Hazard Assessment and Risk

Management Techniques for

Industries
Prepared by : VIJAY ASAR
Chief Co-ordinator,
DPMC

Disaster Prevention & Management Centre

Fire Station, GIDC, Ankleshwar- 2
disasterm@dataone.in
dpmcank@sancharnet.in
Ph. No. (02646) 220229, 653101

Disaster Risk Management

The systematic process of using
administrative decisions,
organisation, operational skills and
capacities to implement policies,
strategies and coping capacities of
the societies and communities to
lessen the impacts of
environmental and technological
disasters.

Disaster Risk Reduction

The conceptual framework of
elements considered with the
possibilities to minimize
vulnerabilitiies and disaster risk
throughout a society, to avoid
(prevention) or to limit (mitigation
and preparedness) the adverse
impacts of hazards.

What is system safety?

The system safety concept is the application of
special technical and managerial skills to the
systematic, forward-looking identification and
control of hazards throughout the life cycle of a
project, program, or activity. The concept calls for
safety analyses and hazard control actions,
beginning with the conceptual phase of a system
and continuing through the design, production,
testing, use, and disposal phases, until the activity
is retired.

Chemical hazards
Type of chemical hazards
Material hazard : Hazardous nature of chemicals
like Inflammable, explosive, toxic, corrosive, reactive,
radioactive, reducing, oxidizing, decomposing or
incompatible.

Process hazards : In process, chemical and

physical change, chemical reaction, pressure,
temperature, level, flow, quantity and other
parameters create.

Vessel hazards : The vessels and equipments in

which the chemicals are stored, handled or reacted
pose.

Chemical hazards
Type of chemical hazards
Control hazards : The inadequate, defective, under
design or wrongly modified control devices or their of
failure cause.

Fire hazards : Fire or explosion

Toxic hazards : Affluent disposal and gaseous
emissions bring pollution and toxic hazards.

Handling hazards : Leaks, spills and splashes

cause.

Chemical hazards
Physical hazards or health hazards

Physical Hazards : Corrosives, Explosives

etc.
Health Hazards : Toxic, Irritants and Oxides.

Accident an emergency hazard

Absence, nonuse or failure of fire fighting

equipments,
personal
protective
equipments, emergency control devices

The Hazard
A potential condition or set of conditions, either
internal and/or external to a system, product,
facility, or operation. Which, when activated
transforms the hazard into a series of events that
culminate in loss (an accident). A simpler and
more fundamental definition of hazard is a
condition that can cause injury or death, damage
to or loss of equipment or property, or
environmental harm.

Hazard Analysis at various stages

of Project Execution

Process Hazard Management

Process Hazard Management includes:
Hazard identification.
Hazard Assessment.
Accidental vapour cloud release (flammable and/or

toxic).
Engineering approaches to mitigation.
Design features for emergency control.
Process Safety Management (PSM).
Planning for counter measures.
Emergency response planning (ERP-onsite).
Alerting local authorities and public.

Process Hazard Management

Some important elements of PSM.:
Employee Participation
Process Safety Information (PSI)
Process Hazard Analysis (PHA)
Operating Procedure
Training
Contractor Safety
Pre-Startup Safety Review
Mechanical Integrity
Hot Work Program
Management of Change (MOC)
Incident Investigation
Emergency Planning & Response Compliance
Audits

Process Hazard Management

1. Operating Procedures
Initial startup
Normal, temporary & emergency operations
Normal shutdown
Startup following a turnaround or after an

emergency shutdown
Operating limits
Consequences of deviation steps required to

correct or to avoid such deviation

Process Hazard Management

1. Operating Procedures
Safety & Health considerations
Precautions necessary to prevent exposure,

including engineering controls

Administrative controls & personal protective
equipment
Controls measure to be taken if physical
contact or airborne exposure occurs
Quality control for raw materials & control of
hazardous chemical inventory levels
Safety systems & their functions.

Process Hazard Management

2. Pre-Startup Safety Review
Construction & equipment is in accordance

with design specifications

Safety,

operating,
maintenance
&
emergency procedures are in place & are
adequate

Modified facilities meet the requirements

contained in Management of Change

Training of each employee involved in

operating a process has been completed.

Process Hazard Management

3. Management of Change (MOC)
The

technical basis for the proposed

change
Impact of change on safety and health
Modifications to operating procedures
Necessary time period for the change
Authorization
requirements
for
the
proposed change
Up-date of Process Safety information
(PSI), PHA & Operating procedures.

