Study 1: Concept Hazard Review

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Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
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Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
GBH Enterprises, Ltd.
Process Safety Guide:
GBHE-PSG-HST-020
Study 1: Concept Hazard Review
Process Information Disclaimer
Information contained in this publication or as otherwise supplied to Users is
believed to be accurate and correct at time of going to press, and is given in
good faith, but it is for the User to satisfy itself of the suitability of the information
for its own particular purpose. GBHE gives no warranty as to the fitness of this
information for any particular purpose and any implied warranty or condition
(statutory or otherwise) is excluded except to the extent that exclusion is
prevented by law. GBHE accepts no liability resulting from reliance on this
information. Freedom under Patent, Copyright and Designs cannot be assumed.

Process Safety Guide: Study 1: Concept Stage Hazard Review
CONTENTS
1.0 PURPOSE
1.0.1 Team
1.0.2 Timing
1.0.3 Preparation
1.0.4 Documentation
HAZARD STUDY 1: APPLICATION
1.1 Project Definition
1.2 Process Description
1.3 Materials Hazards
1.4 External Authorities
1.5 Organization and Human Factors
1.6 Additional Activities to be Completed
1.7 Review of Hazard Study 1
APPENDICES
A Chemical Hazard Guide Diagram
B Safety Risk Criteria - Limit Values for Tolerable Risk
C List of Additional Assessments

1 PURPOSE
The depth of hazard identification and risk assessment and the methodology
used should be appropriate to the risk to the Business, safety, health or the
environment.
This document covers Hazard Study 1, where the basic hazards of the materials
and the operation are identified and SHE criteria set. It identifies what information
is needed and the program of studies required, ensuring that all safety, health
and environmental hazards and risks are adequately addressed. In addition, any
constraints due to relevant legislation are identified.
An outcome from this study is a decision on which of the remaining hazard
studies (two to six) should also be undertaken.
This document should be used in conjunction with a process safety publication
such as ’HAZOP: Guide to best practice’ (available from IChemE) or ‘Guidelines
for Hazard Evaluation Procedures’.
1.0.1 Team
The team composition should be agreed between the Hazard Study Leader and
the Project Manager. Assistance in selecting team size and membership can be
found in chapter 5.2.3 of the 'HAZOP: Guide to best practice' book.
The final outcome of Hazard Study 1 should be agreed by the full team. Separate
sub-groups may be formed to progress specific parts of the study.
1.0.2 Timing
Hazard Study 1 should start as early as possible in the life of a project. enerally,
the Business or project management will have formed a basic idea of the project
before appointing the project team and Hazard Study Leader.

Since the study defines the key parameters for the project on safety, health and
environmental issues it should be completed prior to the production of a sanction
estimate on every project.
1.0.3 Preparation
Before the first formal meeting it is advisable that the project team has been
identified and that the following is available:
(a) A draft project definition.
(b) A process description.
(c) A project plan that is part of a capital project management process. This
will include defined project stage-gates. A typical project process model is
available from GBHE.
(d) A review of SHE incidents with respect to the same or similar technology.
(e) A block diagram or flowsheet of the process.
(f) Completed chemical hazard, interactions and handling worksheets
(information from MSDS’s).
GBHE's preferred approach to the control of hazards will always be their
elimination where this is reasonably practicable. This is aided by the application
of the concept of Inherent SHE. This concept can be applied particularly
effectively at the early stages of a project and it is therefore specially valuable
and important at Hazard Study 1. Inherent SHE is explained in the book
'Guidelines for Engineering Design for Process Safety'.

1.0.4 Documentation
A draft Hazard Study 1 Report (worksheet f) should be issued as soon as
practicable, giving details of the information still lacking and actions to be
completed.
The study report should be updated and reissued when all the actions have been
resolved. A copy of this report should be filed in the Project SSHE dossier
(worksheet j). This document should be retained and updated throughout the life
of the plant.

HAZARD STUDY 1: APPLICATION
The following sections 1.1 to 1.7 describe how to conduct Hazard Study 1.

