9

Introduction to the Worked Examples

A hazard evaluation (HE) study is an organized effort to identify and analyze the
significance of hazards associated with a process or activity. Specifically, HE studies
are used to pinpoint weaknesses in the design and operation of facilities
weaknesses that could lead to accidental chemical releases, fires, explosions, and
other undesirable events. An effective hazard evaluation program is one of the
cornerstones of an organization's process safety management (PSM) program.
Each organization's PSM program should require that hazard evaluation studies
be performed throughout the life of a process. These studies can provide
information that will help organizations make decisions about improving safety and
managing the risk of operations. Using this "life cycle* approach along with other
PSM activities can help organizations make the most effective use of resources spent
to ensure the safe and productive life of a facility.
The dramatic increase in the number of companies who use HE techniques has
created a large demand for skilled hazard analysts. Unfortunately, hazard evaluation
is a relatively new field, and there are only a few established academic or industrial
training programs that equip engineers with the necessary skills. Moreover, to
become an expert hazard analyst, one also needs the practical knowledge and insights
that normally come only through years of industrial experience.
The Center for Chemical Process Safety (CCPS) recognized the increased need
for analysts who are proficient in the use of hazard evaluation techniques. Thus,
CCPS published these Guidelines for Hazard Evaluation Procedures, Second Edition
with Worked Examples, designed to help people understand the theory and
application of the HE techniques.
9.1 Purpose
The HEP Worked Examples can help people become competent practitioners
of hazard evaluation techniques, but first they must become familiar with standard
HE methods. Beginners can acquire basic knowledge about the techniques by using
the HEP Guidelines. Then, they should use the HEP Worked Examples to study the
ways the techniques can be applied. Tb become seasoned analysts, however, they
must hone their hazard analysis skills and intuition through participation in actual
studies. Only then can company managers be confident that their hazard analysis
leaders have acquired the necessary expertise for performing high quality hazard
evaluation studies.

The purpose of the HEP Worked Examples is to illustrate the use of commonly
accepted HE techniques on a realistic process. The HEP Worked Examples
demonstrate how each technique can be applied and how the results can be
documented for management's use. Although these examples describe typical
applications of the techniques, they should not be considered as the only way these
methods could be used. The ultimate aim of the Worked Examples is to give the
beginner a look at the kinds of problems that arise when these techniques are
actually applied in industry.

9.2 Instructional Strategy

A fictional, yet realistic, process has been defined for use in the Worked
Examples. A vinyl chloride monomer (VCM) plant will be constructed by ABC
Chemicals, Inc. in Anywhere, U.S.A. Hazard evaluations are to be performed on the
example process as the project evolves through the various phases of a typical
process lifetime. During each phase, the reader is challenged with the following
questions:
Why is the hazard evaluation needed? What are its objectives?
What information and resources are available at this stage of the
project?
What HE technique should be used? Are there alternatives?
How should the results be documented? Who will be responsible for
follow-up?
Tb help answer these questions, each chapter provides the following information to
the reader:
Problem definition. Gives the background for the proposed study.
Provides information about the status of the VCM process, available
resources, and selection of HE techniques. Describes study preparation.
Analysis description. Discusses pertinent details of the analysis.
Presents portions of models (e.g., fault trees, event trees), along with
narratives of typical HE team meetings.
Discussion of results. Presents salient results of portions of the analysis.
Includes documentation examples.
Follow-up on recommended actions. Discusses the importance of
developing a management response to the findings of each HE study.
Integrates safety improvements into the process for use during the next
phase of the example.

 Conclusions and observations. Presents the conclusions of the study.

Includes observations on how the study was performed. Describes
successes and difficulties experienced by the HE team.
Each chapter ties together all phases of the project to develop a realistic picture of
the process's evolution. Essential data for the various applications of HE techniques
are summarized in each chapter.

93

How to Use the Worked Examples

Chapters 10 and 11 give the necessary background for understanding the

example process and its inherent hazards. Appropriate hazard evaluation techniques
are selected and applied to a portion of the VCM plant during each of nine phases
of its life. Tkble 9.1 lists the various phases of this example project along with the
HE techniques chosen for each phase.
Readers who want to focus on a particular technique may skip to the
appropriate chapter; however, some confusion may occur because essential
information that was presented in an earlier chapter may not be repeated in the
chapter of interest. Tb help avoid this problem, readers are cautioned to review
Chapters 10 and 11 before proceeding to the example application of a particular
technique. Chapter 10 describes the example VCM process and facility. Chapter 11
gives the results of the initial hazard identification for the VCM process. Chapters
12-20 illustrate the use of the HE techniques at different points in the process's
lifetime.
9.1 Summary of Example Problems
Chapter

Project Phase

Selected HE Tbchniques

12

Research and Development

What-If Analysis

13

Conceptual Design

Preliminary Hazard Analysis

14

Pilot Plant Operation

HAZOP Analysis

15

Detailed Engineering

Fault Itee and Event Thee Analysis

16

Construction/Start-Up

Checklist Analysis and Safety Review

17

Routine Operation

HAZOP Analysis

18

Plant Expansion

Relative Ranking and HAZOP Analysis

19

Incident Investigation

FMEA and HRA

20

Decommissioning

What-WChecklist Analysis