Safety Process Benefits and Risks in Industry

What are the benefits of the process of safety involving people and community?

Prevents fatalities, injuries, exposure, evacuations, and long term harm.

What are the benefits of the process of safety involving avoiding major losses?

Reduces explosions, fire, toxic releases, environmental damage, and asset losses.

What are the benefits of the process of safety involving improve reliability?

fewer upsets and shutdowns, stringer maintence, inspections, etc...

What are the benefits of the process of safety involving support compliance?

improves alignment with regulatory, corporate and industry expectations

What are the benefits of the process of safety to reduce total cost?

prevention is more than incident response,

What happens when processes are not safe?

Hazard not recognized, deviation grows, barriers fail, loss of containment, major accident

What is the outcome when the process’ safety breaks the chain?

Protection of people, assets, community, environment

Why did the engineering iron ring begin?

1925 Quebec Bridge Tragedy

What does the engineering iron ring represent?

Ethical duty, technical humility, and professional discipline

Causes of chemical process incidents catagories?

Technology failures, human failures, management system failures, and external circumstances or natural phenomena

Define a scenario?

A sequence of events which causes the hazard to result in an accident

Define risk analysis

Quantitate estimate of risk using engineering evaluation and math techniques involving estimates of hazard, probability of their occurrence, and combination of both.

Chemical Hazards

Risks from the properties and behaviors of substances involved in the process

Types of chemical hazards

flammable, toxic, reactive, corrosive

define physical hazards

Hazards arising from the physical state, conditions, or stored energy in the process.

What types of physical hazards are there?

Pressure, Temperature, Mechanical, and Radiation

Why identify Hazards?

To protect assets and business continuity or/and improve safety culture and awareness

What are the controlling process safety hazards from most to least effectve?

Elimination, Substation, Engineering controls, administrative controls, and PPE

What are the inherent safety techniques that make process safer?

(1) Minimize: Reduce hazardous material/energy quantity

(2) Substitute: Replace w/ less hazardous material

(3) Moderate: Use under less hazardous conditions

(4) Simplify: Reduce unnecessary complexity

Hazard vs Risk

Hazard: something has the potential to harm you

Risk: the likelihood of a hazard causing harm

Define event consequesnce

For an event of failure, consequence can be defined as the degree of damage or loss from a failure

Define Safety

a judgment of risk acceptability for the system based on the avoidance of risk

Define qualitative risk analysis

The potential loss is qualitatively estimated

Define quantitative risk analysis

risk analysis attempts to estimate the risk in form of probability of a loss

what steps are involved in risk assessment methodology

definition of system, identification of hazards, identification of system barriers, event consequence assessment, estimation of frequency, risk assessment and evaluation

what are the types of risk categorization?

health risk, safety risk, security risk, financial risk, environmental risk

what is risk management

A practice involving coordinated activities to prevent, control, and minimize losses incurred due to a risk exposure, weighing alternatives, and selecting appropriate actions into account

Objective uncertainty

it included the physical and statistical variability

Ex: identical safety valves may open at different pressures because of small manufacturing differences

Subjective uncertainty

lack of knowledge, inconsistency in knowledge

Ex: we don't know exactly how a new chemical will react in emergency because no tests have been done

Risk Matrices is?

A 2D presentation of the likelihood and consequences of risk estimation. Qualitative scales for both dimensions to characterize the risk by categorizing probabilities and consequences on the two axes of a matrix

What if analysis is?

structured hazard identification technique used in process safety to systematically evaluate potential hazards and their consequences by asking 'what if' questions about a process or system.

HAZOP (Hazard and Operability Study)

Identifies all the possible hazards and operational problems, recommends changes and studies

Failure Mode and Effects Analysis (FEMA)

semi-quantitative approach it identifies potential failure modes, causes, and effects. Used in design, modification, or operation stages before accidents.

Risk Priority Number formula

S (severity) x O (occurrence) x D (detection)

Fault Tree Analysis (FTA)

defines multiple causes leading to an undesired event, this is a logic diagram based on the principle of multi-causality defining all branches of events

Under an or gate terms get

Added

Under an and gate

terms get multiplied

Square event in FTA

more basic fault event

Circular event in FTA

Primary basic event

Event Tree Analysis (ETA)

Defines the consequential events which flow from the primary 'initiating' event. Uses to investigate the consequences of loss-making events to find mitigation

What are the Quantitative methods

FEMA (semi) and FTA

What are the qualitative methods?

HAZOP and What-If

Chornobyl incident occurred when and where

April 26th 1986 in USSR (Ukraine)

What happened at Chornobyl

-A maintenance test planned to shut down reactor 4

-emergency electrical safety features to keep cooling water circulating during a blackout

-emergency core cooling system deactivated during test

-due to all of this the reactor went into over production

What happened in the Piper Alpha incident

-Maintence work on relief valve (safety valve removed)

- Pump activated (operating without valve) hydrocarbon released

-explosion

- fire intensifies triggering additional explosions

When and where did the Piper Alpha incident occur

July 6-7th 1988 in North Sea (120 miles from Aberdeen)

Define toxicant

a chemical physical agent

Define Toxicology

qualatitive and quantitative study of entry of a toxicant into human and its adverse effects in organisms

Define Industrial Hygiene

Identification, evaluation, and control of occupational conditions that cause sickness and injury

Define Dose

Amount of a toxicant, which causes any noticeable responses in biological organisms

What are the types of doses

Lethal dose, Effective dose, Toxic dose, lethal concentration

Effective dose is

Response is minor and reversible (eye irritation)

Toxic dose is

Response is toxic and irreversible

Lethal Concentration

Used to measure the response to a toxic gas

Threshold Limit Values (TLV)

Allowable exposure limit of a dose or concentration, when under this dose the body is able to detox

Three types of TLVs?

Time Weighted Average (-TWA), Short term limit exposure limit (-STEL), ceiling limit (-C)

3 steps of Industrial hygiene

Identification, evaluation, control

An industrial hygiene physical hazard is

evaluated by comparing the existing strength with threshold value

An industrial hygiene chemical hazard is

evaluated by comparing the concentration of toxicants with the allowable limit

Industrial hygiene hazard data types are

Physical state, TLVs, Temperature sensitivity, Rate of heat reaction, Reactivity with other chemicals, and Explosion limits

What are the two techniques of industrial hygiene

Environmental controls and Personal protection