PROCESS HAZARD ANALYS

SEVERITY
Potential Effect(s) of
Process Step # Process Potential Hazard / Failure Mode
Failure

5
Over Pressure to associated
1 Loss of containment
Piping
5

Equipment untight before

2 Loss of Containment
unloading 4

Loss of Containment/ 6
3 Poor Pump Maintenance
Equipment Failure
DING OPERATION

6
4 Hose Rupture Loss of Containment
6

8
5 Receiving Tank Overfill Loss of Containment
7

10

6
6 Slip, Trip and Fall Loss Of control
6

7
 BLENDIN
6

Overheating in Blending Kettles/ 8

7 Exposure of danerous gases due Loss of Control
to excessive heat
7

7
8 Manual Handling Loss of Containment

10

Loss of
9 ForkLift Operation
Containment/Control
7

8
CESS HAZARD ANALYSIS - HAZOP
OCCURRENCE
Potential Cause(s) of Hazard / Failure
Design and pressure not aligned with maximum
working pressure of pump
Relief valve set to max piping design presseure
Relieve valve not at safe location to prevent splash
and revert flow back into process on low pressure
side
Gasket Design not compatible with service
Inadequate design of hose pipe and not well
connected
Coupling design not compatible with truck and
working pressure
Unattendent offloading
Pump seals failure
No daily visual inspection
Design and pressure of hose not aligned with the
service
Hose not inspected and tested for pressure
Not checked visually for damage
Unoperational High level alarm on receiving tank
ullage not checked in receiving tank
Loading/offloading plan not confirmed
Lack of Communication
Not following and using pathways, staircase,
handrails, ladders, platforms and sacffold as per
procedure
Bad lighting
Procedure not defined for work at height and not
clearly explained each step
Improper house keeping
No use of anti slip shoes/foot ware
Unidentified trip hazards that cannot be eleminated.
DETECTION
R
Current Process Controls P
N
Piping is designed higher than max working
1 3
pressure of Pump
1 NA 0
1 NA 0
4 Compatible gasket are available for the service 4
All hoses are avaialbe as per design and double
3 1
check by operator before start of unloading
Coupling are checked for any damage and
2 compatibility with the truck by operator and 1
pressure is kept under observation
Covered in SOP for attendant offloading under
2 1
supervision
6 4
Visual inspection is done daily or before and after
3 3
of loading and unloading
Staff training has been conducted for slection of
2 1
hose
2 0
2 operator checks for damages 1
Level measurent is cross check with physical Dip.
4 There is limit switch control to cut off pump supply 3
incase of overfilled
2 Dip is taken before offloading the bulk 3
Confirm unloading plan - double check : ullage in
3 receiving tank and volume to unload match, line- 2
up ok
2 ways communicaion between unloading gantry
2 2
and receiving tank monitoring station
Proper walkways, handrails and scaffold with
2 ralling are available on site and TBT is conducted 2
before non routine activites
3 Lighting are installed as per requirement 2
Procedure are in place for routine work at height
3 2
activites
3 Housekeeping is part of work procedures 2
3 Anti slip foot ware are mandotary for the site 2
Caution sign are displayed for hazard that can not
3 3
be eleminated
Oil spillage on Floor
Unavailability of automatic temperature control
High temperature sensor and Alarm without
operator action
Independent high high temperature sensor and
alarm to cut energy supply
Unaware staff handling heavy loads without proper
techniques and equipment
Unavailability of lifting/handling equipment for
heavy & awkward equipment and objects
Lifting / handling equipment is not maintained so as
to ensure correct operation (e.g. lifting device for
drums; chain lift etc.).
unIdentified activities requiring handling of heavy
& awkward equipment and objects
Mechanical failure of forklift truck (forks, brakes…)
Inadequate working environment
improper manoeuvre of Forklift truck
Unstable pallet/pallet load
3 2
Automated scada control available for
4 3
temperature control
Only visual (Red/yellw/blue) background
4 3
notification with operator action
4 NA 4
Manual handling is included in SOPs where the
4 risk assessment identified such a risk. Training is 3
ensured for each activity identified as risk
Properly designed equipment for such activities
3 and provision of the correct type of equipment for 2
the job at hand are available
Scheduled maintenance program are in place to
3 2
ensure.
list of such activities and their risk assessment is
2 2
provided
Daily forklift truck integrity checks as per forklift
truck standard, including hydraulic systems.
6 3
Adequate tyres in good condition for the working
surface
Non-slippery floor. Area free for access and
4 2
manoeuvring
Slow speed approaching pallet for pick-up. Fork
tilt adequately for pick-up. Forks positioned at
4 2
right height for pick-up. Forklift truck position in
straight-line to pallet for pick-up
Pallets compliant with pallet standard and of good
2 quality (dry, free of damage). all packs to be 3
wrapped/strapped on pallets before movement
 Reviewed by:
Approved By:

OCCURRENCE

DETECTION
RESIDUAL

RESIDUAL

RESIDUAL
SEVERITY
Responsibilit Actions
R
y & Target Taken and
Recommended Corrective Actions P
Completion Completion
N
Date Date

Technical inspection plan must be

0
in place

0
0

0
 0

Alarm must sound for higher

0
temperature
Auto cutoff of temprature control
0
should be in place

0
 PROCESS HAZARD ANALYSIS

SEVERITY
Potential Effect(s) of
Process Step # Process Potential Hazard / Failure Mode
Failure

6
1 Pack Overfill Loss of Containment

2 Slip, Trip and Fall Loss Of control 7

3 Hazardous Tools/Knives Loss of Control 6

ING OPERATION

4 Pinch Poiint Loss Of control 6

5
Over Pressure to associated
5 Loss of containment
Piping
5

6 Manual Handling Loss of Containment

 FILLING O
7
6 Manual Handling Loss of Containment

10

Loss of
7 ForkLift Operation
Containment/Control
7

6
8 Poor Pump Maintenance Loss of Containment

6
9 Hose Rupture Loss of Containment
6
ESS HAZARD ANALYSIS - HAZOP
OCCURRENCE
Potential Cause(s) of Hazard / Failure
Wieght Scale malfunction
Weight not calculated according to density
Filling weight not confirmed
Control malfunction
Bad lighting
Improper house keeping
No use of anti slip shoes/foot ware
Unidentified trip hazards that cannot be eleminated.
Oil spillage on Floor
Not utilizing specifiied tools for the job
Procedure not followed for using knives and cutters/
sharp objects
Not using proper body position
Not using proper tool for the Job
Equipment not designed to eleminate pinch points
Design and pressure not aligned with maximum
working pressure of pump
Relief valve set to max piping design presseure
Relieve valve not at safe location to prevent splash
and revert flow back into process on low pressure
side
Gasket Design not compatible with service
Unaware staff handling heavy loads without proper
techniques and equipment
DETECTION
R
Current Process Controls P
N
weigh scale are well calibrated and
3 4
maintained
Weight is doucble checked by supervisor
2 3
and operator as per blend sheet
Filling operation not started witout filling
4 3
sheet
Emergency shutdown is available to
1 3
prevent overfill
2 Lighting are installed as per requirement 2
2 Housekeeping is part of work procedures 2
Anti slip foot ware are mandotary for the
4 2
site
Caution sign are displayed for hazard that
3 3
can not be eleminated
2 2
Tools and training to utilize them are
4 provided to operators/ IBCs opener and 2
Drum bung seal openers
4 PPEs to be worn while using sharp objects 2
Pinch points are well explained to operators
4 and body postions are explained to 3
specified operators
Tools are provided and respected
4 2
supervisor is responsible for safe usage
Equipment desgned considering pinch
3 4
points elemination
Piping is designed higher than max working
1 3
pressure of Pump
1 NA 0
1 NA 0
Compatible gasket are available for the
4 4
service
Manual handling is included in SOPs where
the risk assessment identified such a risk.
4 3
Training is ensured for each activity
identified as risk

Unavailability of lifting/handling equipment for
heavy & awkward equipment and objects
Lifting / handling equipment is not maintained so as
to ensure correct operation (e.g. lifting device for
drums; chain lift etc.).
unIdentified activities requiring handling of heavy
& awkward equipment and objects
Mechanical failure of forklift truck (forks, brakes…)
Inadequate working environment
improper manoeuvre of Forklift truck
Unstable pallet/pallet load
Pump seals failure
No daily visual inspection
Design and pressure of hose not aligned with the
service
Hose not inspected and tested for pressure
Not checked visually for damage
Properly designed equipment for such
3 activities and provision of the correct type of 2
equipment for the job at hand are available
Scheduled maintenance program are in
3 2
place to ensure.
list of such activities and their risk
2 2
assessment is provided
Daily forklift truck integrity checks as per
forklift truck standard, including hydraulic
6 3
systems. Adequate tyres in good condition
for the working surface
Non-slippery floor. Area free for access and
4 2
manoeuvring
Slow speed approaching pallet for pick-up.
Fork tilt adequately for pick-up. Forks
4 positioned at right height for pick-up. Forklift 2
truck position in straight-line to pallet for
pick-up
Pallets compliant with pallet standard and
of good quality (dry, free of damage). all
2 3
packs to be wrapped/strapped on pallets
before movement
6 4
Visual inspection is done daily or before
3 3
and after of loading and unloading
Staff training has been conducted for
2 1
slection of hose
2 0
2 operator checks for damages 1
 Reviewed by:
Approved By:

OCCURRENCE

DETECTION
RESIDUAL

RESIDUAL

RESIDUAL
SEVERITY
Responsibilit Actions
R
y & Target Taken and
Recommended Corrective Actions P
Completion Completion
N
Date Date

0
 0

Technical inspection plan must be

0
in place

0
0
 PROCESS HAZARD

Process Step # Process Potential Hazard / Failure Mode

1 Equipment untight before loading

OADING OPERATION
2 Over Pressure to associated Piping

3 Poor Pump Maintenance

4 Hose Rupture

5 Bulk Truck Movement

6 Receiving Loading Truck Overfill

7 Unexpected Pressure
 BULK LOA
7 Unexpected Pressure

8 Slip, Trip and Fall

 PROCESS HAZARD ANALYSIS - HAZOP

OCCURRENCE
SEVERITY
Potential Cause(s) of Hazard /
Potential Effect(s) of Failure
Failure

Inadequate design of hose pipe

4 2
and not well connected

Loss of Containment Coupling design not compatible

4 3
with truck and working pressure

6 Unattendent offloading 3
Design and pressure not aligned
7 with maximum working pressure of 2
pump
Relief valve set to max piping
5 3
design presseure
Loss of containment Relieve valve not at safe location
to prevent splash and revert flow
5 3
back into process on low pressure
side

Gasket Design not compatible with

6 3
service

6 Pump seals failure 2

6 No daily visual inspection 3

Loss of Containment
3
3
Design and pressure of hose not
7 2
aligned with the service
Hose not inspected and tested for
6 2
Loss of Containment pressure

6 Not checked visually for damage 3

3
Truck movement not locked with
7 2
chokes
Signal to prevent driving (Stop
7 3
Loss of Containment sign) not visiblle from cabin

6 Un attendent Loading 2
Chamber not checked before start
8 3
of Loading
Loss of Containment
8 Loading plan not confirmed 3

7 Lack of Communication 3

Site procedure not defining how to

6 monitor pressure before opening 2
up piping and containment

Loss of Control
 Site procedure not defining how to
Loss of Control open blown down valve piping and
7 3
containment to reduce pressure
before opening

3
3

Not following and using pathways,

staircase, handrails, ladders,
10 2
platforms and sacffold as per
procedure

7 Bad lighting 3
Improper/no use of harness belt at
8 3
height
Harness not inspected and
8 3
maintained for fit for use.

User did not conduct self check

Loss Of control 7 3
before using harness belt

Procedure not defined for work at

6 height and not clearly explained 3
each step
6 Improper house keeping 3

7 No use of anti slip shoes/foot ware 3

Unidentified trip hazards that

7 3
cannot be eleminated.
6 Oil spillage on Floor 3
OP

DETECTION
R
Current Process Controls P Recommended Corrective Actions
N

All hoses are avaialbe as per design and double check by operator
1
before start of unloading

Coupling are checked for any damage and compatibility with the
1
truck by operator and pressure is kept under observation

Covered in SOP for attendant offloading under supervision 1

Piping is designed higher than max working pressure of Pump 3

NA 0

NA 0

Compatible gasket are available for the service 4

Technical inspection plan must be in

4
place
Visual inspection is done daily or before and after of loading and
3
unloading

Staff training has been conducted for slection of hose 1

operator checks for damages 1

Procedure in place to always place choke before starting bulk

1
Loading and unloading

1 A sinage must be made for this

Un attended loading is not allowed 3

Always checked from top of chamber 2

Confirm unloading plan - double check : ullage in receiving tank and

2
volume to unload match, line-up ok (Covered in SOP)

2 ways communicaion between loading gantry and receiving end 2

Personnel are trained to monitor pressure guauges and procedure is

2
in place
 1

Proper walkways, handrails and scaffold with ralling are available on

2
site and TBT is conducted before non routine activites

Lighting are installed as per requirement 2

Training has been given to the personnel using harness belt 1

Periodic inspection is done for fit to use harness 1

Part of procedure to self check the harness belt condition before use 1

Procedure are in place for routine work at height activites 3

Housekeeping is part of work procedures 3

Anti slip foot ware are mandotary for the site 2

Caution sign are displayed for hazard that can not be eleminated 4

4
Reviewed by:
Approved By:

OCCURRENCE

DETECTION
RESIDUAL

RESIDUAL

RESIDUAL
SEVERITY
Responsibility & R
Actions Taken and
Target Completion P
Completion Date
Date N

