Hazard Analysis Technique Selection

Transcription

1 Hazard Analysis Technique Selection Kelsey L. F. Curran, CIH, CHMM Principal Hazard Analyst and ES&H Specialist Clover Leaf Solutions Alliance of Hazard Materials Professionals 2016 National Conference Washington, DC Monday, August 29 10:00 AM Hazardous Materials Session

2 What Is Hazard Analysis? Hazard Identification + Hazard Evaluation HI + HE = Hazard Assessment (HA) Systematic Approach to Analyzing Hazards Identifies Controls/Safeguards/Layers of Protection Many HE Techniques to Choose From

3 Why Do Hazard Analysis? Requirements per OSHA PSM Fewer Incidents Over the Life of the Process Reduced Consequences of Incidents Improved Emergency Response (Understanding of Hazards) Improved Training & Understanding of the Process More Efficient & Productive Operations Improved Regulatory & Community Relations

4 Where Do I Start? Define Analysis Scope & Boundaries Focus Resources Resources Wasted Evaluating Out-of-Scope Processes Neglect/Miss Important Parts of Process Identify Consequences of Interest Receptors Consequence Severity Other Impacts ~ Environment, Business, Facility Damage Document Scope Select Hazard Evaluation (HE) Technique

5 Common HE Techniques Non-Scenario vs. Scenario Non-Scenario Based Preliminary Hazards Analysis (PreHA) [Inherent] Safety Review Relative Ranking Checklist Analysis Scenario Based What-If Analysis What-If/Checklist Analysis Hazard & Operability (HazOp) Studies Failure Modes & Effects Analysis (FMEA) Fault Tree Analysis (FTA) Event Tree Analysis (ETA)

6 HE Selection Criteria Guidelines for Hazard Evaluation Procedures - The Redbook Purpose Technique Description Type of Results Resource Requirements Analysis Procedure Documenting Results

7 HE Selection Criteria Lifecycle Based Comparison Guidelines for Hazard Evaluation Procedures 3 rd Edition, CCPS ( The Redbook ), pg. 185

8 How Do I Choose? #1: Motivation For Study & Results Needed A. Motivation What is the Reason for the Study? Is it a New Process? Is it a Response to Accident? B. Type of Results List of Hazards List of Potential Incident Situations List of Alternatives for Reducing Risk, or Areas Needing Further Study Prioritization of Results Input for a Quantitative Risk Analysis

9 How Do I Choose? #2: Available Information & Perceived Risk C. Type of Information Available Stage of Lifecycle ~ R&D/Design & Operations Quality/ Currentness of Available Documentation D. Characteristic of Analysis Complexity & Size of Problem Type of Process & Types of Process Operations Nature of Inherent Hazards Types of Incidents, Situations of Concern, Failures & Events E. Perceived Risk Experience ~ Amount, Nature, Continued Higher Risk Requires a Higher Level of Analysis Change to Operations/Personnel/Experience

10 How Do I Choose? #3: Resource Availability & Preference F. Resource Availability Skilled & Knowledgeable Leaders in the Given HE Technique Skilled & Knowledgeable SME(s) for Process/Hazards Target Dates to Perform Study Financial Resources G. Analyst/Management Preference Management Preference Based on Other Influences Analyst Preference Based on Specific HE Skills & Experience

11 HA Team Members Skilled and Qualified Facilitator, Dedicated Scribe, Leader & Contributors Process/Activity Expert Operations Personnel Maintenance Personnel Industrial Hygiene Fire Protection Safety Engineer Packaging & Transportation Specialist Manager (optional) Others Environment, Safety, & Health

12 Accident Scenario Example BP Petrochemical Disaster History Channel Modern Marvels (9:43) CSB Video (5:57 min) CSB 10-Year Anniversary Safety Message (4:04 min) CSB Anatomy of a Disaster (55:33 min)

