Contents

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

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

Abbreviations .................................................................................................. xxi

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

Acknowledgments .......................................................................................... xxix

Part I – Guidelines for Hazard Evaluation Procedures .............................. 1

Preface to the Guidelines ......................................................................................... 3
Management Overview of the Guidelines ................................................................. 7
1. 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
2. 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
3. Hazard Identification Methods and Results ...................................................... 35
3.1 Analyzing Material Properties and Process Conditions ...................... 36
3.2 Using Experience ............................................................................. 44

This page has been reformatted by Knovel to provide easier navigation. vii
viii Contents

3.3 Developing Interaction Matrixes ........................................................ 45

3.4 Using Hazard Evaluation Techniques to Identify Hazards .................. 47
3.5 Hazard Identification Results ............................................................ 49
4. 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
5. Selecting Hazard Evaluation Techniques ......................................................... 73
5.1 Factors Influencing the Selection of Hazard Evaluation
Techniques ....................................................................................... 74
5.2 Decision-Making Process for Selecting Hazard Evaluation
Techniques ....................................................................................... 84
5.3 Example Using the Proposed Selection Criteria ................................ 84
6. 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
6.10 Event Tree Analysis .......................................................................... 175
6.11 Cause-Consequence Analysis .......................................................... 184

This page has been reformatted by Knovel to provide easier navigation.

 Contents ix

6.12 Human Reliability Analysis ................................................................ 189

6.13 Other Techniques ............................................................................. 196
7. 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
8. 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. Introduction to the Worked Examples ............................................................... 233
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

This page has been reformatted by Knovel to provide easier navigation.

x 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

This page has been reformatted by Knovel to provide easier navigation.

 Contents xi

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

This page has been reformatted by Knovel to provide easier navigation.

xii 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

This page has been reformatted by Knovel to provide easier navigation.