1.1 PROJECT DEFINITION
Designs that will be safe and meet environmental and health standards require a
clear understanding of the objective of the project and the processes involved.
The Business Manager or the Project Manager should provide a definition of the
project. The project definition should cover:
(a) Objective.
(b) Scope:
(1) Capacity and patterns of demand;
(2) Overall equipment effectiveness (OEE);
(3) Process operating philosophy;
(4) Maintenance philosophy;
(5) Control principles (see 1.6.1);
(6) Containment philosophy;
(7) Buildings (e.g. purpose, numbers of people);
(8) Demolition.
(c) Timetable.
(d) Location.
(e) Project risks (e.g., the effect on the Business of loss or unavailability of the
plant).

1.2 PROCESS DESCRIPTION
The Project Manager should ensure that a brief description of the process or
proposed operations is produced. This should also include:
(a) Process raw materials, intermediates, and catalysts; specification,
quantities and storage.
(b) Products; specification, conditions and storage.
(c) Effluents; quantities and treatment philosophy.
(d) Utilities.
It is recommended that at least a simple block diagram or
process flowsheet be provided.
1.3 MATERIALS HAZARDS
The purpose is to ensure that the material hazards will be
fully understood by the project team and, subsequently,
operating personnel, by use of the Chemical Hazard Guide
Diagram shown in appendix A. In cases where large numbers of similar
chemicals are involved, it may be appropriate to group these generically.
1.3.1 Material List
Prior to the first Hazard Study Meeting a list of the materials,
chemicals or substances involved should be produced (see Hazard
Study 1 Chemical Hazards Worksheet, Part 1 - Materials List)
(worksheet a).
This should cover:
(a) Raw materials, intermediate and/or intermediate mixtures,
main product or products, by-products.
(b) Effluents, Emissions and Waste produced from this process - gaseous,
liquids, solids, slurries.

(c) Emissions from adjacent facilities or materials from elsewhere which may
be airborne, encountered in drains, utilities or in the ground and which
may impact this process.
(d) Support materials including catalysts, inhibitors, biological, radio-chemical,
decontamination and detoxification materials, fumigants, any special
maintenance materials or materials involved in supporting activities.
(e) Services, including heat transfer oils, dielectric fluids, gases, steam, oil,
nitrogen, cooling water, water, instrument air, waste disposal. (Include
additives and contaminants in the list).
(f) Principal materials of construction/construction materials
(g) Materials encountered during construction/demolition. For example,
contaminated ground, in ducts, drains, pipes and vessels or on surfaces:
PCBs, insulation material (e.g. asbestos), lead, flammable materials, etc.
Describe the material including, as far as possible, the composition and
appropriate name (e.g. trade names, abbreviations, product codes/numbers).
When the same material is present in different physical states, it may be helpful
to list each physical state separately.
1.3.2 Hazard Data Sheets
The Hazard Study should confirm that all necessary Material Safety Data Sheets
(MSDS) are available and identify where data is lacking and needs to be
collected/determined. Often data will initially only be available for a limited
number of process streams and individual component substances. Identify
limitations in the data that could affect decision making and factors of safety
which need to be applied.
1.3.3 Chemical Hazards
Quantities of materials stored on plants may trigger the enforcement of major
hazards legislation such as 29 CFR 1910.119 The Process Safety Management
of Highly Hazardous Chemicals and 40 CFR Part 68, Chemical Accident
Prevention Provisions (The EPA’s Risk Management Program – the RMP) and
SARA, (The Superfund Amendments and Reauthorization Act) in the US.

