OSH Risk Management

regarding module 10...osh risk management
Def:
A Hazard and Operability (HAZOP) study is a structured and systematic examination of a planned or existing process or operation in order to identify and evaluate problems that may represent risks to personnel or equipment, or prevent efficient operation.
The HAZOP technique was initially developed to analyze chemical process systems, but has later been extended to other types of systems and also to complex operations and to software systems.
A HAZOP is a qualitative technique based on guide-words and is carried out by a multi-disciplinary team (HAZOP team) during a set of meetings.
HAZOP = HAZard and OPerability Study
â Method for identifying (and assessing) problems that may represent risks to personnel or equipment, or prevent efficient operation
â Systematic and qualitative method based on the use of guide-words
â Multi-disciplinary team effort
HAZOP objectives
i. To identify all deviations from the way the design expected to work, their causes, and all the hazards and operability problems associated with these deviations
ii. To decide whether action is required to control the hazard or the operability problems and if so, to identify the ways in which the problems can be solved
iii. To identify the cases where a decision cannot be made immediately, and to decide on what information or action is required
iv. To ensure the action decided upon are followed through
Purpose of HAZOP:
i. An aid to the design safe plant. It can be incorporated as a step in the overall procedures for design, both in terms of safety and also the operability of the plant
ii. A training aid for plant personnel and in the preparation of Operating Manual
iii. A tool to rigorously and systematically checking a design for safety, operability and conformity with codes and practices
iv. To demonstrate to interest parties that all possible action has been taken to eliminate hazard
HAZOP Procedures:
i. Divide the system into sections (i.e., reactor, storage)
ii. Choose a study node (i.e., line, vessel, pump, operating instruction)
iii. Describe the design intent
iv. Select a process parameter
v. Apply a guide-word
vi. Determine cause(s)
vii. Evaluate consequences/problems
viii. Recommend action: What? When? Who?
ix. Record information
x. Repeat procedure
The role of the plant (or site) manager in this responsibility should be to:
i. Developed and use operations procedures
ii. Ensure the HAZOP study are conducted for each operations unit on a periodic basic, and for modifications
iii. Provide appropriate participant and leadership for these HAZOP study
iv. Appoint a HAZOP coordinator at each plant site to coordinate and facilities the HAZOP program
v. Follow up the recommendations developed by the HAZOP study
The role of Project Manager
i. Appoint a secretary and team leader
ii. Ensure that the study is scheduled at the proper time in the design phase
iii. Make available the appropriated personnel to participant in the study as team member
iv. Make certain that adequate time is allotted in the project scheduled for conducting and following up the HAZOP study activities
v. Assist the HAZOP study leader in arranging for meetings sites, outsides members and vendors representatives
vi. Ensure that normal safety design is not omitted just because a HAZOP study is to be carried out
Preparation for HAZOP study
i. Establish the ground rules of the study
ii. Plan the study schedule
iii. Identify the team members n arrange for their assistance
iv. Organize the data base
v. Become familiar with the data base
vi. Ensure all the member familiar with the major design n operating principles
vii. Arrange the suitable meeting places
Establishing the ground rules of the study ( the objectives)
i. 2 identify all deviations this could lead to a safety hazard
ii. 2 identify all causes of deviations this could lead 2 an operability problems
iii. 2 recommend changes or further study, to overcome safety hazard
iv. 2 review operating procedures
v. 2 record the background to all recommendation made
vi. 2 record all usefull information from the study



Responsibilities of the HAZOP leader:
i. Responsibilities for the success of the HAZOP study
ii. Res 2 carry out an objectives HAZOP study
iii. Selection of the team
iv. Planning of the study
v. Reporting the study
vi. Follow up the action
HAZOP Recorder
i. 2 take notes of the study in sufficient detail to allow the background to each recommendation to be understood
ii. 2 record recommendations in sufficient detail for them to be implemented
iii. 2 inform the HAZOP leader if he needs more times for notes taking
iv. 2 check the wording of recommendations if he is unsure
System Design Eng;
i. 2 provide a simple description for each system to be studied
ii. 2 provide a information of the design intention of each system
iii. 2 provide information on the design and operating conditions
iv. 2 provide information on the hazard of process/operations
Mechanical Design Eng:
i. 2 provide specification detail of the equipment, support, structure and other mechanical design detail
ii. 2 provide detail of vendor packages so far as these are known
iii. 2 provide information on equipment and system layout, site layout and access
iv. 2 provide information on design codes applicable to the equipment
Instrument and Control Specialist:
i. 2 provide details of control and interlock philosophy
ii. 2 provide information on control and interlock hardware and software
iii. 2 give information on hardware reliability and modes of failure
iv. 2 provide information of control system, control states and safety features
Project Eng
i. 2 provide details of the project not known to other team member
ii. 2 provide details of the implication of scheduled and timing
iii. 2 allow a rapid response to design changes suggestions
Company Safety/Quality Representative:
i. 2 ensure that company safety and standards are observed in the design
ii. 2 ensure a common approach to safety in this facility in comparison to other company facilities
Failure Modes Effect Analysis:
Def:
i. Systematic driven approach that identify potential failure modes in the system, product, or manufacturing/ assembly causes by either design or manufacturing/ assembly process efficiency
ii. It also identified critical or significant design or process characteristic that required special control to prevent or detect failure modes
iii. Tools to prevent problem to occurring
Benefits:
i. Provides an auditable method for the identification of equipment failure modes and resulting consequences or hazard
ii. Provides an objectives basic upon which to decide upon potential corrective action
iii. It can identify non compliance with regulatory requirements
iv. It identify the need for built in test or suitable testing provisions in service
v. To aid communication between the various engineering disciplines involved in the project
vi. To identifies single point failure and requirement for redundancy or safety system
Limitations:
i. It can only used to identify single failure not combinations of failure
ii. Unless adequately controlled and targeted it can be time consuming and costly
iii. It can be difficult and tedious and complex multi layered systems
iv. It not suitable for quantification of system reliability
FMEA Process:
i. Obtain all necessary information on the system to be analyzed
ii. Establish ground rules and assumptions for the analysis
iii. Construct a hierarchical block diagram for the system
iv. Conduct the FMEA based upon the information derived in step 1 – 3
FMECA:
Failure modes, effects, and criticality analysis (FMECA) is a methodology to identify and analyze:
i. All potential failure modes of the various parts of a system
ii. The effects these failures may have on the system
iii. How to avoid the failures, and/or mitigate the effects of the failures on the system
iv. FMECA is a technique used to identify, prioritize, and eliminate potential failures from the system, design or process before they reach the customer
v. FMECA is a technique to “resolve potential problems in a system before they occur”

FMEA Procedures:
i. FMECA prerequisites
ii. System structure analysis
iii. Failure analysis and preparation of FMECA worksheets
iv. Team review
v. Corrective actions