Contents

List of Tables ..................................................................................................

xi

List of Figures .................................................................................................

xvii

Abbreviations ..................................................................................................

xxi

Glossary ......................................................................................................... xxiii

Acknowledgments .......................................................................................... xxix
Part I Guidelines for Hazard Evaluation Procedures ..............................

Preface to the Guidelines .........................................................................................

Management Overview of the Guidelines .................................................................

1.

2.

3.

Introduction to the Guidelines ...........................................................................

11

1.1

Background ......................................................................................

12

1.2

Relationship of Hazard Evaluation to Risk Management

Strategies .........................................................................................

13

1.3

Elements of a Process Accident ........................................................

15

1.4

Hazard Evaluation Throughout a Project Lifetime ..............................

20

1.5

Limitations of Hazard Evaluation .......................................................

20

Preparing for Hazard Evaluation Studies ..........................................................

24

2.1

Infrastructure ....................................................................................

24

2.2

Analysis Objectives and Scope .........................................................

25

2.3

Information Requirements .................................................................

27

2.4

Personnel and Skills .........................................................................

30

2.5

Schedule and Execution ...................................................................

32

Hazard Identification Methods and Results ......................................................

35

3.1

Analyzing Material Properties and Process Conditions ......................

36

3.2

Using Experience .............................................................................

44

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4.

5.

Contents
3.3

Developing Interaction Matrixes ........................................................

45

3.4

Using Hazard Evaluation Techniques to Identify Hazards ..................

47

3.5

Hazard Identification Results ............................................................

49

Overview of Hazard Evaluation Techniques .....................................................

51

4.1

Safety Review ..................................................................................

53

4.2

Checklist Analysis .............................................................................

54

4.3

Relative Ranking ..............................................................................

56

4.4

Preliminary Hazard Analysis .............................................................

59

4.5

What-If Analysis ...............................................................................

60

4.6

What-If/Checklist Analysis ................................................................

62

4.7

Hazard and Operability Analysis .......................................................

64

4.8

Failure Modes and Effects Analysis ..................................................

66

4.9

Fault Tree Analysis ...........................................................................

67

4.10 Event Tree Analysis ..........................................................................

69

4.11 Cause-Consequence Analysis ..........................................................

70

4.12 Human Reliability Analysis ................................................................

71

Selecting Hazard Evaluation Techniques .........................................................

73

5.1

Factors Influencing the Selection of Hazard Evaluation

Techniques .......................................................................................

74

Decision-Making Process for Selecting Hazard Evaluation

Techniques .......................................................................................

84

Example Using the Proposed Selection Criteria ................................

84

Using Hazard Evaluation Techniques ...............................................................

93

6.1

Safety Review ..................................................................................

95

6.2

Checklist Analysis .............................................................................

99

6.3

Relative Ranking .............................................................................. 104

6.4

Preliminary Hazard Analysis ............................................................. 112

6.5

What-If Analysis ............................................................................... 117

6.6

What-If/Checklist Analysis ................................................................ 122

6.7

Hazard and Operability Analysis ....................................................... 131

6.8

Failure Modes and Effects Analysis .................................................. 151

6.9

Fault Tree Analysis ........................................................................... 160

5.2
5.3
6.

6.10 Event Tree Analysis .......................................................................... 175

6.11 Cause-Consequence Analysis .......................................................... 184
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6.12 Human Reliability Analysis ................................................................ 189

6.13 Other Techniques ............................................................................. 196
7.

8.

Analysis Follow-Up Considerations ..................................................................

198

7.1

Prioritization of Hazard Evaluation Results ........................................ 198

7.2

Documentation of Hazard Evaluation Studies .................................... 210

7.3

Development of a Management Response to a Hazard

Evaluation Study .............................................................................. 214

7.4

Resolution of Action Items ................................................................ 216

Future Research and Development ..................................................................

220

8.1

Hazard Identification Techniques ...................................................... 220

8.2

Hazard Evaluation Techniques ......................................................... 221

8.3

Methods for Using Qualitative Results in Decision Making ................ 224

8.4

Integrating HE Study Results into PSM Programs ............................. 224

Part II Worked Examples for Hazard Evaluation Procedures ................ 227

Preface to the Worked Examples .............................................................................

229

Management Overview for the Worked Examples ...................................................

231

9.

233

Introduction to the Worked Examples ...............................................................

9.1

Purpose ............................................................................................ 233

9.2

Instructional Strategy ........................................................................ 234

9.3

How to Use the Worked Examples .................................................... 235

10. Description of the Example Facility and Process ..............................................

236

10.1 Company and Facility Background .................................................... 236

10.2 Process Overview ............................................................................. 237
10.3 Description of the Process Lifetime ................................................... 237
11. Hazard Identification for the Example Process .................................................

