What if the bearing cooling water pump fails? They look at the entire process from the receipt of raw materials through the delivery of the finished product to the customer. The result is a list of possible hazard conditions along with recommended actions that can be taken to protect against undesirable outcomes.
A checklist hazard analysis begins with an existing safety checklist. It may have been created by an individual, or be the result of a previous hazardous analysis. A typical checklist includes items such as:.
The team goes through the checklist item by item, to stimulate questions about the process and possible hazards. The final result is a set of questions about possible hazards. The team discusses these, reaching agreement on what is truly hazardous.
They develop a list of recommendations for eliminating or protecting against those hazards and may recommend extended research of some of the questions. A Hazard and Operability Study HAZOP systematically identifies all of the ways in which operating conditions can deviate from the intended design, with the result being a safety hazard or an operating problem. A team of experienced people, who are familiar with the process brainstorm potentially hazardous situations.
They look at each section of pipe, valve, flange, pump, vessel, and other components in the system to identify potentially hazardous conditions. Failure Mode and Effect Analysis FMEA is an approach to hazard analysis that involves intense study of individual machines and components to identify failure modes and the consequences.
Each component identified as a potential source of a safety hazard is listed on a tabulation sheet, and questions are asked:. Based on answers to these types of questions, the risk associated with the potential failure of each component is evaluated, and appropriate recommendations are made. A fault tree analysis uses a diagram that shows the relationship of contributing causes to a specific undesirable outcome. This may be found by reviewing incident records, and in particular near-miss records, or simply brainstorming.
This and a handful of other major safety incidents in the s prompted the U. Occupational Safety and Health Administration to implement process safety management regulations Environmental Protection Agency.
Today, these regulations are combined under the umbrella of process safety management. This includes Process Hazard Analysis PHA , which is a system used to identify potential hazards before they occur and help prevent a risk pathway from developing. A PHA is a thorough, step-by-step review of chemical and manufacturing plant operating procedures. The goal is to identify potential causes and evaluate the consequences of hazardous chemical releases.
The process helps organizations identify a range of risks from equipment failures to human factors to improving safety, preventing downtime and protecting the surrounding environment. PHA teams should include engineers, operators, maintenance, supervisors and any other staff members or workers who are well-acquainted with the operational process being reviewed.
Once appointed, the team leader generally chooses the most appropriate method to assess the process. Here is a brief overview of these common methods:. Future-Proofing Process Hazard Analysis. General Inquiries Press Inquiries. All rights reserved. Sphera's integrated Environmental, Social, and Corporate Governance ESG solution aims to help companies achieve their sustainability goals. The scalable platform and personalized configuration pave the way for compliance, reporting and performance improvement.
It brings together disparate data from systems, sensors, and human-derived activities to provide a normalized, real-time view of ESG performance.
Industry operators striving for Operational Excellence can rely on Sphera to help establish a unified, integrated, technology-driven strategy for control of work, risk assessment and master data management processes. Use an Integrated Environmental, Social and Governance ESG performance and Risk Management approach to break down information silos and empower decision-making with powerful predictive and prescriptive capabilities. Integrate sustainability and risk management throughout the building and construction value chain so you can navigate the challenges posed by climate change, urbanization, resource scarcity and demographic shifts.
Efficiently manage complex environmental regulations for the acquisition, handling and disposal of hazardous materials, when you connect information, innovation and insights to reduce risk and costs across your operations.
Government Services Sustainability. Manage quality and risk across the entire lifecycle of your products to mitigate costly errors and reduce operational complexities to keep your employees, your operations and your reputation safe. Drum is corroded? Ventilation at mixing tank is not operating? Granular powder becomes dusty? Tank liquid level too high? Example of Completed Step No. Ventilation at Mix Tank is not operating?
Back injury potential when breaking up clumps. Quality issue only. If wet, could cause exotherm. Back injury potential. Leg, foot, back, arm injury. Same as above. Possible burn. Possible caustic splash as well as quality issue. Example of Completed Step Nos. If done correctly, reviewing the potential equipment failures and human errors can point out the potentials for not only safety and health improvements but also the opportunity to minimize operating and quality problems.
Including the operators and trades personnel in the review can bring a practical reality to the conclusions that will be reached. In other words what is the risk. For example, consider the following risk judgments and recommendations to the answers in our example as illustrated in Figure C Design delumping equipment.
Contact vendor. Include inspection in procedure. Require 2 nd check on weight. Ensure hoist on PM program. Include vent check in SOP.
None beyond existing procedure. Use goggles and apron. The hard work of conducting the analysis has been competed. The important work of reporting the results still remains. The make up of the organization generally determines to whom and how the results get reported. Usually, the department or plant manager is the customer of the review. The leader of the review team will generate a cover memo that details the scope of the review as well as the major findings and recommendations.
In some organizations, the report recommendations will also include who has been assigned the responsibility to follow up and time frame. In other cases, a separate staff or function will review the recommendations and determine the actions required. A periodic report is then generated to summarize the present status of each of the recommendations. Those organizations that have a well developed hazard review program require follow-up assignments every three to five years based on the associated hazard levels.
The What-If Analysis technique is simple to use and has been effectively applied to a variety of processes. It can be useful with mechanical systems such as production machines, with simple task analysis such as assembly jobs, as well as with reviewing tasks in chemical processing.
No specialized tools or techniques are needed. Individuals with little hazard analysis training can participate in a full and meaningful way. It can be applied at any time of interest such as during construction, during debugging, during operations, or during maintenance.
The results of the analysis are immediately available and usually can be applied quickly.
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