Fine Print

Educational/ Training Material

Issued as a service to the industry
for Free Distribution
Hazard & Identification

HAZID
Based on industry practices
Introduction

Chemical Process Industries (CPI) are top Safest Performers
 Fatal Accident Frequency Rate (FAFR) – No. of fatalities in a group of
1,000 people per 100 million hours over their working lifetimes for a
variety of occupations
 Construction: 67 Road travel: 57 CPI: 4 Stay at home: 3
Bureau of Labor Statistics 2006, US Department of Labor

Still spectacular accidents happen, blowing up the image. We

need to identify hazards that are present
H2S: Toxic. H2/LPG: Flammable/ Explosion

Hazard: Machinery: Can injure.
 An inherent physical or chemical characteristic with a potential to
cause harm to people, the environment, or property (AICHE Center for
Chemical Process Safety)
 Any activity, procedure, process, substance, situation or other
circumstance that has the potential to cause injury or illness
Still accidents happen

Time to take stock; Reflect
WHAT WENT WRONG Bhopal: 20,000++ Dead

Boat hit

Hurricane hit

Hydrocarbon into Boiler Air Erosion Corrosion Column overflow

Safety Studies

Companies that regularly perform Safety Studies
usher in a Safety culture and reduce frequency and
severity of accidents

Hazid: One of many safety reviews performed in a
plant processing hydrocarbon or hazardous material
 Part of Process Safety Management (PSM); Process
Hazard Analysis (PHA) etc
HAZID: Why & When

Why: Identify hazards or risks.
 It is employer’s responsibility to identify
 All reasonably foreseeable hazards
 Potential accidents and their likely consequences as a
result of failures in process, procedures, or equipment

When: As early as possible, FEED stage, based on
min info - layout and process & utility flow diagrams
 A follow-on study during Detailed Engg, if required, to
follow-up recommendations of previous studies
 Early study enables timely inputs. Delayed studies fail to
influence or apply course-correction to proposed design
Operations team learns about design limits and
Design team learns about operational constraints
HAZID: Who

By a team - bigger “experience envelope”

Members:
 Study chairman or facilitator
 Scribe
 Process engineer
 Safety engineer
 Layout or Piping engineer and
 Client representatives
 Supplemented on a call basis by
 Civil or Structural engineer, and Mechanical engineer

Recommendations & solutions are team dependent

HAZID: How

Team selects areas to study
 Plot or deck wise or system wise
 Too many areas, wastes time. Repetition and waning focus
 Too few, may miss out a few threats
 Experienced judgment is the key

Each system or area reviewed against a pre-agreed
checklist
HAZID: How

When a hazard is identified, following are evaluated
 All potential causes or scenarios that could trigger the
hazard
 Their potential consequences - direct as well as escalated
 Impact on personnel, assets and environment
 Effectiveness of safeguards/ risk reduction/ or operating
procedures present
 Recommendation, if any, to add to existing measures
 Select a Area / Node
HAZID: Steps
Select a Hazard

Identify Causes

Identify Consequences

What are the safeguards?

Risk Reduction Measures? Caution: What is normal
Operating Procedures? practice in a company
may be a hazardous
Recommendations practice in another
Changes to design, operation company which may not
have adequate
experience with a
Other Causes particular process or
equipment. Example:
Other Hazards regenerator insulation
failure resulting in hot
Other Nodes spots and vessel failure
or H2S
Follow up! Follow up!!
HAZID: Recommendations

The team should not attempt to provide a solution
unless one is obvious

Its role is to identify hazards and provide a high level
qualitative assessment

The project and discipline engineers should find an
acceptable solution as part of design development
 Some studies may assign Risk Ratings for the identified
hazards, based on a risk matrix by the client
 These ratings help prioritize follow-on actions
 Whether there is a high or low risk, all actions should be
properly closed out
HAZID: Study Session & Next

HAZID worksheet is projected overhead for members to see,
comment and concur. Hazards that are not present are not
recorded

Worksheet is circulated in DRAFT format for team members
to review and comment. Then it is released for action

Actions or recommendations proposed are assigned to
individuals by a project engineer via a suitable tracking
system

