Hazard analysis programs

The site must develop a documented system for determining what hazard data is necessary, obtain such data, evaluate and analyze the data for process safety issues and incorporate the information into the new product introduction and/or process hazard analysis program. 

When an employee thinks and acts in this manner, the hazards analysis program is working very well indeed because it has become a part of the broader topics of culture and workforce involvement. 

The material provided up to this point has been written on the assumption that the hazards analysis is the first to be conducted on the facility being reviewed. However, given that most companies in the process industries started their hazards analysis program in the late 1980s or early 1990s, the majority of facilities have been analyzed at least once. 

Job Hazard Analysis (4) Employees involved in the development of current hazard analysis on their jobs. (3) Hazard analysis program exists for some jobs/processes and understood by affected employees. (2) Hazard analysis program exists for a few jobs/processes and understood by affected employees. (1) Hazard analysis program exists, but few employees involved and most not aware of results. (0) No routine hazard analysis process in place at facility. 

The Job Safety Analysis Process A Practical Approach. The precept behind using JSA/JHA is that fatalities, accidents, and injuries can be reduced by working together and sharing safety knowledge. An accident prevention method that has proven effective in industry is the Job Safety/Hazard Analysis program. 

Hazards analysis is a systematic procedure for identifying, evaluating and controlling potential hazards in a facility. A hazards analysis program should be applied to all phases of the life of a facility from project inception through abandonment to assess potential hazards during design, construction and operation. 

HOUR INTRODUCTION HAZARD LIST (PHL) VERIFICATION HAZARD ANALYSIS PROGRAM... 

Probabilistic Seismic Hazard Models, Fig. 5 Examples of global and national PSH maps (a) Global seismic hazard analysis program (GSHAP) model (Giardini et al. 1999), (b) New Zealand national seismic hazard... 

The EPA Contract Laboratory Program (CLP) has responsibility for managing the analysis programs required under the U.S. Comprehensive Environmental Response, Compensation, and Liability Act (CERCLA). The approved analytical methods are designed to analyze water, soil, and sediment from potentially hazardous waste sites to determine the presence or absence of certain environmentally harmful organic compounds. The methods described here all require the use of GC/MS. 

Risk-Based Inspection. Inspection programs developed using risk analysis methods are becoming increasingly popular (15,16) (see Hazard ANALYSIS AND RISK ASSESSMENT). In this approach, the frequency and type of in-service inspection (IS I) is determined by the probabiUstic risk assessment (PRA) of the inspection results. Here, the results might be a false acceptance of a part that will fail as well as the false rejection of a part that will not fail. Whether a plant or a consumer product, false acceptance of a defective part could lead to catastrophic failure and considerable cost. Also, the false rejection of parts may lead to unjustified, and sometimes exorbitant, costs of operation (2). Risk is defined as follows ... 

Two standard estimation methods for heat of reaction and CART are Chetah 7.2 and NASA CET 89. Chetah Version 7.2 is a computer program capable of predicting both thermochemical properties and certain reactive chemical hazards of pure chemicals, mixtures or reactions. Available from ASTM, Chetah 7.2 uses Benson s method of group additivity to estimate ideal gas heat of formation and heat of decomposition. NASA CET 89 is a computer program that calculates the adiabatic decomposition temperature (maximum attainable temperature in a chemical system) and the equilibrium decomposition products formed at that temperature. It is capable of calculating CART values for any combination of materials, including reactants, products, solvents, etc. Melhem and Shanley (1997) describe the use of CART values in thermal hazard analysis. 

Included in OSH As JHA Booklet, 3071, is a good description of a process hazard analysis (PHA) [1]. This is being used in the Process Safety Management (PSM) program (29 CER 1910.119) to understand how hazards exist. There are some good methods listed in the manual that can be used to conduct a JHA. As you review each method you can determine which one may be useful for your operation. The typical method chosen is the checklist. 

Complete and accurate written documentation of chemicals properties, process teclinology, and process equipment is essential to the PSM program and to a process hazards analysis (PrHA). This information serves many users including the PrHA team. The needed chemical information includes fire and explosion characteristics, reactivity hazards, safety and health hazards and the corrosion and erosion effects. Current material safety data sheet (MSDS ) information helps meet this requirement, but must be supplemented with process chemistry information regarding runaway reactions, and over-pressure hazards. 

Safety and environmental information is needed to provide a basis for implementation of further program components such as operating procedures and hazards analysis. Specific guidelines as to what information is needed are contained in API RP 141. 

Prevention Program —Management System —Process Hazards Analysis —Process Safety Information —Standard Operating Procedures —Training... 

You can quickly identify these plant sections by reviewing process flow diagrams and valving arrangements. Isolation points are defined by control valves or powered block valves that can be remotely activated. Process hazard analysis techniques help you identify the maximum credible accident scenarios. (Note that manual valves should not be considered reliable isolation points unless they are located to be accessible following a major accident. However, remotely-activated valves can only be considered reliable isolation points if there are adequate reliability engineering and maintenance programs in place.)... 

One of the most important elements of the PSM Rule is the process hazard analysis (PrHA). It requires the systematic identification of hazards and related accident scenarios. The PSM Rule allows the use of different analysis methods, but the selected method must be based on the process being analyzed. The PSM Rule specifies that PrHAs must be completed as soon as possible within a 5-year period. However, one-fourth of the PrHAs must have been completed by May 26, 1994, with an additional one-fourth completed each succeeding year. The highest risk processes were to be done first. A schedule for PrHAs must be established at the outset of a process safety management (PSM) program to give priority to the highest risk processes. PrHAs must be reviewed and updated at least every 5 years. 

Preliminary Hazard Analysis. The next step in the process is the development of a PHA. This analysis is the core of the FSS program and as such is vital in eliminating or reducing the inherent hazards associated with this laboratory operation. The PHA is used to further analyze the data identified in the PHL. This enhances the hazard control data base and provides specific recommended corrective action for the resolution of hazardous conditions. A combination of the informational sources used in the PHL development and any additional design information should be used in PHA development. 

RMP requires covered processes to have a hazard assessment, a prevention program, and an emergency response program. The hazard assessment must evaluate the accidental release of regulated substances, including the worst case scenario. RMP contains requirements for prevention of accidental releases, which include the same basic elements as the OSHA PSM Standard. Therefore, the limitations described in Section 5.1.2.2 with respect to process safety information and process hazard analysis also apply to RMP. 

Reactive chemical hazard management is one element of an overall process safety program, but is emphasized through thermal hazards analysis. 

The program includes a preliminary screening test, team-based screening, reactive evaluation, and process hazard analysis. 

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