241

11.1 Analysis of Material Properties .......................................................... 241

11.2 Review of Experience ....................................................................... 242
11.3 Interaction Matrix .............................................................................. 242
11.4 Hazard Evaluation Techniques Used for Hazard Identification ........... 245
11.5 Summary .......................................................................................... 245
12. Research and Development Phase An Illustration of the What-If
Analysis Method ...............................................................................................

247

12.1 Problem Definition ............................................................................ 247

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Contents
12.2 Analysis Description ......................................................................... 253
12.3 Discussion of Results ....................................................................... 256
12.4 Follow-Up ......................................................................................... 260
12.5 Conclusions and Observations .......................................................... 260
13. Conceptual Design Phase An Illustration of the PHA Method .......................

262

13.1 Problem Definition ............................................................................ 262

13.2 Analysis Description ......................................................................... 266
13.3 Discussion of Results ....................................................................... 269
13.4 Follow-Up ......................................................................................... 272
13.5 Conclusions and Observations .......................................................... 272
14. Pilot Plant Operation Phase An Illustration of the HAZOP Analysis
Method ..............................................................................................................

274

14.1 Problem Definition ............................................................................ 274

14.2 Analysis Description ......................................................................... 278
14.3 Discussion of Results ....................................................................... 288
14.4 Follow-Up ......................................................................................... 294
14.5 Conclusions and Observations .......................................................... 295
15. Detailed Engineering Phase An Illustration of the Fault Tree and
Event Tree Analysis Methods ...........................................................................

296

15.1 Problem Definition ............................................................................ 296

15.2 Analysis Description ......................................................................... 299
15.3 Results ............................................................................................. 308
15.4 Follow-Up ......................................................................................... 309
15.5 Conclusions and Observations .......................................................... 309
16. Construction/Start-Up Phase An Illustration of the Checklist Analysis
and Safety Review Methods .............................................................................

311

16.1 Problem Definition ............................................................................ 311

16.2 Analysis Description ......................................................................... 313
16.3 Discussion of Results ....................................................................... 317
16.4 Follow-Up ......................................................................................... 319
16.5 Conclusions and Observations .......................................................... 319
17. Routine Operation Phase An Illustration of the HAZOP Analysis
Method for Periodic Review ..............................................................................

320

17.1 Problem Definition ............................................................................ 320

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17.2 Analysis Description ......................................................................... 324

17.3 Discussion of Results ....................................................................... 329
17.4 Follow-Up ......................................................................................... 334
17.5 Conclusions and Observations .......................................................... 334
18. Plant Expansion Phase An Illustration of the Relative Ranking and
HAZOP Analysis Methods for a Batch Process ................................................

336

18.1 Problem Definition ............................................................................ 336

18.2 Analysis Description ......................................................................... 341
18.3 Discussion of Results ....................................................................... 349
18.4 Follow-Up ......................................................................................... 349
18.5 Conclusions and Observations .......................................................... 350
19. Incident Investigation Phase An Illustration of the FMEA and HRA
Methods ............................................................................................................

364

19.1 Problem Definition ............................................................................ 364

19.2 Analysis Description ......................................................................... 367
19.3 Discussion of Results ....................................................................... 375
19.4 Follow-Up ......................................................................................... 381
19.5 Conclusions and Observations .......................................................... 381
20. Decommissioning Phase An Illustration of the What-If/Checklist
Analysis Method ...............................................................................................

383

20.1 Problem Definition ............................................................................ 383

20.2 Analysis Description ......................................................................... 388
20.3 Discussion of Results ....................................................................... 393
20.4 Follow-Up ......................................................................................... 393
20.5 Conclusions and Observations .......................................................... 394

Appendices ................................................................................................... 395

Appendix A Guide to Compatibility of Chemicals ..................................................

397

Appendix B Supplemental Questions for Hazard Evaluations ...............................

399

I.

Process ............................................................................................ 399

II.

Equipment ........................................................................................ 404

III.

Operations ........................................................................................ 426

IV.

Maintenance ..................................................................................... 428

V.

Personnel Safety .............................................................................. 430

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Contents
VI.

Fire Protection .................................................................................. 435

VII. Environmental Protection .................................................................. 439

VIII. Management and Policy Issues ........................................................ 442
Appendix C Symbols and Abbreviations for Example Problem Drawings .............

445

Bibliography ................................................................................................. 447

Index .............................................................................................................. 453

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