Event tree analysis, process hazard review

Process Hazard Reviews—The facility and subsequent changes are subjected to a process hazard analysis commensurate to the level of hazards the facility represents (i.e.. Checklist, What-If, PHA, HAZOP, Event Tree, FMEA, LOPA, etc.). The results of these analyses are fully understood and acknowledged by management. Where high risk events are identified as probable, quantifiable risk estimation and effects of mitigation measures should be undertaken and applied if productive. 

HAZOP and What-If reviews are two of the most common petrochemical industry qualitative methods used to conduct process hazard analyses. Up to 80% of a company s process hazard analyses may consist of HAZOP and What-If reviews with the remainder 20% from Checklist, Fault Tree Analysis, Event Tree, Failure Mode and Effects Analysis, etc. An experienced review team can use the analysis to generate possible deviations from design, construction, modification, and operating intent that define potential consequences. These consequences can then be prevented or mitigated by the application of the appropriate safeguards. 

There are various types of analyses that are used for a process hazard analysis (PHA) of the equipment design and test procedures, including the effects of human error. Qualitative methods include checklists, What-If, and Hazard and Operability (HAZOP) studies. Quantitative methods include Event Trees, Fault Trees, and Failure Modes and Effect Analysis (FMEA). All of these methods require rigorous documentation and implementation to ensure that all potential safety problems are identified and the associated recommendations are addressed. The review should also consider what personal protective equipment (PPE) is needed to protect workers from injuries. 

CONSTRUCTING THE FAULT TREE. Fault tree construction begins at the top event and proceeds, level by level, until all fault events have been traced to their basic contributing events or basic events. The analysis starts with a review of system requirements, function, design, environment, and other factors to determine the conditions, events, and failures that could contribute to an occurrence of the undesired top event. The top event is then defined in terms of sub-top events, i.e., events that describe the specific "whens and wheres" of the hazard in the top event. Next, the analysts examine the sub-top events and determine the immediate, necessary, and sufficient causes that result in each of these events. Normally, these are not basic causes, but are intermediate faults that require further development. For each intermediate fault, the causes are determined and shown on the fault tree with the appropriate logic gate. The analysts follow this process until all intermediate faults have... 

First, the importance of learning lessons from past process safety incidents is highlighted in Section 3.2. The subsequent section presents preliminary hazard review procedure, risk matrix, what-if method, plot plan and layout review, pressure relief system review and fire safety design aspects. Section 3.4 presents PHA techniques and procedures hazards and operability analysis (HAZOP), failure modes and effects analysis (FMEA), instrumented protective system (IPS) design, fault trees, event trees, layer of protection analysis (LOPA) and finally SIS life eyele. The importanee of revision of PSI is highlighted in Seetion 3.5. 

In this study detailed fault trees with probability and failure rate calculations were generated for the events (1) Fatality due to Explosion, Fire, Toxic Release or Asphyxiation at the Process Development Unit (PDU) Coal Gasification Process and (2) Loss of Availability of the PDU. The fault trees for the PDU were synthesized by Design Sciences, Inc., and then subjected to multiple reviews by Combustion Engineering. The steps involved in hazard identification and evaluation, fault tree generation, probability assessment, and design alteration are presented in the main body of this report. The fault trees, cut sets, failure rate data and unavailability calculations are included as attachments to this report. Although both safety and reliability trees have been constructed for the PDU, the verification and analysis of these trees were not completed as a result of the curtailment of the demonstration plant project. Certain items not completed for the PDU risk and reliability assessment are listed. 

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