Actions closed out are recorded in the final HAZID report
issued as a project deliverable. A few projects may maintain a
Hazard Register wherein identified hazards are input by area
and type. The HAZID report is used to populate it
Hazid: Checklist
Hydrocarbon, Chemicals & Utilities
1. Hydrocarbons release - with or without ignition
 Dropped objects, Swing loads, Corrosion, Small bore pipes, Fitting
leaks, Seal failure, low temperature embrittlement, AIV/FIV, Gas
blowby
2. Hydrocarbon ingress
 Hydrocarbon ingress into gas turbine, diesel engine, fired heater air
intakes
3. Moisture ingress
 Water ingress into heated or hot oil storage
4. Draining / Sampling
 Discharge of produced water (with mercury), mud, cuttings to sea or
soil
5. Thermal radiation/ Flaring and Venting
Hazid: Checklist
Hazardous Chemicals & Health Hazards
6. Hazardous gas, liquids and solids release
 Mercury, Arsenic, H2S, CO2, CH4, NOx, SOx, VOC
7. Non Process Fire/ Flammable chemicals
 Fire in LER, GT Enclosure
8. Explosion
 H2 in Hypochlorite Tank or Battery Room
9. Asphyxiation / Confined space
 Inert gas release, Smoke, CO2, Vessel entry
10. Particulates (sand, dust, ash)
 Sand, Catalysts, Desiccant,
11. Radioactive / Explosive material
Hazid: Checklist
Structural
12. Structural failure
 Weather, Earthquake, Collision, Overload, Fire, Cyclic loads
Occupational Hazards
13. Electrical energy
 Electrocution, Static electricity
14. Stored energy (Pneumatic / Thermal)
 High pressure hoses, Hot surfaces
15. Vibration / Noise
 High pressure drop valves, Machinery, slugging, Water hammer
16. Manual work
 Rigging, Handling drums, Cutting & Welding, Hand tools, Fall overboard
17. Natural and Environmental Hazards
 Wind, Cyclones/ hurricanes/ tornadoes, Waves, High tides, tsunami, Sea
currents, Floods, Ice, Blizzards, Earthquake, Volcano, Ground slide, Soil
subsidence, Summer, Winter, Saliferous or sand/ dust laden wind, Humidity,
Heavy rains and Lighting
Hazid: Checklist
Marine
18. Marine operations
 Personnel Transfer, Supply boat operations, Passing ships, Helicopter
operations
19. SIMOP
Emergency, Escape and Rescue
20. Impeded Access / Approach / Escape/ Evacuation
 Slippery steps, Blocked access, Laydown area, Maintenance activities
Man-made Hazards
21. Security issues
 Unauthorized entry; Sabotage; Piracy, Terrorist activities
Construction and Start-up
22. Construction difficulties
 Poor planning, Legislation, Compliance to local codes & standards
23. Start-up & Shutdown difficulties
 Poor planning, Missing black start fuel, Low inventory, Untrained crew
Hazid: Checklist
System or location specific issues
Pigging Operation
Cellar or Lowest Deck or Upper Deck
FPSO
Poor planning - Hull delivery; Storage volume; hull to shipping standards (batch
mode) and topsides to process industry standards (continuous operation)
Effect of FPSO’s axial (Surge, Sway, Heave), rotational (Roll, Pitch, Yaw) and static
(List, Trim) separation, distillation, liquid levels, internals support
Hogging/ sagging of decking plates on equipment support & structures, rotating
equipment support
Green water waves; Maintenance - storage tanks, sea chest, seawater pumps etc
Onshore Location
Proximity to population, Ground water contamination, Historical monuments
damaged by fumes, Public roads, Nearby land use (Farming/ Fishing)
Biological
Endemic diseases, Infection, Contaminated water / food, Biological agents
(viruses, pathogens, parasites, poisonous reptiles and plants)
HAZID: Preparation-Before the study

Get a team
 Nominate an individual (Project Engineer in new projects
or Works Engineer in an operating plant) to initiate the
study with authority to implement the actions; otherwise it
is a waste of time - for a given study and all future studies
 Nominate an experienced team leader . Give him/ her clear
scope, objectives and terms of reference
 Nominate a balanced team - knowledge and experience.
Design provides insight. Operations provides review &
objectivity
 Members notified in advance to make own preparation and
get familiar with the facility
Checking and stamping by individual experts miss impact of
interactions. Together as a team they act as a force-multiplier.
HAZID: Preparation

Review Key Documents
 PFDs, UFDs, Equipment location/ Plot plans

Electrical area classification - not a must in a new project

Fire & Gas detection - not a must in a new project

Active/ passive fire protection - not a must in a new project

Fire fighting & safety equipment locations - not a must in a new
project

Escape & Evacuation - not a must in a new project
 Corporate standards/ engineering practices
 For a new project:

Safety studies proposed to avoid too many action items

Caution: Practices based on corporate/ industry/ statutory codes are

not adequate to cover changes in new plant/ operation/ design
HAZID: Study Duration

4-8 hours for a standard facility
 3 hours/ morning when hand recording by hand. 6 hours/
day with computer recording and on screen projection
 2 - 3 sessions/ week

During the study
 Adequate time for review
 Creative and “brain storming” mode . Should not “drop down”
to a mechanical process
 If fatigue sets in, the study should be halted by the leader and
restarted when the team is fresh
 No single PERSON should be allowed to dominate the meeting.
We need more inputs
HAZID: Nodes

Difficult to focus on a full facility

Review done in steps, in small bites, usually one ISBL
unit or one deck at a time

Remember:
 Too many nodes - Repetition and waning focus
 Too few - may miss out a few threats
 Experienced judgment is the key
HAZID: Worksheet

