Process Risk Management
Process Risk Management - Risk tree analysis methods PDF
By Ian Sutton
Risk Tree Analysis + Process Safety Information = accurate operational risk assessment
Process Risk Management Sample - Contents
| Process Risk Management EBook | |
| ESBN: C60-3070-1A90-99B3 | |
| Description: The Process Risk Management EBook - Ian Sutton uses methods such as risk tree analysis combined with process safety information to help you gain an accurate operational risk assessment. This 272 page HSE book is a must read for the HSE Manager and those studying process hazards analysis.
Excellent safety and environmental performance in the process industries does not happen by chance; after all, most process facilities handle large quantities of toxic, flammable and explosive materials, often at high temperature and pressure. Such processes are inherently hazardous. Therefore process risk must be properly understood and managed.
An effective risk management program has three elements. First, the program must be properly grounded in theory. Second, risk management has to be based practical. Many risk analyses are theoretically interesting, but they do not provide much practical help to managers, operators and engineers working on operating facilities and on projects.
The third element in an effective risk management program is the appropriate use of both the 'hard' and 'soft' approaches to both analysis and follow-up. The 'hard' approach relies on the use of formal models, quantitative data and an objective examination of equipment and instrumentation. The 'soft' approach, on the other hand, is oriented more toward understanding people and their behaviors. The best risk management programs and this book, combine both approaches.
Synopsis by Chapter: Chapter 1 - Risk Management provides an overview of risk management in the process industries. Terminology - such as the important distinction between the words 'frequency' and 'probability' - is explained, as are fundamental concepts, such as the role of safeguards in a process safety management system. Chapter 2 - Hazards Identification describes how hazards can be identified, usually in a team environment. The role of the team leader (facilitator), scribe and department specialists is discussed, as is the all important topic of writing the final report. The chapter points out some of the limitations of typical hazards analyses, and discusses how hazards analysis fits into the overall topic of process safety management. Chapter 3 - Hazards Analysis Techniques describes some of the more commonly used methods for identifying hazards. The Hazard and Operability (HAZOP) method is discussed in depth, as are Failure Modes & Effects Analysis (FMEA), Checklists and the What-If approach. The strengths and limitations of each technique are described. Chapter 4 - Consequence Analysis provides an overview of some of the major consequence issues facing the process industries. These include fires, explosions, and toxic gas releases. Chapter 5 - Likelihood Analysis provides a background to the difficult yet important issue of risk quantification. The chapter starts by discussing the Pareto Principle, then discusses the Fault Tree Analysis method in some depth. The final section of the chapter outlines some of the limitations that are inherent in quantification work. (Note: The fault tree content of this chapter is available in an expanded form in Fault Tree Analysis .) Chapter 6 - Common Hazards explains that many hazards are common to a wide variety of processes and technologies. A wide range of such common hazards are listed in this chapter.
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Table of Contents
Chapter 1: Risk Management
Introduction
About this Series
EBooks
Books
Engineering Minutes / Events
Reference Material
Worked Example
Clients / Customers
Senior Management
Facility / Plant Managers
Project Managers
Regulators / Auditors
Malicious Acts
Health, Safety & Environmental (HSE) Programs
Environmental and Sustainability Programs
Health
Safety
Process Safety Management
Process
Safety
Management
Non-Prescriptive
Performance Based
Elements of Risk
Hazards
Hazard Scope
Safe Limits
Maximum Allowable Working Pressure (MAWP)
Unsafe Mixing Scenarios
Materials of Construction Table
Consequences
Type of Consequence
Safety
Environmental
Health
Economic
Predicted Frequency
Presence of Persons
Economies of Scale
Levels of Protection / Safeguards
Safeguard Level 1: Normal Operations
