes      
   Operating Procedures What-If
   Common Scenarios        
     
Reverse Flow to a Utility Header     
      Survivability of Utilities
     
Distributed Control Systems        
     
Water in Hot Liquid          
     
Blocked-In Pump      
     
Polymerization      
     
External Fire       
     
Multiple Uses of Equipment      
     
Critical Control Valves in Manual      
      Fail Safe Positions
     
Check Valve Reliability      
     
Heat Exchanger Tube Failure      
     
Blocked-In Relief Systems        
     
Pressure in Relief Headers        
     
Overload of Overhead Vacuum Lines   
      Underground Piping
     
Hoses      
   Conclusions        

Chapter 5
Checklist and FMEA

   Introduction 
   Checklist Method         
      Checklist Structure
     
Checklist Format     
     
Checklist Questions      
     
Nodes      
   Failure Modes And Effects Analysis (FMEA)     
      The FMEA Technique
     
Organization of an FMEA       
      Failure Modes      
   Conclusions        


Chapter 6
Fault Tree Analysis

   Introduction 
   Fault Tree Development
      Top Event       
      Failure / Fault
      OR Gate
      Top Event OR Gate
      Intermediate Events
     
AND Gate        
      Base Events
      Labeling
      Voting Gate
   Static Model
   Cut Sets
   Quantification
      OR Gate
      AND Gate
      Voting Gate
      Cut Sets
   Risk Ranking
      The Pareto Principle
      Data Quality
      Event Contribution
   Common Cause Effects
   Generic Fault Trees      
      Generic Safety Fault Tree
      Generic Reliability Fault Tree
   Software
   Discussion of the Fault Tree Method
   Qualitative Fault Tree
  
Conclusions        

Chapter 7
Reporting and Follow-Up

   Introduction 
   Attributes of a Good PHA Report      
     
Timeliness      
     
Completeness/Thoroughness      
     
Clarity      
     
Sensitivity       
      Positive Attitude
   Reporting Organization
   Reporting Process        
      1. Notes Clean-Up
      2. Team Review
      3. Draft Report 
      4. Client Review
      5. Final Report
      6. Follow-Up
   Report Structure
      A. Disclaimer
      B. Summary of Findings
      C. Objective of The PHA
      D. Regulatory Issues
      E. Method Used
      F. The Team
      G. Risk Ranking Technique
      H. Findings and Action Items
      I. Links to the PSM Program
      J. PHA Notes
      K & L. Attachments and References
  
Report Distribution
   Shorter PHAs
   Writing Guidelines       
     
Minimalist Writing      
     
Language Style        
     
Findings Terminology        
      Writing Quality     
     
Appearance        
   Report Template
   Follow-Up
   Findings Management
      1. Create Recommendation(s)
      2. Implement
      3. Close Finding
  
Conclusions        

Chapter 8
Regulations, Standards and Legal Issues
   Introduction 
   The OSHA Regulation      
   OSHA Guidance       
   Analysis Of The Regulation      
   Siting
   Human Factors
      Slips
      Mistakes
      Violations
      Error Following an Emergency
   EPA Risk Management Program (RMP)
      Tiering / Program Levels
      Covered Chemicals
      Formal Management System
      Community Participation
      Emergency Plan
      Five-Year Accident History
   Legal Issues      
      Follow Up to Findings
      Communication with the Public
      Internal Communication
     
Letter of Certification        
   Conclusions        

Chapter 9
Process Safety Management

   Introduction 
   Definition Of Process Safety Management
   Process Safety Management Principles
   Process Safety Management Elements
      Element #1 - Employee Participation        
      Element #2 - Process Safety Information        
      Element #3 - Process Hazards Analysis
      Element #4 - Operating Procedures 
     
Element #5 - Training
     
Element #6 - Contractors 
     
Element #7 - Prestartup Safety Review
     
Element #8 - Mechanical Integrity
     
Element #9 - Hot Work         
      Element #10 - Management Of Change         
      Element #11 - Incident Investigation
      Element #12 - Emergency Planning And Response
      Element #13 - Compliance Audits
      Element #14 - Trade Secrets
   Revalidating PHAs
   Future PHAs
      Quantitative
      Computer Control
      Industry Standards
      Reliability And Quality
      Risk Based Techniques
      Other Industries
      Malicious Acts
   Conclusions         

Price:  US$65.00  US$ 59.99 

Shop More

Automated download system is powered by our preferred method of payment, secure PayPal. If you prefer us to manually process your order or would like to mail or fax order in, please click CD and Book Order Form on our secure servers.

  Please click here to contact us with your questions and comments. 

Related titles:

The Practical Guide to Hazardous Area Classification

Hazardous Area Instrumentation Course

Performance Safety: Lessons For Life

Process Safety Management

Fault Tree Analysis

Writing Operating Procedures for Process Plants

Process Risk Management