These regulations may have a significant impact on the capital and operating
costs of manufacturing facilities. Non compliance could result in significant fines
and other sanctions.
(a) Consider the hazards associated with the handling, storage and use of
materials this can be done using the Chemical Hazards worksheet
(worksheet a) to record relevant hazards and identify any need for
additional information on the materials involved.
Much of the information can be assembled before the meeting possibly
with the help of an Occupational Hygienist, Environmental Specialist,
Chemist or other specialist. In all cases, the worksheet and resulting notes
should be reviewed by the Hazard Study team.
Confirm that the required data is available or will be obtained. The
purpose of the Chemical Hazards worksheet is to indicate the hazards of
the materials used in the process and to ensure that the means of
handling is commensurate with the hazards posed.
(b) Identify potential hazardous interactions between the
chemicals/substances To identify potential hazardous interactions
between the chemicals/substances in the process, materials of
construction and services, the Hazard Study 1 Chemical Interaction
worksheet (worksheet b) should be completed outside the meeting and
reviewed by the Hazard Study team.
The purpose of the worksheet is to identify any combinations of materials
used in or near the process which are incompatible or have a significant
hazard. Fill the worksheet in a similar fashion to the Chemical Hazards
worksheet. Materials of construction should be listed in the lower section
of the worksheet: these include materials in direct contact with process
fluids but consideration should also be given to other tools and equipment
or building/construction materials which may come into contact with the
process material.
Use the matrix to consider possible hazardous interactions of each
material with each of the other materials in the top section of the
worksheet and with materials of construction in the lower section.
The materials section may also be used to signal materials that are
incompatible (e.g. copper with ammonia solutions) and should therefore
not be used.

Information on interactions is available in Bretherick's 'Handbook of
Reactive Chemical Hazards'.
Ambient materials (e.g. air, water, soil) may be added to prompt possible
oxidation, reactions with water and/or corrosion issues.
When processing operations are being undertaken with reactive
chemicals, the possibility of an exothermic run away reaction should be
considered and will probably require further action in the form of a
Chemical Hazard Assessment (assuming that one has not already been
carried out for the exact system). Reactive Chemical Hazards are most
often encountered in exothermic batch reactors and may impact on the
design of the relief system. Some form of screening study should be
carried out for these reactors. Materials which exotherm (start to
decompose) at temperatures below 60º C or 140º F can also give
problems in handling, storage and transportation. In this category are
organic peroxides often used as catalysts. A full assessment will involve
experimental work by a specialist contractor. The results of this work will
ensure safe operation and the correct sizing of reliefs, etc.
With research projects, where the material hazards are not precisely
known, the appropriate safeguards should be established.
1.3.4 Loss of Containment
Consider whether a quantity of material released from any section of the plant, or
from any operation, with total loss of containment and under the conditions of
storage or use, can give rise to unacceptable consequences for safety, health or
the environment.
If so, review the consideration that has been given to Inherent SHE acceptability
and identification of Critical Equipment for the control of these hazards (e.g.
GBHE_EP’s).
Consider the potential effect of loss of containment on occupied buildings, (e.g.
control rooms, workshops, offices, laboratories, houses, schools, hospitals, retail
and sports centers, etc.).
Methods of assessing risks are available. If risks appear to be significant then
seek specialist advice.

Where the quantity of material to be handled is not known, the quantity that will
cause off-plot effects should be estimated.
1.4 EXTERNAL AUTHORITIES
Consideration needs to be given to the authority approval process.
This should involve the full co-operation of staff with experience of
the country in which the plant will be located.
It is most important that a full and exhaustive list of the regulatory
requirements for the project is obtained. The following questions
should be addressed:
(a) Which authorities will need to be contacted?
(b) Who will be responsible for each contact?
(c) Will the project change the status of the site under any
existing legislation?
(d) Do plant or site inventory lists need to be updated?
(e) Are chemicals handled that are controlled by international protocols
(e.g. chemical warfare).
1.5 ORGANIZATION AND HUMAN FACTORS
In addition to the physical/geographical factors associated with site
selection already considered, assess if it is necessary to review the
major organizational and human factors.
More detailed study of any of the following outside the meeting may
need to be commissioned:
(a) Will the site be able to provide suitably qualified and
experienced staff for the construction, project development,
commissioning, operation and maintenance? These
considerations will be of prime importance where new
hazards and/or a new technology is being introduced to a site, particularly
if significantly different from those existing and familiar to site personnel.