Process Hazard Management

4. Process Hazard Analysis (PHA)
Engineering & administrative controls
Detection methods for providing early

warning of releases
Consequences of failure of engineering
and administrative controls
Facility site
Human factors
Qualitative evaluation of a range of the
possible safety and health effects of failure
of controls on employees and others

HAZID Technique
HAZID is an automated hazard identification tool
for continuous process plants and principle
features of
Sectionalizing the process plant into several units
Generation of hazardous incident scenarios
Use of models to distinguish between the feasible

and infeasible scenarios

Use rules to detect plant configuration problem.

HAZID Technique
HAZID Process
Divide the Process Plant into smaller
section
Generate Hazardous Incident Scenarios
Identify the feasible Scenarios only
Identify plant configuration problem
Generate output in HAZOP table

The Hazard
Hazard severity
Category

Name

Catastrophic

Characteristics
Death
Loss of system

II

Critical

Severe injury or morbidity

Major damage to system

III

Marginal

Minor injury or morbidity

Minor damage to system

IV

Negligible

No injury or morbidity
No damage to system

The Hazard

Possible hazard likelihood

Description

Level

Specific Individual Item

Fleet or Inventory

Frequent

Likely to occur frequently

Probable

Will occur several times in Will occur frequently

life of an item

Occasional

Likely to occur sometime Will occur several times

in life of an item

Remote

Unlikely but possible to Unlikely

but
can
occur in life of an item
reasonably be expected
to occur

improbable

So unlikely, it can be Unlikely to occur, but

assumed occurrence may possible
not be experienced

Continuously
experienced

The Hazard

Hazard Assessment Matrix

HAZARD CATEGORIES

Frequency of
Occurrence

I
Catastrophic

II
Critical

III
Marginal

IV
Negligible

(A) Frequent

1A

2A

3A

4A

(B) Probable

1B

2B

3B

4B

(C) Occasional

1C

2C

3C

4C

(D) Remote

1D

2D

3D

4D

(E) improbable

1D

2E

3E

4E

The Hazard

Hazard Assessment Matrix

Hazard Risk Index

HRI

1A, 1B, 1C, 2A, 2B, 3A

1D, 2C, 2D, 3B, 3C

II

1E, 2E, 3E, 3E, 4A, 4B

III

4C, 4D, 4E

IV

Suggested Criteria

Unacceptable
Undesirable (Management decision required)
Acceptable with review by management
Acceptable without review

The Hazard

Relationship of qualitative probability

ranking to quantitative values

Description Level

Frequency of
occurrence

Potential relationship
to Quantitative Value

Frequent

High

10-1

Probable

Occasional

Medium

> 10-3

Remote

> 10-4

Improbable

Low

> 10-6

The Concept of Risk

Risk: Chances or possibility of accidental losses
or undesired consequences."

The probability of a dangerous event posed by a

hazard, over a definite time period of exposure or

The frequency at which such events will occur

and results in fatalities to certain number of
people and

The consequence of such events in terms of

expected number of fatalities per year.

Risk = (Probability) x (Consequences)

Consequence Analysis or
Semi Quantitative Risk Analysis
Assessment of possibilities
--- By use of various hazard
identification techniques like
* Preliminary Hazard Analysis
(PHA)
* Hazard & Operability Study
* Safety Audit
* Fault tre analysis
* Event tree analysis, etc.

EFFECT MODELS
Conceiving a credible scenario by
hazard identification techniques
Computation of physical effects of the scenario
by suitable models like:
-- Outflow model
-- Dispersion model
-- Unconfined vapour cloud explosion models
-- Jet fire dimensions
-- Damage from shock wave on BLEVE
-- Fire ball radiation damages
-- Pool fire radiation damages etc.

TECHNIQUES AVAILABLE
o Fire & Explosion Index (Dow Index) and
Toxicity Index
o Calculation of damages likely from the
fires,explosions and toxic releases and
combining the damages with
probabilities of occurrence in terms of
Individual Risk and Societal Risk.
( The later is more objective for
estimating the distances likely to be
affected)

The Mathematical Models

Available to Compute the Effects
-- Release rate of liquids under pressure.
-- Distance of Lower Explosive Limit in the windward
direction.
-- Contours of LEL concentrations at the ground
level.
-- Mass of gas within explosive range (For
unconfined vapour cloud)
-- Shockwave damage on ignition of unconfined
vapour cloud explosion.
-- Mass of gas in explosive range on BLEVE.
-- Fire Ball Radius.
-- Fire ball duration.
-- Radiative flux.
-- Thermal Dose.