0
0

0
 PROCESS HAZARD

Process Step # Process Potential Hazard / Failure Mode

1 Equipment untight before unloading

FLOADING OPERATION
2 Over Pressure to associated Piping

3 Poor Pump Maintenance

4 Hose Rupture

5 Bulk Truck Movement

5 Receiving Tank Overfill

5 Unexpected Pressure
 BULK OFFLO
5 Unexpected Pressure

5 Slip, Trip and Fall

 PROCESS HAZARD ANALYSIS - HAZOP

OCCURRENCE
SEVERITY
Potential Cause(s) of Hazard /
Potential Effect(s) of Failure
Failure

Inadequate design of hose pipe

4 2
and not well connected

Loss of Containment Coupling design not compatible

4 3
with truck and working pressure

6 Unattendent offloading 3
Design and pressure not aligned
7 with maximum working pressure of 2
pump
Relief valve set to max piping
5 3
design presseure
Loss of containment Relieve valve not at safe location
to prevent splash and revert flow
5 3
back into process on low pressure
side

Gasket Design not compatible with

6 3
service

6 Pump seals failure 2

6 No daily visual inspection 3

Loss of Containment
3
3
Design and pressure of hose not
7 2
aligned with the service
Hose not inspected and tested for
6 2
Loss of Containment pressure

6 Not checked visually for damage 3

3
Truck movement not locked with
7 2
chokes
Signal to prevent driving (Stop
7 3
Loss of Containment sign) not visiblle from cabin

Unoperational High level alarm on

8 2
receiving tank
ullage not checked in receiving
8 3
tank
Loss of Containment
Loading/offloading plan not
7 4
confirmed

7 Lack of Communication 2

Site procedure not defining how to

6 monitor pressure before opening 2
up piping and containment

Loss of Control
 Site procedure not defining how to
Loss of Control open blown down valve piping and
7 3
containment to reduce pressure
before opening

3
3

Not following and using pathways,

staircase, handrails, ladders,
10 2
platforms and sacffold as per
procedure

7 Bad lighting 3
Improper/no use of harness belt at
8 3
height
Harness not inspected and
8 3
maintained for fit for use.

User did not conduct self check

Loss Of control 7 3
before using harness belt

Procedure not defined for work at

6 height and not clearly explained 3
each step
6 Improper house keeping 3

7 No use of anti slip shoes/foot ware 3

Unidentified trip hazards that

7 3
cannot be eleminated.
6 Oil spillage on Floor 3
OP

DETECTION
R
Current Process Controls P Recommended Corrective Actions
N

All hoses are avaialbe as per design and double check by operator
1
before start of unloading

Coupling are checked for any damage and compatibility with the
1
truck by operator and pressure is kept under observation

Covered in SOP for attendant offloading under supervision 1

Piping is designed higher than max working pressure of Pump 3

NA 0

NA 0

Compatible gasket are available for the service 4

Technical inspection plan must be in

4
place
Visual inspection is done daily or before and after of loading and
3
unloading

Staff training has been conducted for slection of hose 1

operator checks for damages 1

Procedure in place to always place choke before starting bulk

1
Loading and unloading

1 A sinage must be made for this

Level measurent is cross check with physical Dip. There is limit

3
switch control to cut off pump supply incase of overfilled

Dip is taken before offloading the bulk 3

Confirm unloading plan - double check : ullage in receiving tank and

2
volume to unload match, line-up ok
2 ways communicaion between unloading gantry and receiving tank
2
monitoring station

Personnel are trained to monitor pressure guauges and procedure is

2
in place
 1

Proper walkways, handrails and scaffold with ralling are available on

2
site and TBT is conducted before non routine activites

Lighting are installed as per requirement 2

Training has been given to the personnel using harness belt 1

Periodic inspection is done for fit to use harness 1

Part of procedure to self check the harness belt condition before use 1

Procedure are in place for routine work at height activites 3

Housekeeping is part of work procedures 3

Anti slip foot ware are mandotary for the site 2

Caution sign are displayed for hazard that can not be eleminated 4

4
Reviewed by:
Approved By:

OCCURRENCE

DETECTION
RESIDUAL

RESIDUAL

RESIDUAL
SEVERITY
Responsibility & R
Actions Taken and
Target Completion P
Completion Date
Date N