Discussions are recorded in a transparent way
Hazard Cause Consequence Safeguards Action or On
Recommendation
Hydrocar Rupture 1) Pipeline / riser / piping leak/ 1) F & G detection / ESD/ Blowdown 3) Provide suitable
bons of risers rupture leading to gas cloud. 2) Lifting procedures / look out man on the topsides / type of crane and a
release - and/ or Potential vapor cloud crane mechanic on standby combination of
with or on-deck explosion (VCE) 3) Crane operating radius away from pipeline cranes, forklifts,
without piping 2) Riser fire (jet fire for a long corridor hydraulic
ignition due to: duration) 4) Certified crane operators. Dead man’s handle to manipulators, lifting
3) Toxic exposure (CO2, H2S, operate crane. beams and appliances.
Dropped Mercury) 5) Regular crane maintenance 4) Check operational
object, 4) Pool fire of oil/ condensate 6) Dropped Object / crane location / laydown area requirements for lay-
Swinging on deck and sea surface study to ensure that crane resting position is not down areas, bumper
load, 5) Equipment/ Structural above equipment or escape routes bars and mechanical
Fitting damage 7) Fusible plugs near riser ESDV to shutdown SDVs handling capabilities.
Failure or 6) Personnel injury upon confirmed fire detection 5) Ensure that
Leak, or 7) Missile generation, 8) PPE to prevent skin exposure to mercury wellheads are
Operator equipment/ structural damage 9) Hazardous area classification and selection of automatically
Error 8) Escalation to adjacent risers electrical equipment conforming classified zone shutdown upon
and other equipment on board 10) Automatic isolation of power to non-essential confirmed fire
electrical equipment on confirmed fire detection detection on topsides
11) Decks are naturally ventilated

Recorded without ambiguity to avoid any misunderstanding.

Must be clear even after 10 years

Only items with potential hazards are recorded
HAZID: Follow-up

Recommendations are reviewed by project team

All recommendations need NOT be accepted. Each is
analyzed and a suitable solution found by project team

Flexible. Not all issues can be fixed by design or
hardware changes. Some require changes to SOP
 Change in process/ op conditions/ design/ operating procedure
 Remove cause or minimize consequence

Each item is assigned to a specific individual for
resolution. Inform all once a resolution is reached.

HSE team is tasked with tracking each to resolution. All
recommendations must be closed - action or no action

HSE team verifies implementation and closes-out.
Management change process in a Tracking Register
Some Owner- Operator go all the way to independent
checking of as-built plants for completion.
Hazid

When
1. Concept stage – Hazards of materials and operation
2. FEED stage – major hazards [Hazid]
3. Detailed engg stage – standard Hazop
4. Construction/ site check – checklist
5. Pre-startup: function testing, purging – checklist
6. Existing or operating plants – lessons learnt

Difficult to get up to date info/ flow sheet; follow-up and close-out

Note: each stage verifies that the actions of previous stages have been completed
HAZID: one of many tools

Other tools
 What-if analysis, Check Lists
 HAZOP - Hazard and operability study
 FEMA - Failures Mode & Effect Analysis; FTA - Fault Tree Analysis
 Instrument (Chazop), Safety Integrity Level (SIL), Electrical Safop.
 LOPA - Layers of protection analysis
 Environmental:

Envid; Process discharges; Exhaust; Waste disposal

EIA - Environmental Impact Assessment

Other tools
 Human factors assessment, Alarms management
 Corporate standards/ Incident reporting
 Emergency Response Planning
 Health:

Toxic/ carcinogenic; Noise & Vibration; AIV/FIV; Flare radiation
Safety Studies
Qualitative Vs Quantitative

Safety Studies Knowledge, Experience and Judgment.. Vs Numerical Analysis

 Qualitative/ Quantitative Risk Analysis (QRA)

 Typical Oil & Gas Offshore facility studies

Dropped Object Risk Analysis

Ship Collision Risk Analysis

Smoke & Gas Ingress Analysis Dispersion (hydrocarbon/ toxic materials)

Fire & Explosion Risk Analysis Pool and jet fires; BLEVE and explosion overpressure

Toxic Gas Risk Analysis

EERA - Escape, Evacuation & Rescue Analysis

Temporary Refuge Integrity Analysis

ESSA - Emergency Systems Survivability Analysis

Emergency Systems Reliability / Availability Analysis

EIA - Environmental Impact Assessment
Safety Case
Hazid/ Design Info Plant
Hazop
Design
Studies

Hazard Safety
Register Studies Recommendations

Risk Performance
Assessment Standards

Safety Case/
Report
Accidents Still happen

No method can identify all accidents that could occur

Team may be unaware of a scenario, may overlook it or
decide it as not credible or significant

You can add redundancy in alarms and shut down valves
(parallel trips, valves in series)

How about the man – to take the right action, in the right
time and right sequence

Failure rates
 100% in an emergency respond to avoid a serious accident, with so
many alarms and phones ringing
 10% in a busy control room with phones ringing
 1% in a quite control room as in a pumping station
 0.1% if the button to press is right below the alarm
Accidents

Do they happen or do we let them happen
Your every action in a day, considering its impact on you, your family,
your colleagues and friends, will make it a way of life!

THANK YOU - BE SAFE