Safeguard Level 2: Procedural Safeguards
Safeguard Level 3: Safety Instrumented Systems
Safeguard Level 4: Mechanical Safeguards
Check Valves
Pressure Safety Relief Valves
Safeguard Level 5: Passive Safeguards
Safeguard Level 6: Emergency Response
Subjective Nature of Risk
Degree of Control
Familiarity with the Hazard
Direct Benefit
Personal Impact
Natural vs. Man-Made Risks
Recency of Events
Effects of the Consequence Term
Acceptable Risk
As Low as Reasonably Practical - ALARP
De Minimis Risk
Citations / Case Law
Indexing Methods
Risk Matrices
Consequence Matrix
Worker Safety
Public Safety and Health
Environmental Impact
Economic Loss
Frequency Matrix
Risk Matrix
Risk Management Process
Step 1. Identify the Hazards
Creative / Imaginative
Experience-Based / Engineering Standards
Logical / Rational
Step 2. Risk Rank
Step 3. Identify Hazard Causes
Step 4. Eliminate or Substitute the Hazard
Step 5. Remove the People
Step 6. Mitigate the Consequences
Step 7. Reduce the Likelihood
Step 8. Install Safeguards
Risk Check
Common Cause Events
Utility Failure
Instruments on Manual
Instrument Pluggage
Vibration
External Events
Maintenance Availability
Human Error / Untrained Personnel
The Risk Register
Finding Number
Node
Hazard / Consequence / Likelihood / Risk
Follow-Up
Conclusions
Chapter 2: Hazards Identification
Introduction
Historical Development
Organization of a Hazards Analysis
Charge / Scope Letter
Abandoned Equipment
Preparations
Logistics
Location of the Meeting
Projection of Notes
Documentation Requirements
Block Flow Diagrams (BFDs)
Process Flow Diagrams (PFDs)
Piping and Instrument Diagrams (P&IDs)
Cause and Effect Diagrams
Layout Diagrams
Security of the Information
Time Required
Kick-Off Meeting
Close-Out Meeting
Short Analyses
The Team
Leader / Facilitator
Process Knowledge
Challenge the Status Quo Ante
Creative Thinking
Casual Remarks
"If We Had Unlimited Money"
Generalizations
Team Management
Knowledge of Actual Incidents
Lawyer-Like Behavior
Persona
Personal Preparation
Engineering Standards
The Scribe
Operations / Maintenance Expert
Process Expert
Instrument Expert
Specialists
Sophisticated Use of Language
The One-Minute Engineering Department
Results of the Analysis
Findings
Recommendations
Action Items
The Hazards Analysis Report
Timeliness
Writing Style
Non-Emotional Language
Findings and Recommendations
Abstraction
Minimalist Writing - Make Every Word Tell
Omit Needless Words
Eliminate Tautologies
Short, Simple Words
Minimize 'Soft' Materials
Eschew Obfuscation
Language Style
Findings Terminology
Completeness
"Non-Findings"
Appearance
Pictures
Report Distribution
Communication with the Public
Table of Contents
1. Disclaimer
2. Executive Summary
3. Objectives of the Analysis
4. Summary of Findings
5. Method Used
6. Risk Rank
7. The Team
8. Regulations
9. Attachments
10. Meeting Notes
Development of the Report
Step 1. Notes Clean-Up
Completeness of the Notes
Date Format
Cross-Reference
Anonymity
Step 2. Team Review
Step 3. Draft Report
Step 4. Client Review
Step 5. Final Report
Step 6. Risk Register
Follow Up
Legal Issues
Need to Act on Findings
Informal Notes
Internal Communication
Letter of Certification
Special Types of Hazards Analysis
Temporary Operations
Non-Process Applications
Decommissioning / Demolition
Revalidation Hazards Analyses
Benefits and Limitations of Hazard Analyses
Strengths
Providing Time to Think
Challenging Conventional Thinking
Cross-Discipline Communication
Education
Development of Technical Information
Economic Payoff
Limitations and Concerns
Imprecision in Defining Terms
Multiple Contingencies
Complexities and Subtle Interactions
Dynamic Conditions
Common Cause Events
Knowledge of Safe Operating Limits
Lack of Quantification
Team Quality
Personal Experience
Boredom
Confusion with Design Reviews
False Confidence
Equipment Orientation
Interfaces
Human Error
Hazards Analysis on Projects
Phase I: Concept Selection
Phase II: Preliminary Engineering
Phase III: Detailed Engineering
Phase IV: Fabrication and Construction
Phase V: Commissioning and Start-Up
Regulations, Standards and Guidance
Paragraph (1) Initial Hazard Analysis
Paragraph (2) Methodology
Paragraph (3) Issues to Address
Paragraph (4) Team
Paragraph (5) Findings and Recommendations
Paragraph (6) Revalidation
Process Safety Management
Element #1 - Employee Participation
Element #2 - Process Safety Information
Piping & Instrument Diagrams
Compatibility of Chemicals
Safe Operating Limits
Engineering Standards
Element #4 - Operating Procedures
