Safety in Design

PLP-200-020-0009
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Modules
• Module 1 : Prepare Engineering Calculations
• Module 2 : Check Engineering Documents
• Module 3 : Prepare package technical documents
Prepare an equipment package
• Module 4 : Conduct Internal Reviews
• Module 5 : Safety in Design
• Module 6 : Perform Design Review
Table of Contents
• Purpose
• What is Safety in Design? 
• Benefits of Safety Design
• Legal Obligations
• Definitions
• Roles and Responsibilities
• Safety in Design Process
• Safety in Design Checklist
• Safety in Design Report
Purpose
• Provides guidance for implementing Safety in Design at
Hatch
• Embraces all engineering and design activities under the
control of Hatch
• Aimed at Managers, Engineers, Designers and anyone else
who has control or influence over engineering and design
Safety in Design
The integration of control measures early in the design process
to eliminate or, if this is not reasonably practicable, minimize
risks to health and safety throughout the life of the product
being designed.
Safety in Design begins at the concept development phase when
making decisions about:
• The design and its intended purpose
• Possible methods of construction, maintenance, operation,
demolition or dismantling and disposal
• Which legislation, codes of practice and standards need to be
considered and complied with
Benefits of Safety Design
Safety in design can result in many benefits, including:
• Prevention and reduction of injury or disease
• Improved functionality of the product, system or facility
• Improved productivity
• Reduced costs throughout the project
• Improved predictability of production and operation costs
• Compliance with legislation and industry technical norms
• Asset lifecycle management
Legal Obligations
• Places an onus on all parties involved to eliminate/ minimize
risks to health and safety
• Hatch’s global policies and “stands” reference the duty of care
principles as defined by the common law precedents of each
jurisdiction
• All designers are responsible for ensuring they understand and
comply with their governing obligations
Definitions
Design The process used to bring together innovation, aesthetics and
functionality to plan and create a product, a process or a system to
meet a specific requirement (e.g. industrial requirement).

It includes research and development, conceptual design, feasibility

design, general design, detailed design, methods of construction or
manufacture, technical specification and redesign.

Designer Anyone who either undertakes or arranges for people under their
control to undertake a design process as defined above.

Hazard Something that has the potential to cause harm, damage or loss to life,
health or property.
Definitions
Risk The measure of how likely harm, damage or loss to life,
health or property will occur in a given hazardous situation.

Residual Risk The risk that remains after the application of controls and
other risk mitigating methods or techniques.

Risk Assessment The process of analyzing the probability and consequence of

injury, illness or damage arising from exposure to identified
hazards.

Lifecycle The stages from concept design to ultimate decommissioning

and disposal operations inclusive.
Roles and Responsibilities
Construction/
Engineering Project Risk Project
Key Activity Design Team Commissioning Client
Manager Manager manager
Manager
Application of this guide A R
Execution of this guide C A R
Plan Safety in Design Program C A R I
Technical Hazard Analysis/ Risk
C A R I C
Reviews
Design Reviews I A,R I I
Construction Risks Reviews C R R A I C
Commissioning/ Start-up Risk
C R R A I C
Reviews
Design Verification I A,R I I
Complete Design Actions R A I I
Design Validation C R I R A

Legend: (R) Responsible (A) Accountable (C) Consulted (I) Informed

Safety in Design
a. Safety in Design Process
Safety in Design is embedded in each of the standard engineering activities and
complements the evaluation activities (design review, verification and validation).
b. Safety in Design Key Elements
The standard Hatch engineering process provides the framework in which the following
five key ‘Safety in Design’ elements can be implemented

Element 1: Use a Risk Management Approach

Element 2: Consider the Lifecycle

Element 3: Safe Design Knowledge and Capability

Element 4: Consultation, Cooperation and Coordination

Element 5: Information Transfer

b. Safety in Design Key Elements Cont’d
Element 1: Use a Risk Management Approach

A Risk Management Approach is seen as the application of a systematic risk

management processes of hazard identification, risk assessment and risk control.

A systematic way of making a workplace/facility/asset as safe as possible involves

the following steps :
• Identify reasonably foreseeable hazards associated with the design of the product.
• If necessary, assess the risks arising from the hazards.
• Eliminate or minimize the risk by designing control measures.
• Review the control measures.
b. Safety in Design Key Elements Cont’d
Element 2: Consider the Lifecycle

Consider how their design will affect the risk of injury/illness to those who will
interact with the product/asset throughout its life, including those who:
• Are at a workplace/facility and use the product/asset for a purpose for which it
was designed
• Construct the product/asset at a workplace/facility
• Carry out any reasonably foreseeable activity at a workplace/facility in relation to
the manufacture, assembly, use, proper demolition or disposal of the product/asset
• Are at or in the vicinity of a workplace/facility and are exposed to the
product/asset or whose health and safety may be affected by an activity related to
the product/asset
b. Safety in Design Key Elements Cont’d
Element 3 – Safe Design Knowledge and Capability
As well as their core engineering and design capabilities, engineers and designers
should develop and practice the following expertise and skills:
• Knowledge of Occupational Health and Safety (OHS) legislation, regulations and
other regulatory requirements
• Knowledge of the full lifecycle of the types of products that they design
• Knowledge of hazard identification, risk assessment and control methods
• Knowledge of technical design codes and standards
• The ability to source and apply relevant data on human dimensions, capacities and
behaviours
• The ability to integrate knowledge from a range of sources and disciplines
b. Safety in Design Key Elements Cont’d
Element 4 - Consultation, Cooperation and Coordination