The Training and Experience worksheet (worksheet c) may be used to
assess requirements.
(b) Does the project introduce hazards for which new systems of work or
procedures are required? If so, who will be responsible for providing
these?
(c) Are the key control, operational and manning concepts clear?
(d) Have facilities for construction manning been considered, (e.g., medical,
hygiene and eating facilities)?
1.6 ADDITIONAL ACTIVITIES TO BE COMPLETED
1.6.1 Control Philosophy
Describe the basic control philosophy. For example:
(a) What is it and what does it do.
(b) Is the proposed application suitable for the intended type of
process control (e.g. Programmable Electronic Systems)?
(c) What type of trip system is proposed and how does it
interface with the process control (e.g. PES)?
(d) Is there an existing plant and how does any PES fit in?
(e) Who is responsible for ergonomic (man-machine communication and
health) aspects?
(f) Vulnerability in an emergency or calamity?
1.6.2 Incident Review
Initiate a review of any incidents with significant safety, health or environmental
effects that have occurred on similar projects or processes/projects using the
same or related technology. This should cover GBHE experience and other
known incidents.

Information should be sourced externally if not available within the company.
The incidents identified above should be reviewed to ensure that the precautions
necessary to control the hazard are understood. It is recommended (mandatory
in the USA) to consider and document how repetition of each incident will be
prevented.
Describe how findings from previous relevant incidents are being incorporated
into this project.
1.6.3 Inherent SHE
Inherent SHE is important.
Inherent SHE emphasizes changing the design as early as possible and makes
use of the concepts of:
(a) Substitute (e.g. replace solvents with water);
(b) Minimize (e.g. lower inventory);
(c) Simplify (e.g. remove separations);
(d) Moderate (e.g. lower temperature or pressure).
Guidance on the application of Inherent SHE is available. This is covered by a
book ’Guidelines for Engineering Design for Process Safety’ published by the
Center for Chemical Process Safety (CCPS), part of the American Institute of
Chemical Engineers.
1.6.4 Safety Risk Criteria
It is a requirement of Group SHE Standards that risks should be reduced as far
as is reasonably practicable. In general, this will be achieved by the proper
application of appropriate codes, standards and good working practices.
In some cases it will be judged necessary (or a regulatory requirement) to use
Quantitative Risk Assessment (QRA) to help decide the level of precautions
needed. Any relevant risk criteria set by site requirements or by local or national
authorities should be identified, e.g.:

(a) Toxic gas emission criteria.
(b) Employee risk.
(c) Off-site individual risk.
(d) Off-site ‘group’ risk (‘societal’ risk).
(e) Major incident frequency.
Normally the business unit will establish agreed safety risk criteria. The limit
values for tolerable risk are summarized in appendix B.
1.6.5 Health
The Occupational Health issues associated with the project should be considered
and any special features should be identified. This should give guidance to the
project team in relation to risk control either by specifying design criteria,
recommending involvement of experts or recommending further studies.
This should identify health hazards resulting from:
(a) Chemical and biological properties of the materials.
(b) Noise.
(c) Ergonomics:
(1) Health related (manual handling, repetitive movements, posture,
visual display terminals);
(2) Human factors (human error and things likely to cause it).
(d) Radiation (radioactive sources, ultraviolet, lasers).

The health risks that may arise during the life cycle of the plant should be
identified:
(1) Construction.
(2) Commissioning.
(3) Operation.
(4) Maintenance.
(5) Demolition.
1.6.6 Environment
As with safety hazards the preferred approach to environmental hazards is their
elimination through choice, selection and development of appropriate process
routes and technology.
The study should consider the 'Environmental Impact’ issues offsite and onsite.
This is normally achieved through an Environmental Statement and an
Environmental Impact Assessment. Hazard Study 1 reviews and agrees the
Environmental Statement. Have means of waste reduction at source been
adequately considered? Is the impact acceptable?
The Environmental Statement should identify:
(a) Process route options.
(b) The treatment options considered and justification of the chosen option.
(c) How will the material be disposed of, controlled and monitored?
(d) Are the potential effects of this disposal understood?
(e) The impact of discharges to the environment.
In comparison with the EIA criteria or national legislation, do you need an
Environmental Impact Assessment for this project? To decide this, Hazard Study
1 should further consider whether:

(1) There are any effluents not included on the list considered within the
Environmental Statement.
(2) The data for the environmental effects of the materials being handled are
sufficient for the project and for ongoing operation.
(3) There are any problems associated with the disposal of catalysts,
inhibitors, decontamination, detoxification, radioactive or biological
/pathological materials, maintenance wastes and packaging from received
materials.
(4) Consideration has been given to the disposal of out of specification,
returned or contaminated material.
(5) Consideration has been given to the need to build on contaminated land
and to the disposal of contaminated land, materials encountered during
construction or demolition, demolition material and building wastes.
(6) Special precautions are needed to prevent dust or leakage of materials
during construction/demolition affecting drains.
(7) It will be necessary to take measures to prevent soil or groundwater
contamination.
(8) Special provision will be needed for containment/treatment of
contaminated firewater.
(9) Consideration is necessary for the disposal of customers' waste (including
packaging).
(10) Any special mechanisms can result in loss of containment and spread
(e.g. flood, wind, storm, fire water runoff).
(11) Harmful or toxic/biologically environmentally active materials can be
created accidentally during unusual conditions, such as process upsets or
fire exposure. Can these have an effect beyond the site boundaries?
(12) Construction, demolition or operation may involve significant effect on tree
removal, natural vegetation or flora and fauna.
(13) Special measures are required to reduce or monitor fugitive emissions
(e.g. leaks from glands or seals).

(14) The location is the site of any endangered flora or fauna.
(15) There are any native titles (access, burial grounds).
Agree and record the responsibility for any further Environmental Assessments’’.
1.6.7 Material Transport and Siting
(a) Material Transport Stages
Consider those factors that are relevant to the selection of a site and a plot,
including the transport between sites and plots. The study should include
consideration of potential knock-on effects on existing hazardous or vulnerable
pipe routes, buildings, services, storage, etc. A key objective is to ensure that the
overall risk is minimized:
(1) Define the transport stages involved in broad terms (e.g., road, rail, ship,
pipeline, etc.) taking account of the flow of major raw materials through to
the destination of the products.
(2) Define in broad terms the transport stages involved in demolition
/construction taking account of the flow and storage of demolition and
construction materials and equipment.
(3) Review whether the risks arising from the construction/demolition work or
from the transport and storage of hazardous materials could be minimized
by the choice of plant location, material to be transported, etc. A simple
diagram showing material and transport movement may assist.
(4) In difficult cases, a Quantified Risk Assessment (QRA) may be called for.
In all of the above it is important to concentrate on the major material flows.
Detailed assessment of routes to individual customers will only be necessary in a
very limited number of cases and will generally not require consideration in the
case of established businesses.

(b) Existing Plants
Consider the potential effect of existing plants or operations on the proposed
development. Existing plants may need modifying or their impact studies
updating. Give consideration to bulk storage of potentially hazardous materials.
Include potential hazards of chemical interactions in or from drains and
contamination of intake air.
Consider if the proposed project will restrict future site development.
1.6.8 Design Guidelines and Codes
Internal GBHE and national guidelines to be followed should be listed.
Consideration should be given as to whether the project requires any new design
guidelines, codes of practice, guides and standards.
1.6.9 Emergency Facilities
Review the adequacy of site emergency facilities to ensure that these are
adequate to meet the needs of the proposed project.
The Site Emergency Facilities worksheet (worksheet d) may be used in
consultation with site personnel to ensure a full coverage.
1.6.10 Further Studies
Consider and agree what additional safety, health, environmental, quality or
financial related studies will be required during the design of the project, and
whether these will be covered as part of the Hazard Study process or carried out
as independent studies. A list of additional assessments is shown in appendix C
and a worksheet (worksheet e) is available to record which studies are to be
considered as part of the project.

1.7 REVIEW OF HAZARD STUDY 1
At the completion of this study the following key activities should have been
completed:
• Agreed the extent of further hazard studies and the need for
any QRA.
• If the hazard study process is to be curtailed then justify and
document the reason, using the Extent of Further Hazard
Studies worksheet (worksheet g).
• Additional assessments to be considered as part of the
project (worksheet e).
• Actions identified (worksheet h).
• Agreed the responsibility and date for progressing actions.
The Project Manager is responsible for progressing any identified hazard studies
and actions.

Study 1: Concept Hazard Review

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