Dow and Mond Indices

Both the methods are closely related and as such
Mond Index was developed as an extension of
DOW index. Primarily, Dow index calculates the
Fire & Explosion index for a process unit taking
into consideration the flammability and reactivity
of the material handled in the process units under
the general and special process condition. Mond
Index on the other hand uses specifically the
material toxicity in addition to the other aspects.

Dow and Mond Indices

Fire & Explosion index

:(F & E1) = MF x (GPH) (SPH)

Toxicity Index

: Th + Ts (1+GPH+SPH)
100

Where,

MF
SPH
GPH
Th
Ts

= Material Factor
= Special Process Hazard
= General Process Hazard
= Toxicity factor based on the NFPA hazard
index (0 4)
= Correction factor (additional penalty) for
toxicity based on Maximum Allowable
Concentration (MAC) value in ppm

Dow and Mond Indices

Toxicity Factors and Correction Factor
for MAC values
NFPA Index
Number

Toxicity Factory
(Th)

50

125

250

325

MAC (in ppm)

TS

5 and blow

125

Between 5 and 50

75

50 and more

50

Process Hazard Management

General Process Hazard (GPH)
GPH includes processes e.g. exothermic reaction,
endothermic reactions, hydrogenation, alkylation,
isomerisation,
sulphurization,
neutralization,
esterification,
oxidation,
polymerization,
condensation, halogenation, nitration, loadingunloading operation, enclosed process units,
inadequate drainage and proper access etc.
different penalties are assigned for different
processes.

Process Hazard Management

Special Process Hazard (SPH)
SPH includes special hazards posed due to
process parameters like temp., pressure,
flammability ranges (UEL, LEL) of material and
issues like internal and external corrosion, leakage
from joints etc. additional penalties are assigned
for special process hazards. Selection of the
process units which may contribute to a fire or
explosion or toxic release

Process Hazard Management

The material factor which are the functions
of flammable and reactivity can be
calculated by the following way ;
Find out flash point of a material or HCV by

multiplying heat of combustion by the vapour

pressure of that substance at 27 C.
Find out flammability factor from the next table
from the flash point data or HCV value.
Find out the adiabatic decomposition temp. of the
substance.
Find out the reactivity factor from the table from
decomposition temp. value.

Dow and Mond Indices

Table for finding out Material Factor (Mf) from the table
Calculate Mf from following Table from Left to Right
Decomposition
temp. Td Deg K
Flash

HCV

Pt.

kJ bar/ mol

F
L

None

< 4 x 10-5

>100

4 x 10-5 2.5

40-100

< 830

830 - 935 - 1010 - >

935
1010 1080 1080
Reactivity

14

24

29

40

14

24

29

40

2.5 - 40

10

14

24

29

40

20-40

40 600

16

16

24

29

40

< -20

> 600

21

21

24

29

40

L
ITY

Material Factor MF

Procedure for Calculating the

Indices

Identify the most process units for risk

point of view.
Determine the material factor (MF) for
each process units (flammability &
reactivity of material)
Determine the Fire & Explosion Index
(F&EI) and the problem exposure area for
each process unit from the formula.
Calculate the Maximum Probable Property
Damage (MPPD).

Indices and the Extent of Hazard

F & E index

Toxicity Index

Degree of Hazard

1 60

16

Light

61 96

6 10

Moderate

97 127

> 10

Intermediate

128 158

> 10

Heavy

> 159

> 10

Severe

Risk Analysis
General Principles of Risk Analysis
1. All

relevant
addressed

risks

are

systematically

Identify major, dont concentrate on minor

Consider

those

aspects

of

work

which

are

hazardous
Take into account & critically assess existing safety
controls & measures provided

2. Address what actually happens

Actual practice, not instruction
Consider non-routine operations
Pay attention to changes/interruptions

Risk Analysis
General Principles of Risk Analysis
3.

Include all who could be affected, including

visitors, contractors, and general public

4.

Take into account, and objectively assess,

control measures

5.

The level of protection measures should

match the level of risk (i.e. risk within the
ALARP region)

6.

In most cases, make a rough assessment

first, find out the need for detailed assessment
and carry out the same, if needed.