13 Limitations of HA Output Dependent on Input & Expertise Never 100% Certainty for Identification of All Hazards, Events, Causes, and Effects Results & Benefits Cannot Be Directly Verified Based on Existing Knowledge or Process/Operation Quality Reflected in Drawing Accuracy, Procedure Accuracy, & Process Knowledge Dependent on Subjective Judgment, Assumptions, & Experience of Analysts Cannot Guarantee Incidents Will Not Occur Limitation Provides Justification Periodic HE Throughout Lifecycle Justification for Management of Change (MOC)

14 Lessons Learned Be Deliberate When Choosing A Technique Stakeholder Buy In Scope, Schedule, & Budget Never Enough Time to Complete Preparation, Analysis, & Documentation Use a Dedicated Workshop Facilitator Respect Team Leader Responsibilities Required to Take On Process Review, Documentation, Factual Accuracy, Comment Resolution, & Concurrence Responsibilities in Addition to Workshop/Meetings Train Team on Technique

15 Available Resources Guidelines for Hazard Evaluation Procedures ( The Redbook ) Published By Center for Chemical Process Safety (CCPS) Established in 1985 by American Institute of Chemical Engineers Develops & Disseminates Technical Information Supporting HE Goal is Prevention of Major Chemical Accidents Guidelines 1 st Published in 1985 Current (3 rd Ed) Guidelines Encompass: Lessons Learned from Industry Accidents US Chemical Safety & Hazard Investigation Board (CSB) Recommendations for Hazard Evaluations Process Safety Management Implementation Laws & Regulations International Standards Experience Gained Since 1985 with Performing Hazard Evaluations

16 Available Resources, cont. Commonly Referenced Guides & Standards System Safety Analysis Handbook The Greenbook, Published by System Safety Society System Safety for the 21 st Century, by Richard A. Stephans OSHA , Process Safety Management of Highly Hazardous Chemicals ANSI Z590, Prevention Through Design Guidelines for Addressing Occupational Hazards and Risks in Design and Redesign Processes MIL-STD-882E, Department of Defense Standard Practice System Safety

17 Thank You! Kelsey L. F. Curran, CIH Principal Hazard Analyst and ES&H Specialist (505)

18 Backup Slides Hazard Evaluation Technique Descriptions

19 Non-Scenario Technique Preliminary Hazards Analysis Purpose: Evaluate Hazards Early in Lifecycle Identify the Basic Risk Control Strategies to be Developed Later in Lifecycle Description: Formulates List of Hazards and Generic Hazardous Situations By Considering Process Characteristics Rather Than Specific Process Information Type of Results: Qualitative Description of the Hazards With Qualitative Ranking of Hazardous Situations Used to Prioritize Recommendations Resource Requirements: Limited Process Information; 1 2 Experienced Analyst; 5 17 Days Duration Analysis Procedure: Collect Information (Typically Limited) Identify Hazards, Safeguards, Causes, & Effects Assign Hazard Category: Negligible, Marginal, Critical, & Catastrophic Identify Potential Controls Documenting Results: Typically Recorded in Simple Table Format

20 Non-Scenario Technique [Inherent] Safety Review Purpose: Ensure Operation & Maintenance Meet Design Intent and/or Standards Performed as a Pre-Startup Safety Review Description: Walkthrough Inspection, Design Review, and/or Interviews Against Requirements Type of Results: Qualitative Description of the Potential Safety Problems & Suggested Corrective Actions For Identified Deviations & Newly Discovered Safety Items Resource Requirements: Detailed Design, Process, and Procedural Information; Small Team of Well Qualified Analyst; 2 14 Days Duration Analysis Procedure: Collect Detailed Information (Design, Codes/Standards, Equipment Information) Formal Team Meeting(s) Review Hazards & Related Requirements (i.e. Codes, Standards, Procedures) Process Review & Inspection Walkthroughs, Design Reviews, & Interviews Documenting Results: Formal Report with Recommendations for Deviations, Discoveries, & Improvements