0
0

0
 Severity, Occurrence, and Detection Criteria for Process HAZOP
SEVERITY EVALUATION CRITERIA SUGGESTED DETECTION EVALUATION CRITERIA
CRITERIA: Severity of Effect
DETECTION CRITERIA A B C SUGGESTED RANGE OF DETECTION METHODS RNK
EFFECT Customer Effect Manufacturing/Assembly Effect RNK
Very high severity ranking when a potential failure
Hazardous
mode effects safe operation and/or involves Or may endanger operator (machine or assembly) Almost Absolute certainty
without
noncompliance with government regulation without without warning.
10 Impossible of Non -Detection
L Cannot detect or is not checked. 10
warning
warning.
Very high severity ranking when a potential failure
Hazardous
mode effects safe operation and/or involves Or may endanger operator (machine or assembly) Very Controls will
with
noncompliance with government regulation with with warning.
9 Remote probably not detect.
L Control is achieved with indirect or random checks only. 9
warning
warning.
Or 100% of product may have to be scrapped, or
Controls have poor
Very High Part/item cannot be used (loss of primary function) part/item repaired in repair department with a repair 8 Remote
chance of detection.
L Control is achieved with visual inspection only. 8
time greater than one hour.
Or product may have to be sorted and a portion (less
Item usable but at a reduced level of performance. than 100%) scrapped or part/item repaired in repair Controls have poor
High
Customer very dissatisfied. department with a repair time between half an hour
7 Very Low
chance of detection.
L Control is achieved with double visual inspection only. 7
and an hour.
Or a portion (less than 100%) of the product may
Item usable but at a reduced level of performance. have to be scrapped with no sorting, or part /item Control is achieved with charting methods, such as SPC
Moderate
Customer dissatisfied. repaired in repair department with a repair time less 6 Low Controls may detect. K K (Statistical Process Control). 6
than half an hour.
Or 100% of product may have to be reworked, or Control is based on variable gauging after parts have left
Part/Item usable but at a reduced level of
Low
performance. Customer somewhat dissatisfied.
part/item repaired off-line but does not go to repair 5 Moderate Controls may detect. K the station, OR Go/No Go gauging performed on 100% of 5
department. the parts after parts have left the station.
Controls have a Error Detection in subsequent operations, OR gauging
Fit & Finish/ item does not conform. Defect noticed Or the product may have to be sorted with no scrap, Moderately
Very Low
by most customers (greater than 75%). and a portion (less than 100%) reworked. 4 High
good chance to K K performed on set-up and first-place check (for set-up 4
detect. Causes only).
Error Detection in -station, OR error Detection in
Or a portion (less than 100%) of the product may Controls have a
Fit & Finish does not conform. Defect noticed by subsequent operations by multiple layers of acceptance;
Minor
50% of customers.
have to be reworked with no scrap, on-line but outof- 3 High good chance to J K supply, select, install, verify. Cannot accept discrepant
3
station. detect.
part.
Or a portion (less than 100%) of the product may
Fit & Finish item does not conform. Defect noticed Controls almost Error Detection in -station (automatic gauging with
Very Minor
by discriminating customers (less than 25%).
have to be reworked with no scrap, on-line but 2 Very High
certain to detect.
J J automatic stop feature). Cannot pass discrepant part.
2
instation.
Or slight inconvenience to operation or operator, or Controls certain to Discrepant parts cannot be made because item has been
None No discernible effect.
no effect. 1 Very High
detect.
J error proofed by progress/product design. 1

This ranking results when a potential failure mode results in a final customer and/or a manufacturing/assembly A = Error Proofed NOTE: The ranking value of 1 is reserved for “Almost
Inspection
plant defect. The final customer should always be considered first. If both occur, use the higher of the two B = Gauging Certain.”
severities. Types:
C = Manual Inspection

SUGGESTED OCCURRENCE EVALUATION CRITERIA

Probability of Failure Likely Failure Rates RNK
Very High: Persistent failures ≥ 100 per thousand pieces 10
50 per thousand pieces 9
High: Frequent failures 20 per thousand pieces 8
10 per thousand pieces 7
Moderate: Occasional failures 5 per thousand pieces 6
2 per thousand pieces 5
Low: Relatively few failures 1 per thousand pieces 4
0.5 per thousand pieces 3
Remote: Failure is unlikely 0.1 per thousand pieces 2
≤ 0.01 per thousand pieces 1