Risk Analysis
Use of Probabilities in Risk
Analysis
The risk of operational activity with hazardous
materials consists of two elements

The consequence of certain unwanted event

The probability of certain consequences that will occur

A distinction is made between 3 types of

probabilities

The probability of the initiating event.

The probability that designed counter measures may
function
The probability of certain consequences of an accident

Risk Analysis
Layers of Protection Analysis
Offsite Emergency Measures Community Alerting & Evacuation, if necessary
Onsite Emergency Measures Onsite Evacuation

Protective Measures & Control Safety Instrumented

Mitigation
Protective Control & Monitoring Process alarms &
Safety Instrumented Control
Process Control & Supervision
Hazardous Process

Nomogram of Risk Assessment

Risk Analysis
Consequence BLEVE Model for Different
Static and Mobile Pressure Vessels

BLEVE Scenarios and Consequence Distances

Storage type

Inventory
(MT)

100% fatality
Distance

1% Fatality
Distance

Road tanker

12

137 M

500 M

--Do---

20

162 M

600 M

Rail Wagon

50

218 M

700 M

Horton Sphere

140

305 M

940 M

---Do---

1150

624 M

1834 M

Consequence Analysis
Consequence Analysis for a Ammonia Tank Leak
Scenario : 20 dia. Tank having leak of NH3 from 10 pipe
Consequence : Distance to IDLH is 8.9 Km

Kilometer

4
2
0
2
4

6
4
Kilometer

10

Consequence Analysis
Sour (containing H2S) Natural Gas pipeline leak scenario
Scenario : full bore rupture of a 42 pipeline
Consequence : Distance to IDLH is 3.9 Km

Kilometer

1.5
0.5
0
0.5
1.5

1
2
Kilometer

Risk Analysis
Risk control techniques / Risk Management
Inherent safe design (built-in safety)
Fault tolerant measures (single or multiple

failures)
Protective measures
Adequate information on the residual risk
Administration controls (e.g. allocation of task
to the human operator, training etc.)
Other Risk Reduction measures
Corrective and preventive actions
Document control

Risk Analysis

Sl.
No.

List of Software's Available for Risk

Analysis and Other Studies
Item Description

Application

1.

SAFETI

Onshore Risk Analysis.

2.

SFU

Offshore Risk Analysis.

3.

CAFTAN

Fault Tree Analysis.

4.

ETRA

Event Tree Analysis.

5.

HAZSEC.

HAZOP Study.

6.

HAZTRAC.

HAZOP Recommendation Tracking.

7.

PHAST.

Consequence Analysis.

8.

WHAZAN

Consequence Analysis.

Risk Analysis

Sl.
No.

9.

List of Software's Available for Risk

Analysis and Other Studies
Item Description

EFFECTS.

Application

Consequence (Effects) Modeling.

10. DAMAGE

Consequence (Damage) Modeling.

11.

Failure & Accident Databank.

PC-FACTS.

12. ASAP

Event Tree Analysis.

13. FMECA

Failure Mode Effects & Criticality Analysis.

14. ANEX

Life Time Analysis & Failure Estimation.

15. E&P FORUM

Hydrocarbon Leak & Ignition Database.

16. ALOHA

Consequence Analysis

Risk Analysis

Sl.
No.

List of Software's Available for Risk

Analysis and Other Studies
Item Description

Application

17. CLASS

Hazardous Area Risk & Classifications

18. RISK CURVES

TNO Individual & Group Risk computations

19. RISKA T

Risk Analysis model of Health & Safety

Executives, UK

20. FACTS

TNO Frequency Estimation Database

21. OREDA

DNV Frequency Estimation Database

22. FRED

Consequence Analysis software of Shell, UK

23. EAHAP

Consequence modeling software of Energy

Analysts Inc. US)

Risk Communication
Seven Cardinal Rules
1.
2.
3.
4.
5.
6.
7.

Accept and involve the public as a legitimate

partner.
Plan carefully and evaluate your efforts.
Listen to the publics specific concerns
(Communication is two way activity)
Be honest, frank and open (Trust and credibility
are most precious assets)
Coordinate and collaborate with other credible
sources
Meet the needs of Media ( provide risk information
tailored to the needs of each type of media)
Speak clearly and with compassion ( Use simple
non technical language with general public)

Have a Healthy Life

In Safe Environment.

DISASTER PREVENTION & MGMT. CENTRE

AnklESHwar.