21 Non-Scenario Technique Relative Ranking Purpose: Determine Most Significant Areas of Concern Rank Areas of Concern Before More Intensive Reviews Description: Use of Index to Rank Hazards/Hazardous Situations Index Based on 3 Questions ~ What Can Go Wrong? Impact? Likely? Type of Results: Ordered List of Processes, Equipment, Operations, or Activities Not Typically Used for Analysis of Safeguards Resource Requirements: Basic Physical & Chemical Information; Single Analyst; 1 4 Days Duration Analysis Procedure: Collect Basic Material/Process Information Assign Relative Ranking Based on 3 Questions (Qualitative vs Quantitative) Rank Hazards/Hazardous Situations Documenting Results: Simple List Ranking Hazards/Hazardous Situations Potential Identification of Safety Weaknesses and Corrective Measures

22 Non-Scenario Technique Checklist Analysis Purpose: Verification of System Status Using Written List of Requirements/Procedural Steps Description: List of Known Hazards, Design Deficiencies, and Incidents List of Requirements/Procedural Steps List of Other Parameters (e.g., chemical properties, codes/standards) Type of Results: Typically List with No, Yes, or Not Applicable & Associated Corrections Resource Requirements: Information to Create Checklist; Single Analyst; 2 12 Days Duration Creating Checklist is Intensive Effort Analysis Procedure: Select Checklist Perform Walkthrough, Design, Procedure, Codes/Standards Review Documenting Results: Qualitative Report (w/ Completed Checklist) & Recommendations Potential for Inherent Safety Review ~ Minimization, Moderation, & Simplification

23 Scenario Technique What-If Analysis Purpose: Brainstorming Approach to Identify Hazards/Hazardous Situations, or Event Sequences with Potential Undesirable Consequences ~ May Include Cause/Initiating Events Description: Use of Facilitator, Scribe, & Team Not Inherently Structured, Requires Skilled Facilitator Ideally Divide Questions Based on Hazards and/or Process Areas What If Can Be Effective & Efficient With Experienced Team/Facilitator Type of Results: Random Tabular Listing of Hazardous Situations with Consequences & Safeguards Resource Requirements: Supporting Information; Representative Team; 1 29 Days Duration Analysis Procedure: Collect Chemical Data, Process Description, Drawings, & Operating Procedures Seed Analysis Tables for Workshop Meetings For Team Brainstorming Documenting Results: Qualitative Report (w/ Completed What If Analysis Worksheet) & Recommendations Potential for Inherent Safety Review ~ Resolve What-If Question May Provide Input into Further More Refine HE Analysis

24 Scenario Technique What-If/Checklist Analysis Purpose: Systematic Use of Checklist Using Brainstorming Approach to Identify Hazards/Hazardous Situations, or Event Sequences with Potential Undesirable Consequences ~ May Include Cause/Initiating Events Description: Use of Facilitator, Scribe, & Team ~ Requires Skilled Facilitator Structured Approach to Identify All Hazards/Hazardous Situations Type of Results: Systematic Tabular Listing of Hazardous Situations with Consequences & Safeguards Resource Requirements: Supporting Information; Representative Team; 1 31 Days Duration Analysis Procedure: Collect Chemical Data, Process Description, Drawings, & Operating Procedures Seed Analysis Tables for Workshop Meetings For Team Brainstorming Qualitatively Determine Significant of Effects and Relative Recommendations Documenting Results: Qualitative Report (w/ Completed What If Analysis Worksheet) & Recommendations Potential for Inherent Safety Review ~ Resolve What-If Question May Provide Input into Further More Refine HE Analysis

25 Scenario Technique Hazard and Operability Study Purpose: Careful, Systematic Review to Determine Whether Deviations Can Lead to Undesirable Consequences Identification of Causes, Consequences, & Safeguards for Process Nodes Description: Use of Prescribed Terminology Guidewords + Parameters = Deviation Use of Facilitator, Scribe, & Team ~ Requires Skilled Facilitator & Trained Team Systematically Identify Hazard & Operability Problems Type of Results: Deviations for Each Node Recorded in Table Format With Consequences & Safeguards Resource Requirements: Extremely Detailed P&ID; Highly Skilled, Trained Team; Days Duration Analysis Procedure: Explicitly Define Purpose, Scope, & Objectives Collect Supporting Information Prior to Workshop So Team Can Prepare Determine Nodes, Standard Guidelines, Deviations, & Safeguards Complete Node by Node Documenting Results: Tabular Format with Separate Action Items

