Testing hazard review process

Procedures Conformance Loss of utilities Vessels Identification Relief devices Review of incidents Inspections, tests Hazards Electrical Process operating ranges... 

When Hazard Studies are performed on new plants and modifications, certain inspection and test frequencies are defined. There should be a review process for changes. If equipment and instrumentation inspections reveal a pattern of failing to meet expectations, the testing or inspection should be increased and alternate equipment must be considered. 

Reactive hazard evaluations should be made on all new processes as well as existing processes on a periodic basis. There is no substitute for experience, good judgement, and good data when evaluating potential hazards. Reviews in process chemistry should include (a) reactions, (b) side reactions, (c) heat of reaction, (d) potential pressure buildup, and (e) intermediate streams. Reactive chemicals test data should be reviewed for evidence of flammability characteristics, exotherms, shock sensitivity, or other evidence of instability. Examine Planned operation of the process should be examined, especially for... 

The first example is of a Process Hazards Review conducted on a flow reactor designed to test the activity of heterogeneous catalysts in the reaction of mixtures of hydrogen, carbon monoxide, and/or carbon dioxide. This reactor system had previously been reviewed and the Review this time was to assess the hazards of the addition of a vaporizer and liquid pump to the system. 

Thermochemical hazard evaluation should be an integral part of any chemical process hazard review. This paper discusses how a pharmaceutical chemical development group performs thermochemical hazard evaluation through a combination of literature searches and physical testing. It will briefly discuss the physical testing methods and some of the philosophy behind them. 

The design constraints identified as necessary to control system hazards are passed to the implementers and assurers of the individual system components along with standards and other requirements. Success is determined through feedback provided by test reports, reviews, and various additional hazard analyses. At the end of the development process, the results of the hazard analyses as well as documentation of the safety-related design features and design rationale should be passed on to the maintenance group to be used in the system evolution and sustainment process. 

The Safety Verification Tasks assure that the hazard control is validated to be appropriate and verified to be in place. Verification of the implementation of system safety processes into company operations is very important, not only for regulatory audit and inspection survival but also to be sure that money is spent wisely. Verification is done through review and approval of the design process, input to specifications that call for verification schemes, and various tests (i.e., acquisition, operational, safety) to physically test hazard control adequacy. Of course, physical inspections (destructive and nondestructive) are part of the verification process. This is extremely important in product safety, but also very important in any plant safety. Explaining the testing of safety-critical systems and testing systems to assure they operate safely is very important. 

System safety is generally involved in the acceptance test process. Safety may review test results to ensure safety concerns are adequately resolved and that design safety requirements are met. Safety may also review acceptance test procedures to ensure that no test hazards exist and that the potential mishap risk of a test is acceptable. It may be necessary for safety to be present as a witness to the conduct of certain acceptance tests, generally on safety-critical components. 

Assessing the safety significance of proposed changes is generally more difficult when dealing with chemical reactivity hazards. New test data may need to be obtained, and experts may need to be consulted. Changes in process quantities, rates or conditions—especially temperature—or the introduction of new or modified materials must be carefully reviewed. 

Inherently safer process checklist, 167-172 Inherent safety review, chemical reactivity hazard management, 22-23 Initiation, management practices, 65-71. See also Management practices Insulated exotherm test, chemical reactivity tests, 87... 

Flowcharts are used for process overview analysis of causes and consequences, lines of defense, and testing data requirements and review of hazard checklist, schedule, and followup on recommendations. 

The company or facility should make use of the services of an engineer knowledgeable and trained in fire protection. Ideally, a registered fire protection engineer should be available to review fire protection designs. Fire safety, loss prevention, or process safety engineers should assist in the analysis of hazards, selection of protection system specifications, approval of the system, and acceptance testing. 

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