• Consultation, cooperation and coordination are legal requirements in some

jurisdictions and are an essential part of managing work health and safety risks.
• A safe workplace is more easily achieved when people involved at the design
stage communicate with each other about potential risks and work together to find
solutions.
• The duty holders involved must consult each other on the hazards and risks
associated with the product and work together on appropriate design solutions.
• This would include a client cooperating with a designer in changing a design to
address a health and safety risk identified in the design process.
b. Safety in Design Key Elements Cont’d
Element 5 - Information Transfer

• Key information about identified hazards and actions taken or required to control
risks should be recorded and transferred from the design phase to those involved
in later stages of the lifecycle. This will make them aware of any residual risks
and minimize the likelihood of safety features incorporated into the design being
altered or removed by those engaged in subsequent work.
Information to be provided includes:
• The purpose for which the product was designed.
• The results of any calculations, testing, analysis or examination.
• Any conditions necessary to ensure that the product is without risks when used for
a purpose for which it was designed or when carrying out any activity related to
the product such as construction, operation, maintenance and demolition.
c. Safety in Design Workflow
• The Workflow which follows, integrates the Safety in Design process
within the design process
• The approach can apply equally for the entire design process (ie.
Engagement lifecycle, concept to detail) or for a single FEL phase
c. Safety in Design Workflow Cont’d

Customer
Design Process Requirements
Design Input

Safety in Design Process Establish Context & Consultation

Activities
 Establish design context  Define skills and competencies  Establish consultation method  Establish risk management process
 Obtain previous documentation  Obtain past risk assessment data  Investigate historical information
 Obtain information on workplace hazards, legislation, regulations, codes of practice, standards etc.

Deliverables
 Client requirements specification  Scope of services  Basis of design  Design criteria  Project execution plan  Risk execution plan
 Engineering execution plan  Schedule
c. Safety in Design Workflow Cont’d

Design Process Design Stages

Preliminary

Safety in Design Process Hazard Identification

Activities
 Identify Hazards  Involve people with a broad range of experience like Operators, Health and Safety Reps, Subject Matter Experts & Others
 Use documentation gathered to promote the identification process

Deliverables
 Hazard Identification register  Safety in Design Hazard checklist  Minutes/reports from identification meetings  Attendance list  Listing of
reference material used
c. Safety in Design Workflow Cont’d

Design Process Design Stages

Design development

Safety in Design Process Analysis Evaluation

Activities
Analysis
 Analysis Hazards that are affected by the design and with designers control  Consider siting of structures & plant, unstable process conditions, systems of work etc.
Evaluation
 Determine how risk will be eliminated or minimized  Apply risk management to understand and control risks

Deliverables
Analysis
 Technical risk register  Planning for studies  Schedule updates for additional tasks/ studies
Evaluation
 Technical risk register  Study evaluation reports  Minutes from meetings  Calculation sheets

c. Safety in Design Workflow Cont’d

Design Process Design Stages

Refine

Safety in Design Process Treatment

Activities
• Apply hierarchy of control in determining control measures  Implement risk mitigation control measures  Consider any risks  Consider the interaction between
risk controls  Review Designs  Refine the design to reduce risks  Conduct design reviews
 Identify risks required to be transferred

Deliverables
 Technical risk register update with risk control measures, residual risk ratings, risks transferred to others  Safety design review minutes  Safety in design audit card
 Workshop minutes/ reports i.e. Guarding treatment
c. Safety in Design Workflow Cont’d

Design Process Design Output

Safety in Design Process Reporting

Activities
• Approve and sign each risk item with client  Collate all deliverables  Conduct design reviews of deliverables  Organize verification and 3rd party audits
 Consider documentation requirements for registered plant

Deliverables
 Technical risk register  Safety in design checklist  Safety in design report  Safety data sheets  Registered plant design report  Safe installation guides
• Safe commissioning guides  Operational guides  Maintenance, inspection, testing guides  Safe disposal guides  Verification and 3rd party audit reports
Safety in Design Hazard Checklist
(PLP-200-008-0004 )

‒ Developed for use through the design process to identify health, safety
and environment hazards, and determine what harm the hazard may
cause and consider how affective the current controls are.
Safety in Design Hazard Checklist (PLP-200-008-0004 )
Safety in Design Hazard Checklist (PLP-200-008-0004 )
Safety in Design Report Template
(PLP-200-086-0019)

‒ The Safety in Design report is an important way to

summarize all the key deliverables mentioned previously in
a suitable format for other parties.
‒ A Template has been developed to capture the Safety in
Design Process Requirements, Reviews, Findings and
Recommendations.
Safety in Design Report Template
(PLP-200-086-0019)
Questions