26 Scenario Technique Failure Modes and Effects Analysis Purpose: Identify Single Component/System Failure Modes, Causes, Effects, & Actions How Can Equipment Fail, What Are Causes, & What Are Effects Description: Evaluates How Equipment Can Fail and Effects of Failures on Process Use of Facilitator, Scribe, & Team ~ Requires Skilled Facilitator & Trained Team Systematically Equipment/Component Level (e.g., pieces & parts) Type of Results: Failure Modes, Causes, Effects, & Safeguards for Each Equipment in Table Format Resource Requirements: Extremely Detailed P&ID, Equipment Functions; Trained Team; 7 42 Days Duration Analysis Procedure: Define Problem (Boundaries) & Resolution Level ~ Typically Lowest Level Analysis Detailed Equipment Descriptions & Unique System, Equipment, & Component Identifiers List All Failure Modes with Specific Equipment, Then Analyze Cause/Effect/Actions Documenting Results: Systematic & Consistent Tabulation of Effects from Equipment Failure Equipment Identification Allows One-on-Correlation to System

27 Scenario Technique Fault Tree Analysis Purpose: Deductive Technique Focusing On A Single Incident or System Failure Identify Combinations of Equipment Failures & Human Errors Resulting In Incidents Description: Graphical Model That Displays Combinations of Equipment/Human Failures Single Analyst (or Team) with Input & Review by Process Engineers Systematically Evaluates Top Event With Specific Logic /Event Symbols & Definitions Type of Results: System Failure Models with Boolean (and, or) Logic Gates to Describe Failures Resource Requirements: Extreme System Knowledge; Qualified Analyst/Experienced Team; Days Duration Analysis Procedure: Define Problem Via Top Event & Boundary Conditions Construct Fault Tree Model/Analyze Fault Tree Model Documenting Results: Formal Report with System Description, Problem Definition, Assumptions, & FTA Models

28 Scenario Technique Event Tree Analysis Purpose: Inductive Technique Focusing On A Single Incident or System Failure Graphic Representation of Possible Outcomes of Success/Failure of Protective Systems Following Specific Initiating Cause Description: Graphical Listing of Incidents That Can Occur ~ Event Sequences Single Analyst or Team for Brainstorming Type of Results: Event Tree Models with System Sequence for Failures Resource Requirements: Extreme System Knowledge; Trained Analyst; 6 80 Days Duration Analysis Procedure: Identify Initiating Causes or Loss Events & Safeguards Constructing Event Tree Describing Resulting Event Sequence Outcomes Determining Minimum Cut Sets (Shortest Branch) Documenting Results: Formal Report with System Description, Problem Definition, Incident Initiating Cause, Assumptions, & Minimum Cut Sets

29 Scenario Technique Cause-Consequence Analysis Purpose: Blend of FTA & ETA Graphic Representation to Identify Causes and Consequences of Potential Incidents Description: Inductive Features of ETA with Deductive Features of FTA Cause-Consequence Diagram Displays Relationship Between Outcomes & Causes Typically Simple Systems Otherwise Graphically Overwhelming Type of Results: Diagrams with Incident Sequences and Qualitative Descriptions of Potential Incident Outcomes Resource Requirements: System & Safeguards Knowledge; Trained Analyst; Small Team; 6 70 Days Duration Analysis Procedure: Selecting Event or Type of Incident & Identifying Safeguards Develop Event Sequence Paths & Intermediate Events With Safeguard Failures Evaluate Event Sequence Minimum Cut Sets Documenting Results: Formal Report with System Description, Problem Definition, Incident Initiating Cause, Assumptions, Cause-Consequence Diagrams, & Minimum Cut Sets

30 What About Risk? Consequence x Frequency = Risk Adequacy of Existing Safeguards Risk As Low As Reasonably Practicable Qualitative vs. Quantitative Analysis Frequency = Initiating Event x Safeguard Failure Consequence Severity Frequency/Likelihood (Numeric vs. Descriptive) Control Analysis Frequency Reduction ~ Preventative Consequence Reduction ~ Mitigative Risk Binning Layer of Protection Analysis