Element #8 - Mechanical Integrity
Element #10 - Management of Change
Conclusions
Chapter 3: Hazard Analysis Techniques
Introduction
The Hazard and Operability Method (HAZOP)
Step 1. Node Selection and Purpose
Step 2. Process Guideword / Safe Limits
Step 3. Identification of Hazards and their Causes
Step 4. 'Announcement' of the Hazard
Step 5. Consequences
Step 6. Identification of Safeguards
Step 7. Predicted Frequency of Occurrence of the Hazard
Step 8. Risk Ranking
Step 9. Findings
Step 10. Next Process Guideword / Node
Failure Modes & Effects Analysis (FMEA)
Checklists
The What-If Method
Node / Functional Area Review
Equipment and Function Review
Utility Systems
Batch Processes
Operating Procedures
Layout Reviews
What-If / Checklist Method
Indexing Methods
Interface Hazards Analysis
Conclusions
Chapter 4: Consequence Analysis
Introduction
Fires
Flammable Range
Ignition Temperature / Flash Point
Ignition Sources
Radiant Heat
Iron Sulfide
Area Classification
Fire Detection and Response
Fire Detectors and Alarms
Fire Zones
Explosions
Deflagrations and Detonations
Blast Effects
BLEVE
Toxic Gases
Terminology
Release Modeling
Effect of Toxic Gases
Short-Term Exposure Limits
Emergency Response Planning Guidelines (ERPGs)
ERPG-3
ERPG-2
ERPG-1
Permissible Exposure Limits (PEL)
Threshold Limit Values (TLV)
Short Term Exposure Limit (STEL)
Immediately Damaging to Life and Health (IDLH)
Effect of Being Indoors
Substance Hazards Index (Volatile Liquids)
Conclusions
Chapter 5: Likelihood Analysis
Introduction
Terminology
Frequency
Predicted Frequency
Probability
Likelihood
Error / Statistical Significance
Failure / Fault
Independence
Randomness
Failure Rate
Early Failures
Constant Failure Rate
Wear-Out Failures
Overall Failure Rate
The Pareto Principle / Importance Ranking
Fault Tree Analysis
Gates
OR Gate
AND Gate
VOTING Gate
Events
Top Event
Intermediate Events
Base Events
Top-Down Development of a Fault Tree
1. Define the Top Event
2. Build the Tree
Create the First Level
Second Level - Illustration of the AND Gate
Third Level - Illustration of the OR Gate
Final Development
3. Identify the Cut Sets
4. Eliminate Repeat Sets
5. Eliminate Repeat Events in a Set
6. Eliminate Redundant Events
7. Quantify the Risk
Mathematics of an OR Gate
Mathematics of an AND Gate
Mathematics of a Voting Gate
Cut Set Quantification
8. Risk Rank
Event Contribution
Important Few
Unimportant Many
Power of the AND Gate
Importance Equalization
Cost-Benefit Analysis
Generic Fault Trees
Generic Safety Fault Tree
Generic Reliability Fault Tree
Discussion of the Fault Tree Method
Qualitative Fault Tree Analysis
Event Tree Analysis
Development of an Event Tree
Event Tree Quantification
Combining Event Trees and Fault Trees
Event Trees in the Process Industries
Short Sequence of Events
Many Events
Partial Success
Discrete Event Analysis
Monte Carlo Simulation
Markov Models
Limitations to Quantification
Mathematical Understanding
Value-Laden Assumptions
Lack of Exhaustivity
Cost of Human Suffering
Human Behavior
Data Quality
Conclusions
Chapter 6: Common Hazards
Introduction
Process Hazards
High Flow
Low / No Flow
Reverse Flow
Misdirected Flow
High Pressure
High Temperature
Blocked-In Pump
Polymerization
External Fire
Low Temperature
Low Pressure
High Level
Wrong Composition
Hazards of Utilities
Electrical Power Failure
Reverse Flow to a Utility Header
Survivability of Utilities
Hazards of Water
Water in Hydrocarbon Tanks
Water in Very Hot Liquid
Static Electricity
Water and Firefighting
Hazards of Steam
Steaming Vessels during Turnarou Reboiler Leak
Wet Steam
Hazards of Ice
Line Freezing
Hydrates
Hazards of Compressed Gas
Gas Cylinders
Pigging Incident
Hazards of Chemicals
Carbon Monoxide (CO)
Nitrogen (N2)
Sulfur Dioxide (SO2)
Hydrogen Sulfide (H2S)
Chemical Embrittlement
Hazards of Airof Air
Flammable Mixture
Blowing a Line Clear
Hazards of External Events
Flooding
Lightning
Earthquakes
Hazards of Equipment and Instruments
Furnace Firing
Multiple Uses of Equipment
Distributed Control Systems
Hazards of Piping, Valves and Hoses
Piping
Hydraulic Hammer
Pig Launchers and Receivers
Pressure in Relief Headers
Overload of Overhead Vacuum Lines
Underground Piping
Hoses
Hoses and Truck Pull-Away
Hose Run Over
Hose Failure
Backflow Preventer
Valves
Blocked-In Pressure Relief Valve
Vents and Bleeders
Critical Control Valves in Manual
Shared Relief Valve
Block Valves below Relief Valves
SDV Bypass
Conclusions
Index
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